Patent Description:
Shipping and packaging industries frequently use paperboard and other sheet material processing equipment that converts sheet materials into box templates. One advantage of such equipment is that a shipper may prepare boxes of required sizes as needed in lieu of keeping a stock of standard, pre-made boxes of various sizes. Consequently, the shipper can eliminate the need to forecast its requirements for particular box sizes as well as to store pre-made boxes of standard sizes. Instead, the shipper may store one or more bales of fanfold material, which can be used to generate a variety of box sizes based on the specific box size requirements at the time of each shipment. This allows the shipper to reduce storage space normally required for periodically used shipping supplies as well as reduce the waste and costs associated with the inherently inaccurate process of forecasting box size requirements, as the items shipped and their respective dimensions vary from time to time.

In addition to reducing the inefficiencies associated with storing pre-made boxes of numerous sizes, creating custom sized boxes also reduces packaging and shipping costs. In the fulfillment industry it is estimated that shipped items are typically packaged in boxes that are about <NUM>% larger than the shipped items. Boxes that are too large for a particular item are more expensive than a box that is custom sized for the item due to the cost of the excess material used to make the larger box. When an item is packaged in an oversized box, filling material (e.g., Styrofoam, foam peanuts, paper, air pillows, etc.) is often placed in the box to prevent the item from moving inside the box and to prevent the box from caving in when pressure is applied (e.g., when boxes are taped closed or stacked). These filling materials further increase the cost associated with packing an item in an oversized box.

Customized sized boxes also reduce the shipping costs associated with shipping items compared to shipping the items in oversized boxes. A shipping vehicle filled with boxes that are <NUM>% larger than the packaged items is much less cost efficient to operate than a shipping vehicle filled with boxes that are custom sized to fit the packaged items. In other words, a shipping vehicle filled with custom sized packages can carry a significantly larger number of packages, which can reduce the number of shipping vehicles required to ship the same number of items. Accordingly, in addition or as an alternative to calculating shipping prices based on the weight of a package, shipping prices are often affected by the size of the shipped package. Thus, reducing the size of an item's package can reduce the price of shipping the item. Even when shipping prices are not calculated based on the size of the packages (e.g., only on the weight of the packages), using custom sized packages can reduce the shipping costs because the smaller, custom sized packages will weigh less than oversized packages due to using less packaging and filling material.

Although sheet material processing machines and related equipment can potentially alleviate the inconveniences associated with stocking standard sized shipping supplies and reduce the amount of space required for storing such shipping supplies, previously available machines and associated equipment have various drawbacks. For instance, previously available machines have had a significant footprint and have occupied a lot of floor space. The floor space occupied by these large machines and equipment could be better used, for example, for storage of goods to be shipped. In addition to the large footprint, the size of the previously available machines and related equipment makes manufacturing, transportation, installation, maintenance, repair, and replacement thereof time consuming and expensive.

In addition, previous box forming systems have required the use of multiple machines and significant manual labor. For instance, a typical box forming system includes a converting machine that cuts, scores, and/or creases sheet material to form a box template. Once the template is formed, an operator removes the template from the converting machine and a manufacturer's joint is created in the template. A manufacturer's joint is where two opposing ends of the template are attached to one another. This can be accomplished manually and/or with additional machinery. For instance, an operator can apply glue (e.g., with a glue gun) to one end of the template and can fold the template to join the opposing ends together with the glue therebetween. Alternatively, the operator can at least partially fold the template and insert the template into a gluing machine that applies glue to one end of the template and joins the two opposing ends together. In either case, significant operator involvement is required. Additionally, using a separate gluing machine complicates the system and can significantly increase the size of the overall system.

The document <CIT> discloses a converting machine for producing box templates according to the preamble of claims <NUM> and <NUM>.

Accordingly, it would be advantageous to have a relatively small and simple box forming machine that can form box templates and fold and glue the templates in a continuous process without significant manual labor.

The present invention relates to box forming machines that convert paperboard, corrugated board, cardboard, and similar sheet materials into box templates and fold and glue the box templates to form un-erected boxes. It also relates to a box forming system according to claim <NUM> and to a method for feeding different sheet materials into a converter assembly according to claim <NUM>.

For instance, one embodiment of a box forming machine includes a converter assembly, a fold assembly, and an attachment assembly. The converter assembly is configured to perform one or more conversion functions on a sheet material to convert the sheet material to a box template. The fold assembly is configured to engage a first end of the box template and move the first end of the box template to a predetermined position. The attachment assembly is configured to engage a second end of the box template and move the second end of the box template toward and into engagement with the first end of the box template.

According to another embodiment, a box forming machine includes a converter assembly mounted on a frame. The converter assembly is configured to perform one or more conversion functions on a sheet material to convert the sheet material to a box template. A fold assembly is configured to engage a first end of the box template and move the first end of the box template to a predetermined position. The fold assembly comprises a fold head having a fold plate and a first clamp between which the first end of the box template can be selected clamped. The fold head is movably connected to the frame to enable movement of the first end of the box template to the predetermined position. An attachment assembly is configured to engage a second end of the box template and move the second end of the box template toward and into engagement with the first end of the box template. The attachment assembly comprises an attachment head having one or more attachment mechanisms for selectively attaching to the second end of the box template. The attachment head is movably connected to the frame to enable movement of the second end of the box template ward and into engagement with the first end of the box template.

According to another embodiment, a box forming machine includes a converter assembly and an infeed changer. The infeed changer is configured to direct different sheet materials into the converter assembly. The infeed changer includes at least one upper set of guide channels configured to direct a first sheet material into the infeed changer and at least one lower set of guide channels configured to direct a second sheet material into the infeed changer. The infeed changer also includes an active roller that is configured to draw the first or second sheet material into the infeed changer. The active roller is configured to rotate in a first direction and in a second direction. Rotation of the active roller in the first direction draws the first sheet material into the infeed changer and rotation of the active roller in the second direction draws the second sheet material into the infeed changer.

Another embodiment includes a box forming machine having a frame, a converter assembly, and a labeler. The converter assembly is mounted to the frame and is configured to perform one or more conversion functions on a sheet material to convert the sheet material to a box template as the sheet material moves through the convert assembly. The labeler is movably mounted to the frame and is configured to move relative to the box template and apply a label to a desired location on the box template as the box template moves through the converter assembly.

These and other objects and features of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosure as set forth hereinafter.

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:.

The embodiments described herein generally relate to systems, methods, and devices for processing sheet materials and converting the same into boxes. More specifically, the described embodiments relate to box forming machines that converts sheet materials (e.g., paperboard, corrugated board, cardboard) into box templates and fold and glue the box templates to form un-erected boxes.

