Patent Abstract:
An automated case erecting apparatus for use in erecting case blanks includes a case blank feeder configured to hold a plurality of upstanding case blanks arranged face-to-face. The case blank feeder includes a path along which the case blanks are directed. A case erecting assembly receives a case blank from the case blank feeder at a case receiving location. The case erecting assembly includes a first arm carrying a first gripper element and a second arm carrying a second gripper element. The first arm and associated first gripper element are arranged and configured such that the first gripper element grips a first flap of the case blank. The second arm and associated second gripper element are arranged and configured such that the second gripper element grips a second flap of the case blank. The case erecting assembly is configured to move in a conveying direction from the case receiving location toward a case bottom fold and seal station to carry the gripped case blank toward the case bottom fold and seal station.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 60/977,401, filed Oct. 4, 2007, the details of which are incorporated by reference as if fully set forth herein. 
     
    
     TECHNICAL FIELD 
       [0002]    The present application relates to case erector and sealer apparatus and more particularly to a case erector and sealer apparatus including a case spread-out system and case sealing device. 
       BACKGROUND 
       [0003]    Case sealing apparatus are known for taping or gluing flaps of a case closed. As used herein, the term “case” is meant to include cartons, boxes, etc. U.S. Pat. No. 4,553,954, as an example, describes an automatic case erector and sealer apparatus useful in the erecting of case blanks using case puncturing and gripping pins. 
       SUMMARY 
       [0004]    In an aspect, an automated case erecting apparatus for use in erecting case blanks includes a case blank feeder configured to hold a plurality of upstanding case blanks arranged face-to-face. The case blank feeder includes a path along which the case blanks are directed. A case erecting assembly receives a case blank from the case blank feeder at a case receiving location. The case erecting assembly includes a first arm carrying a first gripper element and a second arm carrying a second gripper element. The first arm and associated first gripper element are arranged and configured such that the first gripper element grips a first flap of the case blank. The second arm and associated second gripper element are arranged and configured such that the second gripper element grips a second flap of the case blank. The case erecting assembly is configured to move in a conveying direction from the case receiving location toward a case bottom fold and seal station to carry the gripped case blank toward the case bottom fold and seal station. 
         [0005]    In another aspect, an automated case erecting apparatus for use in erecting case blanks includes a case blank feeder configured to hold a plurality of upstanding case blanks arranged face-to-face. The case blank feeder includes a path along which the case blanks are directed. A case erecting assembly receives a case blank from the case blank feeder at a case receiving location. The case erecting assembly includes a first arm carrying a first gripper element and a second arm carrying a second gripper element. The first arm and associated first gripper element are arranged and configured such that the first gripper element grips a first case flap of the case blank. The second arm and associated second gripper element are arranged and configured such that the second gripper element grips a second case flap of the case blank. The second case flap is opposite the first case flap. The case erecting assembly is configured to erect the case blank by pivoting both the first arm and the second arm from respective case receiving orientations to respective case erecting orientations. 
         [0006]    In another aspect, an automated case erecting apparatus for use in erecting case blanks includes a case blank feeder configured to hold a plurality of upstanding case blanks arranged face-to-face. The case blank feeder includes a path along which the case blanks are directed. A case erecting assembly receives a case blank from the case blank feeder at a case receiving location. The case erecting assembly includes a first arm carrying a first gripper element and a second arm carrying a second gripper element. The first arm and associated first gripper element are arranged and configured such that the first gripper element grips a first bottom case flap of the case blank. The second arm and associated second gripper element are arranged and configured such that the second gripper element grips a second bottom case flap of the case blank. At least one of the first arm and the second arm moves to erect the case. 
         [0007]    In another aspect, an automated case erecting apparatus for use in erecting case blanks includes a case blank feeder configured to hold a plurality of upstanding case blanks arranged face-to-face. The case blank feeder includes a path along which the case blanks are directed. A case erecting assembly receives a case blank from the case blank feeder at a case receiving location. The case erecting assembly includes a first arm including a first plurality of pin and dome assemblies mounted thereon and a second arm including a second plurality of pin and dome assemblies mounted thereon. A multiplicity of the pin and dome assemblies of the first arm are mounted for movement and selective positioning along a lengthwise slot of the first arm. A multiplicity of the pin and dome assemblies of the second arm are mounted for movement and selective positioning along a lengthwise slot of the second arm. 
         [0008]    In yet another aspect, an automated case erecting apparatus for use in erecting case blanks includes a case blank feeder configured to hold a plurality of upstanding case blanks arranged face-to-face. The case blank feeder includes a path along which the case blanks are directed. A case erecting assembly receives a case blank from the case blank feeder at a case receiving location. The case erecting assembly includes a first arm including a first case flap gripper element carried by the first arm and a second arm including a second case flap gripper element carried by the second arm. The case erecting assembly is selectively configurable in a first orientation to handle right hand open style cases and in a second orientation to handle left hand open style cases. 