While the present disclosure will be described in detail with reference to specific configurations, the descriptions are illustrative and are not to be construed as limiting the scope of the present invention. Various modifications can be made to the illustrated configurations without departing from the spirit and scope of the invention as defined by the claims. For better understanding, like components have been designated by like reference numbers throughout the various accompanying figures.

As used herein, the term "bale" shall refer to a stock of sheet material that is generally rigid in at least one direction, and may be used to make a box template. For example, the bale may be formed of a continuous sheet of material or a sheet of material of any specific length, such as corrugated cardboard and paperboard sheet materials. Additionally, the bale may have stock material that is substantially flat, folded, or wound onto a bobbin.

As used herein, the term "box template" shall refer to a substantially flat stock of material that can be folded into a box-like shape. A box template may have notches, cutouts, divides, and/or creases that allow the box template to be bent and/or folded into a box. Additionally, a box template may be made of any suitable material, generally known to those skilled in the art. For example, cardboard or corrugated paperboard may be used as the box template material. A suitable material also may have any thickness and weight that would permit it to be bent and/or folded into a box-like shape.

As used herein, the term "crease" shall refer to a line along which the box template may be folded. For example, a crease may be an indentation in the box template material, which may aid in folding portions of the box template separated by the crease, with respect to one another. A suitable indentation may be created by applying sufficient pressure to reduce the thickness of the material in the desired location and/or by removing some of the material along the desired location, such as by scoring.

The terms "notch," "cutout," and "cut" are used interchangeably herein and shall refer to a shape created by removing material from the template or by separating portions of the template, such that a divide through the template material is created.

<FIG> illustrates a perspective view of a system <NUM> that may be used to create boxes. The system <NUM> includes bales 102a, 102b of sheet material <NUM>. The system <NUM> also includes a feed assembly <NUM> that helps direct the sheet material <NUM> into a box forming machine <NUM>. As described in greater detail below, the box forming machine <NUM> includes a feed changer <NUM>, a converter assembly <NUM>, a fold assembly <NUM>, and an attachment assembly <NUM>. The feed changer <NUM>, converter assembly <NUM>, fold assembly <NUM>, and attachment assembly <NUM> are mounted on or connected to a frame <NUM>.

Generally, the feed changer <NUM> is configured to advance the sheet material <NUM> from a desired bale 102a, 102b into the converter assembly <NUM>. The bales 102a, 102b may be formed of sheet material <NUM> that have different characteristics (e.g., widths, lengths, thickness, stiffness, color, etc.) from one another. As illustrated in <FIG>, for instance, the width of the bale 102a may be smaller than the width of the bale 102b. Thus, it may be desirable to use the sheet material <NUM> from the bale 102a to form a smaller box so there is less sheet material wasted.

After the sheet material <NUM> passes through the feed changer <NUM>, the sheet material <NUM> passes through the converter assembly <NUM>, where one or more conversion functions are performed on the sheet material <NUM> to form a box template from the sheet material <NUM>. The conversion functions may include cutting, creasing, bending, folding, perforating, and/or scoring the sheet material <NUM> in order to form a box template therefrom.

As the box template exits the converter assembly <NUM>, the fold assembly <NUM> engages the leading end of the sheet material <NUM>/box template. The fold assembly <NUM> moves and reorients the leading end of the sheet material <NUM>/box template to a known position where glue is applied to the leading end of the sheet material <NUM>/box template. In some embodiments, fold assembly <NUM> begins moving/reorienting the leading edge of the sheet material <NUM>/box template while the converter assembly <NUM> continues to perform conversion functions on the sheet material <NUM> to complete the box template.

While the leading end of the box template is being moved/reoriented and glue is being applied thereto, the remainder of the box template is advanced out of the converter assembly <NUM>. At this point, the attachment assembly <NUM> engages the trailing end of the box template. The trailing end of the box template and the leading end of the box template are then brought together and joined or attached to one another (to create a manufacturer's joint) with the glue that was previously applied to the leading end of the box template. After the leading and trailing ends of the box template are attached together, the folded and glued box template is an un-erected box. The un-erected box is then released from the box forming machine <NUM> and can be erected into a box.

Attention is now directed to <FIG>, which illustrate the feed changer <NUM> in more detail. For the sake of clarity and ease of illustration, <FIG> show the feed changer <NUM> without the rest of box forming machine <NUM>. The sheet material <NUM> enters the feed changer <NUM> from the first or entry side thereof shown in <FIG>. The sheet material <NUM> exits the feed changer <NUM> from the second or exit side thereof illustrated in <FIG>.

As can be seen in <FIG>, the feed changer <NUM> may include one or more guide channels <NUM> (118a-<NUM>). The guide channels <NUM> may be configured to flatten the sheet material <NUM> so as to feed a substantially flat sheet thereof through converter assembly <NUM>. As shown, for instance, each guide channel <NUM> includes opposing upper and lower guide plates that are spaced apart sufficiently to allow the sheet material <NUM> to pass therebetween, but also sufficiently close enough together to flatten the sheet material <NUM>. In some embodiments, as shown in <FIG>, the upper and lower guide plates may be flared or spaced further apart at on opening end to facilitate insertion of the sheet material <NUM> therebetween.

Some of the guide channels <NUM> may be held or secured in a fixed position along the width of the feed changer <NUM> while other guide channels <NUM> are able to move along at least a portion of the width of the feed changer <NUM>. In the illustrated embodiment, the feed changer <NUM> includes movable guide channels 118b, 118c, 118f, <NUM>, and fixed guide channels 118a, 118d, 118e, <NUM>. More specifically, fixed guide channels 118a, 118d, 118e, <NUM> may be secured in place near opposing sides of the feed changer <NUM>. Movable guide channels 118b, 118c, 118f, <NUM> are disposed between left and right sides of the feed changer <NUM> and fixed guide channels 118a, 118d, 118e, <NUM> such that the movable guide channels 118b, 118c, 118f, <NUM> are able to move back and forth between the opposing sides of feed changer <NUM> and the fixed guide channels 118a, 118d, 118e, <NUM>.

The movable guide channels 118b, 118c, 118f, <NUM> may be able to move so feed changer <NUM> can accommodate sheet materials <NUM> of different widths. For instance, movable guide channels 118b may be able to move closer to fixed guide channel 118a when a narrower sheet material <NUM> is being converted than when a wider sheet material <NUM> is being converted. When a wider sheet material <NUM> is being converted, movable guide channels 118b may be moved away from fixed guide channels 118a so that the wider sheet material <NUM> may be passed between guide channels 118a, 118b. Similarly, movable guide channel 118c may be movable relative to fixed guide channel 118d to accommodate different widths of sheet materials <NUM>. Likewise, movable guide channels 118f, <NUM> may be movable relative to fixed guide channels 118e, <NUM>, respectively, to accommodate different widths of sheet materials <NUM>.

The movable guide channels 118b, 118c, 118f, <NUM> may be biased toward their respective fixed guide channels 118a, 118d, 118e, <NUM> so that, regardless of how wide the sheet material <NUM> is, the sets of movable and fixed guide channels <NUM> will be properly spaced apart to guide the sheet material <NUM> straight through the feed changer <NUM>. The movable guide channels 118b, 118c, 118f, <NUM> may be biased toward the fixed guide channels 118a, 118d, 118e, <NUM> with springs or other resilient mechanisms.

In the illustrated embodiment, the feed changer <NUM> includes four sets of guide channels <NUM> (e.g., fixed guide channel 118a and movable guide channel 118b; movable guide channel 118c and fixed guide channel 118d; fixed guide channel 118e and movable guide channel 118f; movable guide channel <NUM> and fixed guide channel <NUM>) that guide lengths of the sheet material <NUM> into the feed changer <NUM>. In the illustrated embodiment, the sets of guide channels <NUM> are arranged in a two-by-two column and row pattern. One row includes the guide channel set 118a, 118b and the guide channel set 118c, 118d, while the second row includes the guide channel set 118e, 118f and the guide channel set <NUM>, <NUM>. Similarly, one column includes guide channel set 118a, 118b and the guide channel set 118e, 118f, while the second column includes the guide channel set 118c, 118d and the guide channel set <NUM>, <NUM>.

The guide channel sets that are in the same row are horizontally offset from one another and vertically aligned with one another. In contrast, the guide channel sets that are in the same column are vertically offset from one another and can be at least partially aligned with one another. For instance, the fixed guide channels 118a, 118e are horizontally aligned and vertically offset from one another. Due to their ability to move to accommodate sheet materials <NUM> of different widths, the movable guide channels 118b, 118f may or may not be vertically aligned with one another. Similarly, the movable guide channels 118fc <NUM> may or may not be vertically aligned with one another.

While the feed changer <NUM> is shown and described with four sets of guide channels in a two-by-two arrangement, it will be understood that the feed changer <NUM> may include one or multiple sets of guide channels in one or more rows and one or more columns for feeding one or multiple, side-by-side and/or vertically offset lengths of sheet material <NUM> (e.g., from multiple bales <NUM>) through the feed changer <NUM>.

As illustrated in <FIG>, the feed changer <NUM> also includes multiple feed rollers that pull the sheet material <NUM> into the feed changer <NUM> and advance the sheet material <NUM> through the feed changer <NUM> and into the converter assembly <NUM>. More specifically, the illustrated embodiment includes an active feed roller <NUM> and multiple pressure feed rollers <NUM> (e.g., top pressure feed rollers 122a, bottom pressure feed rollers 122b). The active feed roller <NUM> may be actively rolled by an actuator or motor in order to advance the sheet material <NUM>. Although the pressure feed rollers <NUM> are not typically actively rolled by an actuator, pressure feed rollers <NUM> may nevertheless roll to assist with the advancement of the sheet material <NUM>.

The active feed roller <NUM> is secured to the feed changer <NUM> such that the active feed roller <NUM> is maintained in generally the same position. In contrast, at least some of the pressure feed rollers <NUM> may be movable along at least a portion of the width of the feed changer <NUM>. For instance, depending on the size of the box template being formed, the pressure feed rollers <NUM> may be moved closer together or further apart to help advance the sheet material <NUM> is a generally straight direction.

In some embodiments, such as the illustrated embodiment, each of the pressure feed rollers <NUM> is connected to or otherwise associated with a guide channel <NUM>. Thus, the pressure feed rollers <NUM> associated with the movable guide channels 118b, 118c, 118f, <NUM> move with movement of the movable guide channels 118b, 118c, 118f, <NUM>. For instance, if movable guide channel 118b is moved to accommodate a wider or narrower length of sheet material <NUM>, then the pressure feed roller 122a associated with guide channel 118b will move so as to be aligned with the wider or narrower length of sheet material <NUM>.

In the illustrated embodiment, there are top pressure feed rollers 122a and bottom pressure feed rollers 122b. The top pressure feed rollers 122a are disposed generally vertically above the active feed roller <NUM> and the bottom pressure feed rollers 122b are disposed generally vertically below the active feed roller <NUM>. The positioning of the top and bottom pressure feed rollers 122a, 122b and the rotational direction of the active feed roller <NUM> allows for sheet material <NUM> from different bales <NUM> to be advanced into and through the feed changer <NUM>.

For instance, if the active feed roller <NUM> is rotated in a first direction (i.e., with the top surface of the active feed roller <NUM> rotating in a direction generally from the entry side of the feed changer <NUM> shown in <FIG> toward the exit side of the feed changer <NUM> shown in <FIG>), sheet material <NUM> disposed between one or both of the top sets of guide channels (i.e., fixed guide channel 118a and movable guide channel 118b; movable guide channel 118c and fixed guide channel 118d) will be advanced through the feed changer <NUM>. In contrast, if the active feed roller <NUM> is rotated in a second direction (i.e., with the bottom surface of the active feed roller <NUM> rotating in a direction generally from the entry side of the feed changer <NUM> shown in <FIG> toward the exit side of the feed changer <NUM> shown in <FIG>), sheet material <NUM> disposed between one or both of the bottom sets of guide channels (fixed guide channel 118e and movable guide channel 118f; movable guide channel <NUM> and fixed guide channel <NUM>) will be advanced through the feed changer <NUM>. Thus, by simply changing the rotational direction of the active feed roller <NUM>, sheet material <NUM> from different bales <NUM> can be selected and advanced through the feed changer <NUM>.

In some embodiments, the pressure feed rollers <NUM> may be moved between active and inactive positions. In the inactive position, the pressure feed rollers <NUM> may not press the sheet material <NUM> against the active feed roller <NUM> (or at least not with enough pressure) to allow the active feed roller <NUM> to advance the sheet material <NUM>. In contrast, when the pressure feed rollers <NUM> are moved to the active position, the pressure feed rollers <NUM> may press the sheet material <NUM> against the active feed roller <NUM> with enough pressure so that the active feed roller <NUM> advances the sheet material <NUM>.

Attention is now directed to <FIG>, which illustrate the converter assembly <NUM> in more detail. For the sake of clarity and ease of illustration, <FIG> show the converter assembly <NUM> without the rest of the box forming machine <NUM>. The sheet material <NUM> enters the converter assembly <NUM> from the first or entry side thereof shown in <FIG>. The sheet material <NUM> exits the converter assembly <NUM> from the second or exit side thereof illustrated in <FIG>.