         [0009]    The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1A  is a front view of an embodiment of a case blank; 
           [0011]      FIG. 1B  is a top view of the case blank of  FIG. 1A ; 
           [0012]      FIG. 1C  is a section view the case blank along line  1 C- 1 C of  FIG. 1A ; 
           [0013]      FIG. 2  is a perspective view of a bottom of a case formed from the case blank of  FIG. 1A ; 
           [0014]      FIG. 3  is a perspective view of an embodiment of a case erector and sealer apparatus for forming the case of  FIG. 2  from the case blank of  FIG. 1A ; 
           [0015]      FIG. 4  is a top view of the case erector and sealer apparatus of  FIG. 3 ; 
           [0016]      FIG. 5  is a side view of the case erector and sealer apparatus of  FIG. 3 ; 
           [0017]      FIG. 6  is a detail, perspective view of a case erector device within area  6  of the case erector and sealer apparatus of  FIG. 5 ; 
           [0018]      FIG. 7  is a perspective view of the case erector device of  FIG. 6  shown in isolation; 
           [0019]      FIGS. 8-10  illustrate operation of the case erector device of  FIG. 6 ; 
           [0020]      FIGS. 11-15  illustrate operation of the case erector and sealer apparatus of  FIG. 3  erecting and sealing a case; 
           [0021]      FIGS. 16-18  illustrate a left hand configuration of the case erector device of  FIG. 6  to handle left hand open style cases; 
           [0022]      FIGS. 19-22  illustrate another embodiment of a case erector device; 
           [0023]      FIGS. 23-25  illustrate operation of the case erector device of  FIG. 19  in a left hand configuration to handle left hand open style cases; 
           [0024]      FIGS. 26-29  illustrate a right hand open configuration of the case erector device of  FIG. 19  to handle right hand open style cases; and 
           [0025]      FIGS. 30-35  illustrate details of an embodiment of a flap folding portion of the case erector and sealer apparatus of  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION 
       [0026]      FIGS. 1A and 1B  show an exemplary case blank  10  in a flat orientation and  FIG. 2  illustrates a case  12  erected from the case blank and bottom sealed. Case blank  10  includes opposite, broad faces  14  and  16 , each with a top edge  18 ,  20  and a bottom edge  22 ,  24 . Side edges  26  and  28  connect the opposite faces  14  and  16 . Top edge  18  is formed by top flaps  30  and  32  and top edge  20  is formed by top flaps  34  and  36 . Bottom edge  22  is formed by bottom flaps  38  and  40  and bottom edge  24  is formed by bottom flaps  42  and  44 . The faces  14  and  16  include respective panels  46 ,  48 ,  50 ,  52  that will form the vertical sidewalls of the erected case. 
         [0027]    Referring to  FIG. 2 , panels  46  and  50  will form opposite sidewalls (also numbered  46  and  50 ) of the erected case  12  and panels  48  and  52  will form the other opposite sidewalls (also numbered  48  and  52 ) of the erected case. The top and bottom flaps  30 ,  38  and  34 ,  42  are associated with and hingedly connected to the sidewalls  46  and  50  and the top and bottom flaps  32 ,  40  and  36 ,  44  are associated with and hingedly connected to the sidewalls  48  and  52 . As used herein, the term “opposite panels” refer to those pairs of panels  46  and  50 ,  48  and  52  opposite each other with respect to the erected case  12  and the term “adjacent panels” refer to adjacent panels (e.g., panels  46  and  52 ) with respect to the erected case. Similarly, the term “opposite flaps” refer to those top and bottom flaps  30  and  34 ,  38  and  42  associated with and hingedly connected to the opposite panels  46  and  50  and to those top and bottom flaps  32  and  36 ,  40  and  44  associated with and hingedly connected to the opposite panels  48  and  52 . As can be seen in  FIG. 2 , opposite panels  46  and  50  and their associated bottom flaps  38  and  42  extend substantially parallel to a bottom seam  54  that is sealed by using glue or tape  56  (represented by broken lines). Note that in  FIG. 1 , the opposite panels  46  and  50 ,  48  and  52  and opposite flaps  30  and  34 ,  32  and  36 ,  38  and  42 ,  40  and  44  are offset from each other when the case blank is in the flat configuration. 
         [0028]    In some embodiments, such as the one shown by  FIGS. 1 and 2 , panels  46  and  50  are wider than panels  48  and  52 . The wider panels  46  and  50  may be referred to as “major panels” and the narrower panels  48  and  52  may be referred to as “minor panels.” The flaps  30 ,  34 ,  38 ,  42  associated with and hingedly connected to the major panels  46  and  50  may be referred to as “major flaps” and the flaps  32 ,  36 ,  40 ,  44  associated with and hingedly connected to the minor panels  48  and  52  may be referred to as “minor flaps.” However, in other embodiments, the panels (and flaps) may be all substantially the same width. 
         [0029]    Referring to  FIG. 1C , each panel and/or flap of the case blank  10  may be formed of laminate material including spaced-apart outer layers  58  and  60  with an intermediate layer  62  of a corrugated medium. In some embodiments, the layers  58 ,  60  and  62  are formed of cardboard or paperboard material. 