In the illustrated embodiment, the converter assembly <NUM> includes an infeed slot <NUM> in the first side thereof. The infeed slot <NUM> receives the sheet material <NUM> as it exits the feed changer <NUM> and directs the sheet material <NUM> into the converter assembly <NUM>. In the illustrated embodiment, the infeed slot <NUM> has a flared open end to assist with guiding the sheet material <NUM> into the converter assembly. The infeed slot <NUM> also includes one or more notches <NUM>. The one or more notches <NUM> may at least partially receive therein ends of the fixed guide channels 118a, 118d, 118e, <NUM> (opposite the flared open ends thereof). Thus, ends of the fixed guide channels 118a, 118d, 118e, <NUM> may extend at least partially into the infeed slot <NUM>. Extending the fixed guide channels 118a, 118d, 118e, <NUM> into the infeed slot <NUM> can assist with a smooth transition of the sheet material <NUM> from the feed changer <NUM> to the converter assembly <NUM>. For instance, the fixed guide channels 118a, 118d, 118e, <NUM> can maintain the sheet material <NUM> is a flat configuration as the sheet material enters the infeed slot <NUM>, thereby reducing or eliminating the possibility of the sheet material <NUM> getting caught in the transition from the feed changer <NUM> to the converter assembly <NUM>.

After passing through the infeed slot <NUM>, the sheet material <NUM> is engaged by an active feed roller <NUM>. The active feed roller <NUM> rotates to advance the sheet material <NUM> through the converter assembly <NUM>. As the sheet material <NUM> advances through the converter assembly <NUM>, one or more converting tools <NUM> perform conversion functions (e.g., crease, bend, fold, perforate, cut, score) on the sheet material <NUM> in order to create packaging templates out of the sheet material <NUM>. Some of the conversion functions may be made on the sheet material <NUM> in a direction substantially perpendicular to the direction of movement and/or the length of the sheet material <NUM>. In other words, some conversion functions may be made across (e.g., between the sides) the sheet material <NUM>. Such conversions may be considered "transverse conversions. " In contrast, some of the conversion functions may be made on the sheet material <NUM> in a direction substantially parallel to the direction of movement and/or the length of the sheet material <NUM>. Such conversions may be considered "longitudinal conversions. " Additional details, including structures and functions, regarding converting tools that may be used in the converter assembly <NUM> are disclosed in <CIT>, and entitled CONVERTING MACHINE (the "'<NUM> Application"), the entire content of which is incorporated herein by reference.

Some of the conversion functions may include cutting excess material off of the sheet material <NUM>. For instance, if the sheet material <NUM> is wider than needed to form a desired box template, part of the width of the sheet material <NUM> can be cut off by a conversion tool. The excess material or trim can be diverted out of the converter assembly <NUM> by one or more diverter tools <NUM>. As illustrated in <FIG>, the diverter tool <NUM> includes an angled surface that redirects the trim through a bottom or lower opening in the converter assembly <NUM>. As a result, the trim does not exit the second or exit side of the converter assembly <NUM> like the box template does. Rather, the trim is directed out of the converter assembly <NUM> prior to the exit side thereof so that the trim is separated from the completed box template.

As discussed in the '<NUM> Application, the converting tools can be repositioned along the width of the sheet material <NUM> in order to perform the conversion functions at desired locations along the width of the sheet material <NUM>. Thus, for instance, the converting tools <NUM> shown <FIG> can be repositioned along the width of the converter assembly <NUM> in order to cut the sheet material <NUM> at a desired locations to remove a desired about of trim therefrom.

The diverter tool <NUM> may be connected to or otherwise associated with one of the converting tools <NUM> (e.g., a cutting wheel or knife) that cuts the trim from the sheet material <NUM>. As a result, when the converting tool <NUM> is moved to the required position to cut the desired amount of trim from the sheet material <NUM>, the diverter tool <NUM> moves with the converting tool <NUM> so that the diverter tool <NUM> is properly positioned to redirect the trim out of the converter assembly <NUM>.

A label or other identifier can be applied to the sheet material <NUM> (at least partially formed box template) during advancement through the converter assembly <NUM>. For instance, as shown in <FIG>, the converter assembly <NUM> may include a labeler <NUM> movably mounted thereto. The labeler <NUM> may move between opposing sides of the converter assembly <NUM> and may apply labels to the at least partially formed box templates. Because there can be multiple side-by-side tracks of sheet material <NUM> processed through the converter assembly <NUM> and because the box templates vary in sizes, the label <NUM> needs to be able to apply labels at various positions along the width of the converter assembly.

A control system can control the operation of the box forming machine <NUM>. More specifically, the control system can control the movement and/or placement of the various components of the box forming machine <NUM>. For instance, the control system can control the rotational direction of the active feed roller <NUM> in order to select the desired sheet material <NUM> and the positioning of the converting tools <NUM> to perform the conversion functions on the desired locations of the sheet material <NUM>.

Similarly, the control system can control the operation of the labeler <NUM>. By way of example, the control system can cause the labeler <NUM> to print and apply a label to a particular box template. For instance, during the formation of a box template that will be used to ship a particular order to a particular shipping address, the control system can cause the labeler <NUM> to print desired information (e.g., shipping address, packing list, etc.) on a label. As the box template moves through the converter assembly <NUM>, the control system can cause the labeler <NUM> to move over the box template and apply the label to the box template.

In some embodiments, the labeler <NUM> applies the label to the box template as the box template is moving through the converter assembly <NUM>, which can reduce the time required to form and label the box template. In other embodiments, however, the movement of the box template through the converter assembly <NUM> can be paused long enough for the labeler <NUM> to apply the label.

The control system can also monitor the position and operation of the various components of the box forming machine <NUM> to enable the labeler <NUM> to apply the labels to desired locations on the box templates. For instance, the control system can monitor the rotational speed of the active rollers <NUM>, <NUM>. The rotational speed of the rollers <NUM>, <NUM> can be used to determine the speed at which the sheet material <NUM> is moving through the box forming machine <NUM>. Similarly, the control system can monitor the location of the converting tools and/or when the converting tools are activated to perform the conversion functions on the sheet material <NUM>.

For a standard box template, the converting tools create cuts and creases in the sheet material <NUM> to define different sections of the box template. The different sections of the box template may include wall sections and closure flap sections. By monitoring the operation and/or positions of the components of the box forming machine <NUM>, the control system can move the labeler <NUM> and cause the labeler <NUM> to apply the label at a particular time so that the label is applied at a particular place or within a particular area on the box template. In some embodiments, for instance, it may be desired to have the label applied to a particular wall section or closure flap. By monitoring the position and/or operation of the components of the box forming machine <NUM>, the control system is able to direct the labeler <NUM> to the proper position over the box template (e.g., over the desired wall section or closure flap) and cause the labeler to apply the label at the proper time (when the desired wall section or closure flap moves or is positioned underneath the labeler <NUM>).

One or more additional feed rollers <NUM> are positioned near the exit or second side of the converter assembly <NUM>. The feed roller(s) <NUM> may be active rollers (similar to rollers <NUM>, <NUM>) or passive rollers (similar to rollers <NUM>). The feed roller(s) <NUM> may assist in directing the box template out of the converter assembly <NUM>. More specifically, the feed roller(s) <NUM> may press the box template against the outfeed plate <NUM> so the box template exits the converter assembly <NUM> at a known orientation and/or position.

Attention is now directed to <FIG>, which illustrate the fold assembly <NUM> in more detail. For the sake of clarity and ease of illustration, <FIG> show the fold assembly <NUM> without the rest of box forming machine <NUM>. Furthermore, <FIG> show a simplified version of a portion of the fold assembly <NUM> and the interactions with a box template. The fold assembly <NUM> engages the box templates formed with sheet material <NUM> as the box templates exit the converter assembly <NUM>. As discussed in greater detail below, the fold assembly <NUM> is configured to engage and move and/or reorient a first end of a box template so glue can be applied thereto and so that a second end of the box template can be attached to the first end.

As can be seen in <FIG>, the fold assembly <NUM> includes first and second sub-frames <NUM>, <NUM> and a fold head <NUM>. The first sub-frame <NUM> is slidably and/or pivotally mounted to the frame <NUM> (<FIG>). For instance, the first sub-frame <NUM> may include one or more tracks, recesses, grooves, or the like that interact with the one or more track clamps connected to the frame <NUM> to allow the first sub-frame <NUM> to slide through and/or pivot relative to the one or more track clamps. The track clamps may be fixedly secured to the frame <NUM>. Similarly, the second sub-frame <NUM> may be slidably and/or pivotally mounted to the first sub-frame <NUM> via one or more track clamps <NUM>. For instance, the second sub-frame <NUM> may include one or more tracks, recesses, grooves, or the like that interact with the one or more track clamps <NUM> connected to the first sub-frame <NUM> to allow the second sub-frame <NUM> to slide through and/or pivot relative to the one or more track clamps <NUM> on the first sub-frame <NUM>.

The movable nature of the first and second sub-frames <NUM>, <NUM> enables the fold head <NUM> to move in a variable range of motion in an X-Y field. As a result, the fold head <NUM> can be moved vertically up and down relative to the converter assembly <NUM> and/or horizontally closer to and further from the converter assembly <NUM>.

In addition to the movement available to the fold head <NUM> from the movement of the first and second sub-frames <NUM>, <NUM>, the fold head <NUM> is movably mounted on the second sub-frame <NUM>. More specifically, as shown in <FIG>, the fold head <NUM> includes a shaft <NUM> that is rotatably mounted to the second sub-frame <NUM> and which can be rotated by an actuator <NUM>. The actuator may take various forms. For instance, in the illustrated embodiment, the actuator <NUM> includes a motor and a drive belt. Mounted on the shaft <NUM> is a fold plate <NUM> and first and second clamps <NUM>, <NUM>. The first and second clamps <NUM>, <NUM> can each be moved via one or more actuators.

In operation, the fold head <NUM> can be moved adjacent to the outfeed plate <NUM> of the converter assembly <NUM> so as to be able to engage the box template as the box template exits the converter assembly <NUM>. For instance, <FIG> illustrates the fold head <NUM> positioned adjacent to the outfeed plate <NUM> of the converter assembly <NUM>. <FIG> also shows a first end of a box template BT exiting the converter assembly <NUM>. As shown, the box template BT can be advanced out of the converter assembly <NUM> so that a glue tab GT extends beyond the edge of the outfeed plate <NUM> and so that a crease between the glue tab GT and an adjacent panel on the box template BT is aligned with the edge of the outfeed plate <NUM>.

Once the glue tab GT is so positioned (i.e., with the crease aligned with the edge of the outfeed plate <NUM>), the fold head <NUM> can rotate into engagement with the glue tab GT to fold the glue tab GT relative to the rest of the box template BT. <FIG> shows the fold head <NUM> rotating about the shaft <NUM> and or moving relative to the box template BT to fold the glue tab GT. As noted above, the glue tab GT is positioned with a crease aligned with the edge of the outfeed plate <NUM>. The alignment of the crease and the rotation/movement of the fold head <NUM> causes the glue tab GT to predictably fold along the crease. The fold head <NUM> can continue to rotate and/or move (e.g., toward the converter assembly <NUM>) until the glue tab GT is folded against the back surface of the outfeed plate <NUM> as shown in <FIG>.

Once the glue tab is folded, the fold plate <NUM> and/or the first clamp <NUM> can be moved from a first or open position (<FIG>) to a second or closed position as shown in <FIG>. When the fold plate <NUM> and the first clamp <NUM> are in the closed position, the folded edge of the box template BT is clamped or held between the fold plate <NUM> and the first clamp <NUM> as shown in <FIG>. In some embodiments, the first clamp <NUM> clamps onto about <NUM> or less of the folded edge of the box template BT. In other embodiments, the first clamp <NUM> clamps onto about <NUM>, <NUM>, <NUM> or less of the folded edge of the box template BT.

With the folded edge of the box template BT clamped or held between the fold plate <NUM> and the first clamp <NUM>, the fold head <NUM> can then move and/or reorient the first end of the box template BT. For instance, as shown in <FIG>, the fold head <NUM> can move away from the outfeed plate <NUM>, thereby pulling the folded box template BT off of the outfeed plate <NUM>.

In some embodiments, the edges of the outfeed plate <NUM> (<FIG>) and the first clamp <NUM> (<FIG>) include notched configurations. More specifically, the edge of the outfeed plate <NUM> includes a plurality of spaced apart notches. Similarly, the edge of the first clamp <NUM> that engages the box template includes a plurality of spaced apart notches. In some embodiments, the notches on the first clamp <NUM> are offset from the notches on the outfeed plate <NUM>. Offset notches can reduce the amount of friction between the box template BT and the outfeed plate <NUM> when the folded box template BT is pulled off of the outfeed plate <NUM>.

Once the first end of the box template BT has been pulled off of the outfeed plate <NUM>, the fold head <NUM> can move and/or reorient (via the movement of the first and second sub-frames <NUM>, <NUM> and/or rotation of the fold head <NUM>) the first end of the box template BT to a desired position and/or orientation. For instance, as illustrated in <FIG>, the fold head <NUM> can move horizontally and vertically away from the outfeed plate <NUM>. Due to the folded end of the box template BT being clamped between the fold plate <NUM> and the first clamp <NUM>, the folded end of the box template BT can also move horizontally and vertically away from the outfeed plate <NUM>. As noted above, the horizontal and vertical movement of the fold head <NUM> can be accomplished with the movement of the first and second sub-frames <NUM>, <NUM>.