         [0030]    Referring to  FIGS. 3 and 4 , a case erector and sealer apparatus  100  is shown for automatically erecting case blank  10  and applying the adhesive, such as tape  56  ( FIG. 2 ). The erector and sealer apparatus  100  includes a case blank feeder  102 , a case erecting portion  104 , a flap folding portion  106  and a case sealing portion  108 . Collectively, portions  104  and  106  form a case bottom fold and seal station of the apparatus. The case blank feeder  102 , case erecting portion  104 , flap folding portion  106  and case sealing portion  108  are all supported by a frame  110  that includes a vertically-oriented infeed assembly  112  through which case blanks are fed from the case blank feeder  102  to the case erecting portion  104  and a horizontally-oriented conveying assembly  114  along which the case blanks  10  conveyed while being erected and sealed. 
         [0031]    Referring also to  FIG. 5 , the case blank feeder  102  includes a pair of sloped feed members  116  and  118  having an L-shape for receiving bottom corners of the case blanks including a vertical portion  120  and a horizontal portion  122  that is substantially transverse to the vertical portion. The sloped feed members  116  and  118  are sloped downwardly toward the infeed assembly  112  to facilitate movement of the case blanks located thereon toward the infeed assembly. A pusher  124  and  126  is associated with the sloped feed members  116  and  118 . The pushers  124  and  126  are also L-shaped for pushing the carton blanks at their sides. Each pusher  124  and  126  is linked by a linkage  128  and  130  to a linear bearing  135  that rides along a track bar  136 ,  138 . In some embodiments, the pushers  124  and  126  move down the sloped feed members  116  and  118  under the influence of a weight  132 ,  134  and gravity to push the carton blanks toward the infeed assembly  112 . The pushers  124  and  126  are able to rotate about the track bars  136  and  138 . The weights  132  and  134  are offset inwards toward the infeed assembly  112  so as to create a tendency for the pushers  124  and  126  to rotate inward toward each other. This rotation is limited by rollers riding on the sloped feed members  116 ,  118  so that the pushers  124  and  126  remain vertical. If the pushers  124  and  126  are rotated outward and pulled back to allow more case blanks to be added to the case blank feeder  102 , they will return to a vertical position to push squarely on the end of the case blanks. Alternatively, the pushers  124  and  126  may be moved using actuators, such as a pneumatic actuator, motor and linkage assembly, etc. 
         [0032]    A case erector device  140  is located at the infeed assembly  112 . Referring to  FIGS. 6 and 7 , the case erector device  140  includes a conveying mount frame  142  that carries a first moveable arm  144  and a second moveable arm  146 . Each moveable arm  144  and  146  includes one or more, in this instance, four gripping devices  148  for gripping a bottom flap (e.g., see flaps  38 ,  40 ,  42 ,  44  of  FIG. 1 ) of the case blank and an extended support member  150  connected to each moveable arm by a connecting member  152 . In the illustrated embodiment, the gripping devices  148  are pin and dome combinations (also labeled element number  148 ), which are mounted on a vertical face  154  of the respective moveable arms  144  and  146 . However, other gripping devices can be used, such as suction cups, other mechanical grippers such as those with moveable fingers, etc. Pin-only gripping devices without the dome may also be used. 
         [0033]    The pin and dome combinations  148  include a panel or block  156  that is mounted to the associated face  154  by a fastener  157 , in this case a thumb screw or alternatively a flat head screw fastener. A mounting block  158  is mounted to the lower end of the panel  156 . Each mounting block  158  is provided with at least one passage, in this implementation, two substantially parallel passages through which holding pins  160  and  162  pass. As can be seen, the holding pins  160  and  162  are pointed vertically upward toward a dome  164  mounted on an upper end of the panel  156 . The holding pins  160 ,  162  and dome  164  are located relative to each other such that a laminate layer  58 ,  60  ( FIG. 1A ) of the laminate material forming the case blank can be gripped therebetween. This gripping of the laminate material is described in greater detail in U.S. Pat. No. 4,553,954. In some embodiments, the pins  160 ,  162 , mounting block  158  along with the pins, and/or dome  164  may be vertically moveable along the panel  156  between release and gripping positions thereby adjusting the space between the dome and the pins. One such adjustable pin and dome combination is described in U.S. Pat. No. 7,192,393. 
         [0034]    In the embodiment shown, the positions of the pin and dome combinations  148  are adjustable by loosening the thumb screw  157  and moving the pin and dome combinations along the lengths of their respective moveable arms  144  and  146  within lengthwise slots  166  of the panels. This allows for adjustment of the distance between adjacent pin and dome combinations  148  to accommodate cases of various dimensions. Pin and dome combinations  148  may also be removable from their associated moveable arm  144 ,  146  manually, for example, without any need for tools. 