As noted above, the fold head <NUM> can also rotate about the shaft <NUM> in order to reorient the folded end of the box template BT. In the embodiment illustrated in <FIG>, for instance, the fold head <NUM> is illustrated as being rotated clockwise about the shaft <NUM>. As the fold head <NUM> rotates, the folded end of the box template BT is reoriented. More specifically, when the fold head <NUM> initial clamps onto the folded edge of the box template BT, the exposed surface of the glue tab GT is facing generally downward. As the fold head <NUM> rotates, the exposed surface of the glue tab GT is reoriented until it is facing generally upward, as shown in the lower portion of <FIG>.

Thus, the fold assembly <NUM> can fold the glue tab GT relative to the rest of the box template BT and clamp onto the folded edge of the box template BT. Thereafter, the fold assembly <NUM> can move and/or reorient the folded edge (at the first end) of the box template BT from a first location and/or orientation (adjacent to the outfeed plate <NUM>, with the glue tab GT facing generally downward) to a second location and/or orientation (vertically lower than the outfeed plate <NUM>, with the glue tab GT facing generally upward) so that the glue tab GT is positioned and oriented in a predetermined or known position and/or orientation.

As shown in <FIG>, the second location and/or orientation may be situated to enable a gluing device <NUM> to apply glue to the exposed surface of the glue tab GT. For instance, once the folded edge of the box template BT is in the second location and/or orientation, the gluing device <NUM> may move relative to the glue tab GT in order to apply glue thereto. The gluing device <NUM> may be connected to the frame <NUM> such that the gluing device <NUM> (or a portion thereof) can move between opposing sides of the box forming machine <NUM> to apply glue to the glue tab GT of the box template BT.

While the folding head <NUM> is moving and/or repositioning the folded edge of the box template BT and glue is being applied thereto, the box template BT may continue to be fed out of the converter assembly <NUM>. As will be discussed in greater detail below, the movement/reorientation of the folded edge of the box template BT and the additional feeding out of the box template BT from the converter assembly <NUM> can cause the box template BT to fold in half.

Once the second end of the box template BT reaches the exit side of the converter assembly <NUM>, the attachment assembly <NUM> engages the second end of the box template BT. With the second end of the box template BT engaged, the attachment assembly <NUM> moves and/or reorients the second end of the box template BT to bring the second end into engagement with the first end thereof in order to attach together the first and second ends of the box template BT.

As illustrated in <FIG>, the attachment assembly includes first and second sub-frames <NUM>, <NUM> and an attachment head <NUM>. In the illustrated embodiment, the first sub-frame <NUM> may be slidably and/or pivotally mounted to the frame <NUM> (<FIG>) via one or more track clamps <NUM>. As with the first sub-frame <NUM>, the first sub-frame <NUM> may include one or more tracks, recesses, grooves, or the like that interact with one or more track clamps <NUM> to allow the first sub-frame <NUM> to slide through and/or pivot relative to the one or more track clamps <NUM> and allow the first sub-frame <NUM> to slide and/or pivot relative to the frame <NUM>.

The second sub-frame <NUM> is slidably mounted to the first sub-frame <NUM> via one or more track clamps <NUM>. The second sub-frame <NUM> can slide along and/or pivot relative to the first sub-frame <NUM> via the track clamps <NUM>. Additionally, the second sub-frame <NUM> is selectively extendable via one or more extension mechanisms <NUM>. The extension mechanism(s) <NUM> can be selectively extended or retracted in order to move the attachment head <NUM>.

The movable nature of the first and second sub-frames <NUM>, <NUM> (including the extension/retraction of the extension mechanism(s) <NUM>) enables the attachment head <NUM> to move in a range of motion in an X-Y field. As a result, the attachment head <NUM> can move vertically up and down relative to the converter assembly <NUM> and/or horizontally closer to and further from the converter assembly <NUM>.

In addition to the movement available to the attachment head <NUM> from the movement of the first and second sub-frames <NUM>, <NUM>, the attachment head <NUM> is movably mounted on the second sub-frame <NUM>. More specifically, the attachment head <NUM> includes a shaft <NUM> that is rotatably mounted to the second sub-frame <NUM> and which can be rotated by an actuator.

As can be seen in <FIG>, the attachment head <NUM> can include one or more guides <NUM>. The one or more guides <NUM> can be disposed on one or both sides of the attachment head <NUM>. The one or more guides <NUM> can help with alignment of the box template BT relative to the attachment head <NUM>.

The attachment head <NUM> can also include one or more attachment mechanisms <NUM>. For instance, as illustrated in <FIG>, the attachment head <NUM> can include an attachment mechanism 172a and/or an attachment mechanism 172b. In the illustrated embodiment, the attachment mechanism 172a is slidably mounted on the shaft <NUM> such that the attachment mechanism 172a can move closer to or further away from a box template BT. For instance, <FIG> illustrates the attachment mechanism 172a position that on the shaft <NUM> in a retracted position. In the retracted position, a clamp <NUM> of the attachment mechanism 172a is positioned outside of the guide <NUM> such that the attachment mechanism 172a is not aligned with the box template BT. In contrast, <FIG> illustrates the attachment mechanism 172a position on the shaft <NUM> in an engaged position. In the engaged position, the clamp <NUM> of the attached mechanism 172a extends beyond (inside) the guide <NUM> toward the middle of the attachment head <NUM> such that the clamp <NUM> is aligned width or least partially overlaps the box template BT.

In addition to the attachment mechanism 172a being movable on the shaft <NUM> between a retracted and engaged positions, the clamp <NUM> can be selectively extended or retracted in order to engage or release a portion of the box template BT. In <FIG>, for example, the clamp <NUM> is extended away from the shaft <NUM>. As result, when the attachment mechanism 172a is moved from the retracted position shown in <FIG> to be engaged position shown in <FIG>, the clamp <NUM> can be positioned below the box template BT so that the box template BT is positioned between the clamp <NUM> and another portion of the attachment head <NUM>. Once the box template BT is positioned between the clamp <NUM> and another portion of the attachment head <NUM>, the clamp <NUM> can be moved to the engaged position so as to clamp the box template BT between the clamp <NUM> and another portion of the attachment head <NUM>, as shown in <FIG>.

In some embodiments the surface of the clamp <NUM> that engages the box template BT may be configured for engaging the box template BT in a secure and/or nonslip manner. For instance, the clamp <NUM> may include a rubber or other nonslip surface. The clamp <NUM> may also or alternatively include one or more projections (such as a set screw or spikes) that engage the box template BT to ensure a secure connection therewith.

In some embodiments, in addition or as an alternative to the attachment mechanism 172a, the box template BT can be engaged and selectively attached to the attachment head <NUM> with the attachment mechanism 172b. In the illustrated embodiment, the attachment mechanism 172b includes one or more vacuum heads. As shown in <FIG>, the one or more vacuum heads can engage a planar surface of the box template BT and use a negative pressure to selectively secure the box template BT to the attachment head <NUM>.