         [0035]    The first and second moveable arms  144  and  146  are pivotally mounted at respective axes A 1  and A 2  to a respective mounting block  168  and  170  by respective linkages  172  and  174 . The linkages  172  and  174  are each connected to a follower assembly  176  of the case erector device  140  that moves along with the conveying mount frame  142 . The follower assembly  176  includes a pair of overlapping rods  178  and  180  where linkage  172  is connected directly to rod  180  and linkage  174  is connected directly to rod  178 . The rods  178  and  180  are adjustably connected together where they overlap by brackets  182  and  184 . 
         [0036]    An adjustment member  186  allows for adjustment of a distance between the moveable arms  144  and  146 . In the illustrated embodiment, the adjustment member  186  is threadably connected to each mounting block  168  and  170  through left-handed and right-handed threads respectively (not shown) such that rotation of the adjustment member  186  (e.g., manually using wheel  188 ) causes either a decrease or an increase in the distance between the moveable arms along the length of the adjustment member depending on the direction of adjustment member rotation. Typically, fasteners  190  of the brackets  182  and  184  are loosened to allow for movement of the rods  178  and  180  along with their respective moveable arms  144  and  146  as the distance between them is being adjusted using the adjustment member  186 . When the distance between the moveable arms  144  and  146  is at the desired distance (which, in the illustrated embodiment, is set according to case blank size so that the gripping devices will engage opposite bottom flaps of the case blank), the fasteners  190  can be tightened thereby locking the rods  178  and  180  together. 
         [0037]    A follower pin  192  extends downwardly from the bracket  184  and is received within a cam track  194  formed in plate  196 . The shape of the cam track  194  causes the follower assembly  176  to move linearly in a cross-conveying direction as the case erector device  140  is moved in the conveying direction. Movement of the follower assembly  176 , in turn, causes movement of the linkages  172  and  174  and their moveable arms  144  and  146  about their respective pivot axes A 1  and A 2 . Alternatively, the function of the cam track  194  and follower pin  192  could be performed by an actuator, such as a pneumatic cylinder or servo actuator. The case erector device  140  is slidably connected to guide rods  198  (only one can be seen in  FIG. 6 ) using linear bearing guides  200  (only one can be seen in  FIG. 6 ) that receive the rods and slide therealong. As can be seen, adjacent plate  202  includes another cam track  204  that is a mirror of cam track  194  and can be used in changing a configuration of the case erector device  140  from a right hand opening configuration as shown to a left hand opening configuration, which is described below. 
         [0038]      FIGS. 8-10  illustrate operation of the case erector device  140  as it is moved in the conveying direction through the apparatus  100  with the case erector device and the plates  196  and  202  shown in isolation. Referring first to  FIG. 8 , the case erector device  140  is moved linearly in the conveying direction along guide rods  198 , for example, using a linear actuator  197 , such as a pneumatic cylinder (not shown) with the follower pin  192  located in the cam track  194 . Servo motor drives could also be used. The moveable arms  144  and  146  are initially parallel to each other and extend in the cross-conveying direction. Referring to  FIG. 9 , as the case erector device  140  moves in the conveying direction toward the bottom fold and seal station, the follower pin  192  moves in the cross-conveying direction (in the direction of arrow  195 ) relative to the mount frame  142  and the mounting blocks  168  and  170  due to the shape of the cam track  194 . This movement of the follower pin  192  results in corresponding movement of the follower assembly  176  which, in turn, results in movement of the linkages  172  and  174  and their moveable arms  144  and  146  about their respective pivot axes A 1  and A 2 .  FIG. 10  illustrates the moveable arms  144  and  146  in their fully rotated configurations where they are parallel to each other and extend in the conveying direction. 
         [0039]    Referring back to  FIGS. 3 and 4 , the flap folding portion  106  is provided for folding the bottom flaps of the opened case blank. The flap folding portion  106  includes a leading bottom flap folding member  206  ( FIG. 3 ) that is used to fold a leading bottom flap of the erected case blank as it passes thereover, a trailing bottom flap folding member  207  part of flap folder  211  and its mirror opposite  209 , a modification of the device described in U.S. Pat. No. 5,440,842 that is used to fold a trailing bottom flap of the erected case blank and side bottom flap folding guides  208  and  210  ( FIG. 4 ) that are used to finish folding the side bottom flaps as they pass thereby (and after the gripping devices  148  have been removed therefrom as will be described), after the leading and trailing bottom flaps are folded. In some embodiments, the trailing bottom flap folder is an actuated member that is moved to fold the trailing bottom flap based on a signal from a position sensor (e.g., a non-contact sensor) that senses when the erected case is in an appropriate position. 
         [0040]    In some embodiments, the leading bottom flap folding member  206  is positioned such that the frame  142  of the case erector device  140  can pass thereunder as the leading bottom flap is folded and while the side bottom flaps are gripped by the gripping devices  140  carried by the respective moveable arms  144  and  146 . The case erector device  146  can then locate the erected case between a pair of side conveyors  212  and  214  where the rear bottom flap is folded and the side bottom flaps are folded. The side conveyors  212  and  214  then carry the erected case through the case sealing portion  108  where an adhesive tape is applied along the seam between the side bottom flaps. 
         [0041]      FIGS. 11-15  illustrate operation of the case erector and sealer apparatus  100  to erect a case from a case blank. Referring initially to  FIG. 11 , a series of upstanding case blanks  10  are stacked face-to-face on the feed members  116  and  118  of the case blank feeder  102 . The pushers  124  and  126  (only pusher  126  and feed member  118  can be seen) apply a pushing force against the case blanks  10  in a direction toward the infeed assembly  112 . 
         [0042]    A case blank positioning device  216  is supported by the infeed assembly  112 . The case blank positioning device  216  is L-shaped, having a vertical portion  218  that forms a stop for the leading case blank  10 . Lower stops  220  and  222  are also used to provide a stop for the leading case blank  10  and to position lower, opposite flaps of the case blank just behind and above the moveable arms  144  and  146  of the case erecting device  140 . Once the leading case blank  10  is positioned, two actuators, such as pneumatic cylinders located in the lower stops  220  and  222  actuate upward to separate and lift the leading case blank so that top edges of the top flaps are moved upward into the case blank positioning device  216 . In doing so, the bottom flaps are freed from the stops  220  and  222  and can move forward to be positioned directly above the moveable arms  144  and  146  of the case erecting device  140 . An actuator, such as pneumatic cylinder  224  is actuated thereby extending a part of the case blank positioning device  216  downward, pushing the opposite bottom flaps onto the pin and dome combinations  148  carried by the moveable arms  144  and  146 . Referring briefly to  FIG. 7 , the moveable arms  144  and  146  each include a guide member  226  having a contoured surface  226  that is used to guide the bottom edge of opposite bottom flaps (e.g., the major flaps) onto the pins such that the pins penetrate into an open space between the outer layers and/or the grip the outer layer of the laminate material between the pins so inserted and the domes. As can be seen by  FIG. 12 , the pin and dome combinations  148  grip the outer layer of the opposite major flaps  38 ,  42  once the case blank  10  is pushed downward by the case blank positioning device  216 . 
         [0043]    The case erecting device  140  is then moved horizontally in the conveying direction by a linear actuator, such as a pneumatic cylinder  197 . Referring to  FIG. 13 , as described above, as the case erecting device  140  is moved, the moveable arms  144  and  146  rotate to begin to open (erect) the case blank  10  due to the cross-conveying direction movement of the follower assembly  176 . The rotating motion of the moveable arms  144  and  146  both rotate the case blank  10  from a position where the major panels  46 ,  50  and flaps  38 ,  42  are oriented substantially parallel to the cross-conveying direction as shown by  FIG. 11  through an intermediate stage as shown by  FIG. 13  to a position where the major panels and flaps are oriented substantially parallel to the conveying direction and separate the major panels and flaps from each other in the cross-conveying direction as shown by  FIG. 14 . 
         [0044]    In some embodiments, the moveable arms  144  and  146  are capable of vertical movement relative to the mount frame  142  (or with the mount frame  142 ), for example, through use of linear actuators, such as pneumatic cylinders. Initially, in the position shown by  FIG. 3 , the case erecting device  140  and the moveable arms  144  and  146  are in their normal, elevated positions and remain in their elevated positions as they approach the flap folding portion  106  of the case erector and sealer apparatus  100 . The case erecting device  140  carries the opened case blank  10  over the leading bottom flap folding member  206  such that the leading minor bottom flap is folded underneath the opened case blank, as shown by  FIG. 14 . After the leading, minor bottom flap is folded and the opened case blank  10  is held in position between the side conveyors  212  and  214 , between the flap folders  209  and  211  and upstream of the side flap folding guides  208  and  210  (e.g., which may be detected by one or more sensor  215 , such as a non-contact sensor), the rear bottom flap folding arms  207  (only one arm  207  can be seen) of folders  209  and  211  are actuated (e.g., by a first stage of a dual stage pneumatic cylinder) thereby folding the trailing bottom minor flap. The moveable arms  144  and  146  are then lowered thereby removing the pin and dome combinations  148  from the side major bottom flaps. The side flap folding guides  208  and  210  of folders  209  and  211  are then actuated (e.g., by the second stage of the dual stage pneumatic cylinder) as a second folding stage to fold the side major bottom flaps into a closed position. The opened case blank  10  is conveyed using the side conveyors  212  and  214  past the side flap folding guides  208  and  210  and over a center flap guide  213  ( FIG. 4 ) which finish folding the side major bottom flaps. The case is then carried to and over the bottom sealing tape head by the side conveyors  212  and  214  where tape is applied along the bottom seam formed between the folded major bottom flaps as shown by  FIG. 15 . In some embodiments, the case erecting device  140  moves back to its initial, starting position as the case blank  10  is moved past the bottom sealing tape head. Additional details of this folding process is described below with reference to  FIGS. 30-35 . 