As can be best seen in <FIG>, the attachment mechanism 172b can include an array of vacuum heads that are aligned in one or more rows. The illustrated embodiment includes two rows of vacuum heads, but the attachment mechanism 172b may include a single row or more than two rows of vacuum heads. Additionally the illustrated embodiment shows that the rows of vacuum heads are offset from one another. Offsetting the rows of vacuum heads can help ensure that a vacuum head is able to make secure contact with the box template BT. For instance, the box template BT may include various creases, scores, or other surface irregularities that make it difficult for one vacuum head to securely attach to the box template BT. In such instances, an offset vacuum head may be able to securely engage another portion of the box template BT that is free from such creases, scores, or other surface irregularities.

Once the box template BT has been fed out of the converter assembly <NUM> and the attachment head <NUM> has engaged the second end of the box template BT (e.g., via attachment mechanism 172a and/or 172b), the attachment assembly <NUM> can move the second end of the box template BT into engagement with the first end thereof. For instance, the upper portion of <FIG> illustrates the attachment head <NUM> engaged with the second end of the box template BT adjacent to the outfeed plate <NUM>. From there, the attachment head <NUM> can move vertically and/or horizontally relative to the converter assembly <NUM> in order to bring the second end of the box template BT into engagement with the first end thereof. As illustrated in <FIG>, for example, the attachment head <NUM> may move the box template BT vertically as well as horizontally. As discussed above, the horizontal and/or vertical movement of the attachment head <NUM> can be accomplished via the movement of the first and/or second sub-frames <NUM>, <NUM>. Additionally, the attachment head <NUM> can rotate about the shaft <NUM> to reorient the second end of the box template BT as it moves the second end of the box template BT toward the first end thereof.

As illustrated in <FIG>, the attachment head <NUM> can bring the second end of the box template BT into engagement with the first end the box template BT such that the two ends of the box template BT are generally parallel to one another. In some embodiments, the attachment head <NUM> can align the edge of the second end of the box template BT against the first clamp <NUM> of the fold head <NUM>. As can be seen in <FIG>, due to the position of the first clamp <NUM> on top of part of the glue tab GT, the second end of the box template BT does not entirely cover the glue tab GT.

With the second end of the box template BT so positioned on top of the first end of the box template BT, the second clamp <NUM> of the fold head <NUM> can move from the open position shown in <FIG> to the closed position shown in <FIG>. Moving the second clamp <NUM> to the closed position compresses the second end of the box template BT, the glue tab GT, and the glue that was applied to the glue tab GT by the gluing device <NUM> between the second clamp <NUM> and the fold plate <NUM>, as shown in <FIG>. Such compression helps to ensure that the second end of the box template BT and the glue tab GT are secured together by the glue. Once the two ends of the box template BT are secured together, the first and second clamps <NUM>, <NUM> are released. The attachment head <NUM> can also release the box template BT to allow the box template BT to be removed from the box forming machine <NUM>. In some embodiments, once the first and second clamps <NUM>, <NUM> are released, the attachment head <NUM> can move the box template BT away from the fold head <NUM> and to a position where the box template BT can be readily removed from the box forming machine <NUM>. For instance, as shown in <FIG>, the attachment head <NUM> can rotate about shaft <NUM> and move (via movement of sub-frames <NUM>, <NUM>) so as to position the box template BT near an exit point from the box forming machine <NUM>.

A comparison between <FIG> and <FIG> shows that the attachment head <NUM> has rotated about <NUM> degrees after the fold head <NUM> releases the box template BT. In other embodiments, the attachment head <NUM> may rotate about <NUM> degrees after the fold head <NUM> releases the box template BT. In some embodiments, prior to rotation of the attachment head <NUM>, the box template BT may be oriented generally parallel to the outfeed plate <NUM>. After rotation of the attachment head <NUM>, the box template BT may be oriented generally perpendicular to the outfeed plate <NUM>.

In any event, after or during rotation of the attachment head <NUM>, the attachment head <NUM> may then move the box template BT towards an exit point (e.g., an opening, slot, or the like in the machine <NUM>) through which the box template BT can be fed out of or retrieved from the box forming machine <NUM>. During such movement, one or more of the attachment mechanisms <NUM> may continue to secure the box template BT to the attachment head <NUM>, such that the box template BT is rotated and moved with the attachment head <NUM>.

In some embodiments, as shown in <FIG>, one or more sets of opposing rollers <NUM>, <NUM> may be positioned adjacent to the exit point of the machine <NUM>. The opposing rollers <NUM>, <NUM> may be activated to feed the box template BT out of the machine <NUM>. For instance, the rollers <NUM> may be advanced towards the rollers <NUM> and rotated to feed the box template BT out of the machine <NUM>. In other embodiments, the rollers <NUM> may advance towards the rollers <NUM>, or the rollers <NUM> and rollers <NUM> may advance towards each other. In any case, one or more of the rollers <NUM>, <NUM> may be active rollers (e.g., rotated by a motor, etc.) that advance the box template BT out of the box forming machine <NUM>.

In some instance, even after the ends of the box template BT have been secured together, the box template BT may not lie flat. For instance, panels of the box template BT may spread apart from one another. This may be caused by folds in the sheet material <NUM> used to form the box template BT. As noted above, the sheet material <NUM> is folded into stacks in bales <NUM> before being used to form the box templates BT. While the folds formed in the sheet material <NUM> may allow the sheet material <NUM> to be stacked into bales <NUM>, such folds can also cause the formed box templates BT to not want to lie flat.

To flatten the box templates BT before feeding them through the rollers <NUM>, <NUM>, the box templates BT may be advanced through an outfeed guide channel <NUM>, as illustrated in <FIG>. The outfeed guide channel <NUM> may gradually flatten the box template BT such that additional creases are not formed in the box template BT as it is fed through the rollers <NUM>, <NUM>.

In the illustrated embodiment, the outfeed guide channel <NUM> includes an angled plate <NUM>. The angled plate <NUM> is positioned opposite the attachment head <NUM> (when the attachment head <NUM> is rotated and moved towards the exit point of the machine <NUM>, as shown in <FIG>) such that the box template BT is positioned between he attachment head <NUM> and the angled plate <NUM>. The angled plate <NUM> is angled towards the attachment head <NUM>, such that advancement of the box template BT along the angled plate <NUM> causes the box template BT to be feed towards the attachment head <NUM>.

The outfeed guide channel <NUM> may also include one or more guides <NUM>. In the illustrated embodiment, the guides are mounted on the attachment head <NUM> such that the guides <NUM> move with the attachment head <NUM>. Each guide <NUM> includes an arcuate or angled frame <NUM>. The frame <NUM> is arranged such that the frame <NUM> and the angled plate <NUM> cooperate to form a tapering channel. In other words, the angled plate <NUM> and the frame <NUM> are shaped and oriented so that a channel formed therebetween gradual tapers. The tapered channel formed by the angled plate <NUM> and the frame <NUM> gradually flattens the box templates BT as the box templates BT advanced therebetween and out of the exit point of the machine <NUM>.