         [0045]    As noted above, in some embodiments, the case erector and sealer apparatus  100  can be converted from a right hand opening apparatus for handling right hand open style cases (see, e.g.,  FIGS. 11-15 ) to a left hand opening apparatus for handling left hand open style cases. Referring particularly to  FIG. 16  and also to  FIG. 8 , to convert the case erector and sealer apparatus  140  from a right hand opening apparatus as shown in  FIG. 8  to a left hand opening apparatus as shown by  FIG. 16 , the follower assembly  176  is disconnected from the linkages  172  and  174 . The moveable arms  144  and  146  may then be rotated about  180  degrees such that alternative linkages  228  and  230  (see  FIG. 9 ) are presented to the follower assembly  176 . The follower assembly  176  is rotated  180  degrees and the follower pin  192  and brackets  182  and  184  are repositioned as shown by  FIG. 16 . The alternative linkages  228  and  230  are pivotally connected to the rods  178  and  180  as shown. In some embodiments, the extended support member  150  connected to each moveable arm  144  and  146  by the connecting member  152  is moved from one end of the respective moveable arm to the opposite end of the respective arm. 
         [0046]    Referring also to  FIGS. 17 and 18 , the case erector device  140  is moved linearly in the conveying direction along guide rods with the follower pin  192  located in the cam track  204  of the adjacent plate  202 . As an alternative, plate  196  may be flipped over on its opposite side and placed where plate  202  is shown to provide the cam track  204 . The moveable arms  144  and  146  are shown initially parallel to each other and extending in the cross-conveying direction. As the case erector device  140  moves, the follower pin  192  moves in the cross-conveying direction relative to the mount frame  142  and the mounting blocks  168  and  170  due to the shape of the cam track  194 . This movement of the follower pin  192  results in corresponding movement of the follower assembly  176  in the direction of arrow  205  which, in turn, results in movement of the linkages  228  and  230  and their moveable arms  144  and  146  about their respective pivot axes A 1  and A 2  in a sense opposite that described above with reference to  FIGS. 8-10  to handle the left hand open style cases.  FIG. 18  illustrates the moveable arms  144  and  146  in their fully rotated configurations where they are parallel to each other and extend in the conveying direction. 
         [0047]    In some embodiments, various features described above are adjustable to accommodate cases of various sizes. For example, referring back to  FIG. 3 , handles  232  and  234  are provided to manually adjust the height of the case blank positioning device  216  to accommodate cases of various heights and to manually adjust the height and/or width of the case blank feeder  102  according to width and height of the bottom flaps. In some embodiments, the sloped feed members  116  and  118  are linked to maintain a center line between the sloped feed members as their distance from each other is adjusted. Additionally, the distance between the side conveyors  212  and  214  may also be adjusted to accommodate cases of various widths and the side conveyors may also be linked to maintain a center line between the side conveyors (e.g., aligned with the bottom tape head) as their distance from each other is adjusted. 
         [0048]      FIGS. 19-22  illustrate another embodiment of a case erector device  240 . The case erector device  240  includes a conveying mount frame  242  that carries a first moveable arm  244  and a second moveable arm  246 . Each moveable arm  244  and  246  includes one or more, in this instance, four and three gripping devices  248  for gripping a bottom flap (e.g., see flaps  38 ,  40 ,  42 ,  44  of  FIG. 1 ) of the case blank. Moveable arm  244  includes an extended support member  250  connected thereto by a connecting member  252 . In the illustrated embodiment, the gripping devices  248  are pin and dome combinations (also labeled element number  248 ), which are mounted on a vertical face  254  of the respective moveable arms  244  and  246 . As above, other gripping devices can be used, such as pins only with no dome. The pin and dome combinations  248  are used to grip opposite bottom flaps of the case blank in a fashion similar to that described above. 
         [0049]    In contrast to the pin and dome combinations  148  described above and referring particularly to  FIG. 19 , pin and dome combinations  248   a  do not include a panel or block  156  that is mounted to the associated face  254 . Instead, the pin and dome combinations  248   a  include a mounting block  258  and dome  264  that are mounted directly to the face  254  of the moveable arm  246  by fasteners. This pin and dome arrangement  248   a  removes the panel  156  so that it does not interfere with gripping of the bottom panels of the case blank. Referring particularly to  FIGS. 20 and 21 , pin and dome combinations  248   b  include panels or blocks  256  that are mounted to the face  254  of the moveable arm  244  by a fastener  257 , in this case a thumb screw or alternatively a flat head screw fastener. The mounting block  258  is mounted to the lower end of the panel  256 . The panels  256  are located within a recessed area  259  of the moveable arm  244  so that the panels  256  do not interfere with gripping of the bottom panels of the case blank. For example, in one embodiment, the area  259  is recessed from surface  261  a distance that is equal to about the thickness of the panels  256 . 
         [0050]    Referring to  FIGS. 19-22 , as above, each mounting block  258  is provided with at least one passage, in this implementation, two substantially parallel passages through which holding pins  260  and  262  pass. As can be seen, the holding pins  260  and  262  are pointed vertically upward toward the dome  264 . The holding pins  260 ,  262  and dome  264  are located relative to each other such that a laminate layer  58 ,  60  ( FIG. 1A ) of the laminate material forming the case blank can be gripped therebetween. 
         [0051]    In the embodiment shown, the positions of only the pin and dome combinations  248   b  are adjustable by loosening the thumb screw  257  and moving the pin and dome combinations along the lengths of their respective moveable arm  244  within a lengthwise slot  266 . This allows for adjustment of the distance between adjacent pin and dome combinations  248   b  to accommodate cases of various dimensions. Pin and dome combinations  248   a  are fixed relative to each other along the length of moveable arm  246 . 
         [0052]    Referring to  FIGS. 19 ,  21  and  22 , the first and second moveable arms  244  and  246  are pivotally mounted at respective axes A 1  and A 2  to a respective mounting block  268  and  270  by respective linkages  272  and  274 . The linkages  272  and  274  are each connected to a follower assembly  276  of the case erector device  240  that moves along with the conveying mount frame  242 . In this embodiment, the follower assembly  276  includes only a single rod  278  (as opposed to the overlapping rods  178  and  180  described above) where linkages  272  and  274  are both connected to rod  278 . The linkages  272  and  274  are rotatably connected to the rod  278  within slots  283  and  285 . 
         [0053]    An adjustment member  286  allows for adjustment of a distance between the moveable arms  244  and  246  in a fashion similar to that described above with respect to adjustment member  186 . The connection between the linkages  272 ,  274  and the rod  278  can be adjusted along the length of the slots  283  and  285 . 
         [0054]    A follower pin  292  extends downwardly from a bracket  284  and is received within a cam track  294  formed in plate  296 . The shape of the cam track  294  causes the follower assembly  276  to move linearly in a cross-conveying direction as the case erector device  240  is moved in the conveying direction. Movement of the follower assembly  276 , in turn, causes movement of the linkages  272  and  274  and their moveable arms  244  and  246  about their respective pivot axes A 1  and A 2 . As can be seen, adjacent plate  302  includes another cam track  304  that is a mirror of cam track  294  and can be used in changing a configuration of the case erector device  240  from a left hand opening configuration as shown to a right hand opening configuration, which is described below. 
         [0055]    As noted above with respect to moveable arms  144  and  146 , the moveable arms  244  and  246  may also move up and down. Referring to  FIG. 20 , actuators  273  and  275  (e.g., pneumatic cylinders) may be used to move the moveable arms  244  and  246  vertically. This vertical movement may be employed to remove the gripping members  248  from the bottom flaps of the case blank before a folding operation, such as a folding operation similar to that described above. Guide members  277  and  279  may be used to prevent horizontal movement of the moveable arms  244  and  246 .  FIG. 20  shows the moveable arms  244  and  246  in their normal, fully raised position when gripping case blanks and  FIG. 22  shows the moveable arms  244  and  246  in their lowered, fully retracted position when releasing case blanks prior to a folding operation. 
         [0056]      FIGS. 23-25  illustrate operation of the case erector device  240  as it is moved in the conveying direction through the apparatus  100  with the case erector device and the plates  296  and  302  shown in isolation. Referring first to  FIG. 23 , the case erector device  240  is moved linearly in the conveying direction along guide rods  298  in a fashion similar to that described above. The moveable arms  244  and  246  are initially parallel to each other and extend in the cross-conveying direction. Referring to  FIG. 24 , as the case erector device  240  moves in the conveying direction toward the bottom fold and seal station, the follower pin  292  moves in the cross-conveying direction (in the direction of arrow  295 ) relative to the mount frame  242  due to the shape of the cam track  294 . This movement of the follower pin  292  results in corresponding movement of the follower assembly  276  which, in turn, results in movement of the linkages  272  and  274  and their moveable arms  244  and  246  about their respective pivot axes A 1  and A 2 . FIG.  25  illustrates the moveable arms  244  and  246  in their fully rotated configurations where they are parallel to each other and extend in the conveying direction. 
         [0057]    As noted above, the case erector device  240  can be converted from left hand opening for handling left hand open style cases to right hand opening for handling right hand open style cases. Referring particularly to  FIG. 26 , to convert the case erector and sealer apparatus  240  from a left hand opening apparatus as shown in  FIG. 23  to a right hand opening apparatus as shown by  FIG. 26 , the follower assembly  276  is disconnected from the linkages  272  and  274 . The positions of moveable arms  244  and  246  may then be exchanged and the linkages  272  and  274  reconnected to the rod  278  at alternative connecting locations  305  and  307 . In some embodiments, the follower assembly  276  is rotated 180 degrees. The follower pin  292  is repositioned as shown by  FIG. 26 . In some embodiments, the extended support member  250  connected to moveable arm  244  by the connecting member  252  is moved from one end of the respective moveable arm to the opposite end of the respective arm. 