In some embodiments, the angled plate <NUM> and/or frame <NUM> may include one or more wheels to assist with the advancement of the box template BT through the tapered channel. For instance, <FIG> shows wheels <NUM> mounted on the frame <NUM>. The wheels <NUM> can rotate to reduce the friction between the frame <NUM> and the box templates BT as the box template BT is advanced out of the box forming machine <NUM>.

Once the rollers <NUM>, <NUM> engage the box template BT, the attachment head <NUM> can release the box template BT. In particular, the attachment mechanism(s) <NUM> may disengage the box template BT, thereby allowing the rollers <NUM>, <NUM> to advance the box template BT out of the machine <NUM>.

Attention is now directed to <FIG>, which illustrate portions of an alternative embodiment of a box forming machine 108a. The box forming machine 108a can be similar or identical to the box forming machine <NUM> in many respects. Accordingly, the following description of the box forming machine 108a will focus primarily on the features that are different from the box forming machine <NUM>. It will be appreciated however that the various features of the box forming machines <NUM>, 108a may be interchanged with one another.

As can be seen in <FIG>, box forming machine 108a includes a converter assembly 112a, a fold assembly 114a, and an attachment assembly 116a. After the converter assembly 112a performs the one or more conversion functions on the fanfold material to transform it into a box template BT, the box template BT is fed out of the converter assembly 112a adjacent to the outfeed plate 136a. As shown in <FIG>, the box template BT is fed out of the converter assembly 112a until a crease is aligned with the edge of the outfeed plate 136a.

Once the glue tab GT crease is aligned with the edge of the outfeed plate 136a, the fold assembly 114a engages the box template BT to fold the glue tab GT relative to the rest of the box template BT. For instance, as shown in <FIG>, the fold assembly 114a can move vertically and/or horizontally to engage the glue tab GT. More specifically, as shown in <FIG>, a first clamp 154a of the fold assembly 114a can engage the glue tab GT in order to fold the glue tab GT around the outfeed plate 136a.

The folded end of the box template BT can be compressed between the first clamp 154a and the fold plate 152a, as shown in <FIG>. As shown in <FIG>, the fold assembly 114a can then move away from the converter assembly 112a. In the illustrated embodiment, the fold assembly 114a can pivot about a pivot axis. As the fold assembly 114a moves, the clamping force applied to the folded end of the box template BT (i.e., by the fold plate 152a and the first clamp 154a) causes the first end of the box template BT to move and be reoriented with the fold assembly 114a.

A comparison between <FIG> and <FIG>, for instance, illustrates that the fold assembly 114a can move and reorient the first end the box template from a first position and orientation adjacent to the converter assembly 112a to a second position and orientation adjacent to a gluing device 157a. As with the previous embodiment, once the first end of the box template BT is in the first position and orientation, the glue tab GT is facing generally downward. In the second position and orientation, the glue tab GT is facing generally upward. Once the first end of the box template BT is moved and reoriented to the second position and orientation, the gluing device 157a can apply glue to the glue tab GT, as shown in <FIG>.

While the fold assembly 114a is moving the first end of the box template BT and the gluing device 157a is applying glue to the glue tab GT, the box template BT continues to be fed out of the converter assembly 112a, as can be seen in <FIG>. The movement of the first end of the box template BT and the continual feeding out of the box template BT causes the box template BT to fold in half as shown in the Figures.

When the second end of the box template BT is fed out of the converter assembly 112a, the attachment assembly 116a engages the second end the box template BT and can move it toward the first end the box template BT. For example, <FIG> illustrate the attachment assembly 116a moving the second end of the box template BT from the outfeed side of the converter assembly 112a toward and into contact with the glue tab GT. In some embodiments, the attachment assembly 116a can press the second end of the box template BT against the glue tab GT (with the glue therebetween) to secure the two ends of the box template BT together. In other embodiments, similar to the embodiment described above, the fold assembly 114a may include a second clamp that presses the second end of the box template BT and the glue tab GT together with the glue therebetween.

Once the two ends of the box template BT are joined together, the box template BT can be removed from the box forming machine 108a. For instance, the fold assembly 114a and the attachment assembly 116a can release their holds on the box template BT. Thereafter, the box template BT can be freely removed from the box for machine 108a.

In light of the foregoing, it will be appreciated that the present disclosure relates to box forming machines that can perform one or more conversion functions on the sheet material to convert the sheet material into box templates. In addition, the box forming machines of the present disclosure can engage a first end of a box template and move the first end of the box template to a predetermined location. When engaging the first end the box template, the box forming machine may fold a first portion of the box template (e.g., a glue tab) relative to a second portion of the box template. In moving the first end the box template to the predetermined location, the box forming machine can reorient the first end of the box template to a desired orientation. With the first end the box template in the predetermined location and the desired orientation, glue can be applied to the first end the box template.

The box forming machines of the present disclosure can also engage the second end of the box template and move the second end of the box template into engagement with the first end the box template. In moving the second end the box template into engagement with the first end the box template, the box forming machine can reorient the second end the box template to a desired orientation (e.g., parallel to the first end of the box template). In some embodiments, the box forming machines can compress the first and second ends of the box template together with glue therebetween in order to secure the first and second ends together. Once the first and second ends of the box template have been secured together, the box forming machine can either release the box template or move the box template to a desired location where it can be removed from the box forming machine.

The embodiments described above include folding the first end the box template and then bringing the second end of the box template into engagement with the folded end the box template. It will be appreciated, however, that this is merely exemplary. In other embodiments, for instance, box forming machines may engage the first end of the box template without folding a portion thereof. The first end the box template may then be moved and/or reoriented to a predetermined and desired position and location. The box forming machine may then engage the second end the box template. Engaging the second end of the box template may include folding a first portion (e.g., a glue tab) relative to another portion of the box template. The box forming machine may then move the folded second end the box template into engagement with the first end the box template to secure the first and second ends together.

Claim 1:
A box forming machine (<NUM>) comprising:
a converter assembly (<NUM>) that is configured to perform one or more conversion functions on a sheet material (<NUM>) to convert the sheet material to a box template (BT); and
an infeed changer (<NUM>) that is configured to direct different sheet materials into the converter assembly, the infeed changer comprising:
at least one upper set of guide channels (<NUM>) configured to direct a first sheet material into the infeed changer;
at least one lower set of guide channels (<NUM>) configured to direct a second sheet material into the infeed changer; and
an active roller (<NUM>) that is configured to draw the first or second sheet material into the infeed changer, characterized in that the active roller is configured to rotate in a first direction and
in a second direction, wherein rotation of the active roller in the first direction draws the first sheet material into the infeed changer and rotation of the active roller in the second direction draws the second sheet material into the infeed changer.