         [0058]    Referring also to  FIGS. 27 and 28 , the case erector device  240  is moved linearly in the conveying direction along guide rods with the follower pin  292  located in the cam track  304  of the adjacent plate  302 . The moveable arms  244  and  246  are shown initially parallel to each other and extending in the cross-conveying direction. As the case erector device  240  moves, the follower pin  292  moves in the cross-conveying direction (in the direction of arrow  315 ) relative to the mount frame  242  due to the shape of the cam track  304 . This movement of the follower pin  292  results in corresponding movement of the follower assembly  276  in the direction of arrow  309  which, in turn, results in movement of the linkages  272  and  274  and their moveable arms  244  and  246  about their respective pivot axes A 1  and A 2  in a sense opposite that described above with reference to  FIGS. 23-25  to handle the left hand open style cases.  FIG. 29  illustrates the moveable arms  244  and  246  in their fully rotated configurations where they are parallel to each other and extend in the conveying direction. 
         [0059]    Advantageously, the moveable arms with their associated gripping elements can be used to grip opposite bottom flaps of the case blank, which can provide increased stability for the case blank as it is being erected, for example, as compared to gripping adjacent flaps of the case blank at one corner. Additionally, the moveable arms and of the case erector device grip the case blank at the bottom flaps from the bottom of the case blank, which can provide for increased stability while erecting the cases (e.g., compared to gripping the case blanks at their top) particularly in instances involves cases having a high height to width and/or height to length ratio. Furthermore, gripping the case blanks at their bottoms may facilitate filling of the erected cases at an earlier stage once their bottom flaps are folded as there are less overhead mechanisms that can interfere will a filling operation, thereby reducing guarding that may be used on the machine. 
         [0060]      FIGS. 30-35  illustrate, in greater detail, the operation of the bottom flap folders of the flap folding portion  106  (see  FIG. 3 ) that act from the underside of each side belt conveyor  212  and  214  to fold both the rear minor case flap and the side major case flaps. Referring to  FIG. 30 , the machine left-hand folder  211  is mounted under conveyor  214  and is shown in its home position with minor flap folder arm  207  and major flap folder arm  322  retracted. There is a matching mirror image folder  209  mounted under the opposite conveyor  212  (not shown). In this home position, the folders  211  and  209  are in position to receive an erected case blank between them as delivered by the case erecting device  140  (or  240 ). After the case blank is in position,  FIG. 31  shows the first stage of the folder action with the minor flap folder arm  207  rotated out or extended as shown by direction arrow  324 . With this motion, the folder arm  207  together with the opposite side folder arm (not shown) make contact with and fold up the rear minor flap as the case blank is held stationary with the major side flaps engaged on the movable arms  144  and  146  (or  244  and  246 ) of the erector device  140  (or  240 ). After the moveable arms  144  and  146  (or  244  and  246 ) are lowered (as shown in  FIG. 22 ) and the pins are withdrawn from the side major flaps, the second stage of the folder action extends the major flap folder arm  322  as shown in  FIG. 32 . The major folder arm  322  together with the opposite side folder arm (not shown) make contact with and fold up the case left-hand and right-hand side major flaps. The conveyors  212  and  214  then move the case over fixed flap guide  213  and, in some embodiments, flap guides  208  and  210  (as shown in  FIG. 4 ) and the case sealing portion  108 . 
         [0061]      FIGS. 33-35  are a sectioned views from underneath (looking up) showing the mechanisms of the left-hand folder  211  and right-hand folder  209 .  FIG. 33  shows both folders in their home position minor flap folders  207  and  327  and major flap folders  322  and  326  retracted.  FIG. 34  shows the first stage of the folder action with the minor flap folder arms  207  and  327  rotated out or extended as shown by direction arrows  330  and  332 . The minor folder arms  207  and  327  are hingedly connected to the bars  334  and  336  which in turn are connected to separate or multi-stage cylinders, in this embodiment dual-stage cylinders  338  and  340  in folder  209  and  342  and  344  in folder  211 . The first stage action of the cylinders causes them to retract and move the bars  334  and  336  to the right as shown just enough to cause the minor folder arms  207  and  327  to rotate out.  FIG. 35  shows the second stage of the folder movement where the second stage action of the cylinders  338  and  340  in folder  209  and  342  and  344  in folder  211  moves the bars  334  and  336  further to the right, causing cam follower rollers attached to the bars to act against the curved cam surface of major flap folder arms  322  and  326  such that they rotate out into an extended position as shown by direction arrows  346  and  348 . Reversing the direction of the cylinders moves the bars  334  and  336  to the left as shown and both the major folder arms  322  and  326  and the minor folder arms  207  and  327  return to their home positions by spring action. 
         [0062]    It is to be clearly understood that the above description is intended by way of illustration and example only and is not intended to be taken by way of limitation, and that changes and modifications are possible. For example, servos may be used to move various components of the case erector and sealer apparatus  100  as opposed to pneumatic cylinders. Additionally, the tape head mechanism may, in some implementations, be replaced with a different adhesive-applying apparatus, such as a glue apparatus. In some embodiments, the moveable arms are arranged to grip adjacent bottom flaps of the case blank, for example, in a clamshell-like fashion as opposed to opposite bottom flaps. Accordingly, other embodiments are within the scope of the following claims.

Technology Classification (CPC): 1