Patent Description:
Sales of goods and services via the internet have risen sharply in recent years and this trend is expected to continue. The vast majority of online orders are shipped to the customer, requiring most products purchased online to be packaged for shipping. With the wide range of products being ordered, packaging can present a number of challenges for manufacturers and distributors. For example, while products of all shapes and sizes need to be packaged and sent to customers, manufacturers and/or distributors may only have a limited variety of box sizes to accommodate such products.

As a result, products are often placed into boxes that are too big. Using boxes that are too big uses additional packaging materials, which is wasteful and costly. Also, packaging boxes that are too big for the product being shipped results in wasted space inside the box and around the product. This extra space can cause the product to shift, bounce, or otherwise move around in the box during shipping, which leads to the product being damaged during transport. In many case, filler material is placed around the product inside the box to prevent the product from being jostled too much. However, the extra filler material costs money and time.

There are packaging machines that are capable of customizing packaging boxes to specific product sizes in order to limit or eliminate some of the challenges mentioned above. In such machines, boxes are formed from sheet material that is fed into the machine, which cuts the sheet material into a box template (or "blank"). The blank is then folded into a box.

Prior to being formed into box templates, the sheet material can be folded back and forth on top of itself in alternating segments in a stack. As such, the sheet material includes score or fold lines extending across the material between segments. Because of these score or fold lines, using fanfold material (e.g., sheet material that has been folded back and forth on itself) to form blanks can be problematic. For example, the blank formed from fanfold material often does extends across multiple segments of the fanfold material. Thus, blanks formed from fanfold material often have score or fold lines extending across one or more panels, tabs, or other sections of the blank. These fanfold score or fold lines extending across the blank are referred to as "false scores" because they likely do not fall directly on the blank where the blank is supposed to be folded. That is, packaging machines typically bend the blanks at boundaries between the panels and tabs to form boxes and false scores do not necessarily align with those boundaries. As such, false scores create weaknesses in the blank material that may cause certain panels or tabs of the blank to collapse, bend, rip, or otherwise fail during bending or other box folding processes within a packaging machine.

The difficulties presented by false scores extending across blanks are exacerbated when the packaging machine is tasked with forming a variety of customizable box sizes, as discussed above, from generic fanfold material. In such situations, false scores extending across blanks can occur at any point along the length of the blank, depending on the size and configuration of the blank, which may change based on the size of the product being packaged. Essentially, the position of false scores on blanks can vary from one blank to the next. This variability makes it difficult for manufacturers and/or distributors to adapt packaging machines to overcome the difficulties false scores present during customizable package forming processes.

The document <CIT> discloses a machine for forming a box from a blank. The blank is driven along a drive line and comprises a leading panel, an intermediate panel, a bottom panel and a trailing panel; a plurality of side panels extend transversely from the main panels. The side panels are alternatively folded upwardly or left flat by the action of folding units,.

Accordingly, there are a number of problems in the art that need to be addressed.

The present disclosure relates to packaging machines. More specifically, the present disclosure relates to methods and apparatus for forming customized packaging boxes from generic fanfold material. For example, in an embodiment of the present disclosure, a method of forming a box from a blank includes providing a blank on a drive line. The blank can include a plurality of panels, including a leading panel, and intermediate panel, a bottom panel, a trailing panel, and a glue tab extending form the trailing panel. Each panel has one or more side flaps extending therefrom. In such an embodiment, the method further includes moving the blank forward on the drive line and folding the side flaps up and down in an alternating fashion.

In one embodiment of the present disclosure, a method for forming a box includes providing a blank on a drive line and moving the blank forward thereon. While the blank is moving forward on the drive line, various side flaps of the blank are moved up and down in alternating fashion to rigidify panels from which the side flaps extend. Also, a holder maintains the side flaps that have been folded up in position and holds a bottom panel of the blank down while adjacent panels of the blank are folded up and over to form back, front, and top surfaces of the box. In such an embodiment, the bottom leading corner of the holder is chamfered so that the leading panels of the blank can be partially folded up before the leading panel completely passes a leading edge of the holder.

In one embodiment of the present disclosure, a method for forming a box includes providing a blank on a drive line and moving the blank forward thereon. While the blank is moving forward on the drive line, various side flaps of the blank are moved up and down in alternating fashion to rigidify panels from which the side flaps extend. In such an embodiment, a holder maintains the side flaps that have been folded up in position and holds a bottom panel of the blank down while adjacent panels of the blank are folded up and over to form back, front, and top surfaces of the box. Also, a spatula arm folds the glue tab downward and the leading edge of the spatula makes contact with a boundary of the leading two panels of the blank. In this way, the leading two panels are folded at the boundary to form the top and front surfaces of the box.

In one embodiment of the present disclosure, a method for forming a box includes providing a blank on a drive line and moving the blank forward thereon. While the blank is moving forward on the drive line, various side flaps of the blank are moved up and down in alternating fashion to rigidify panels from which the side flaps extend. Also, a holder maintains the side flaps that have been folded up in position and holds a bottom panel of the blank down while adjacent panels of the blank are folded up and over to form back, front, and top surfaces of the box.

In one embodiment of the present disclosure, a method of forming a box from a blank includes providing a blank on a drive line. The blank can include a plurality of panels, including a leading panel, and intermediate panel, a bottom panel, a trailing panel, and a glue tab extending form the trailing panel. Each panel has one or more side flaps extending therefrom. In such an embodiment, the method includes moving the blank forward on the drive line and folding the side flaps up and down in an alternating fashion. A holder maintains the folded side flaps in position while the blank moves forward on the drive line. As the blank continues to move forward, the two leading panels and the two trailing panels are folded up and over to form the top, front, rear, and glue tab surfaces of the box, respectively. In addition, in such an embodiment, one or more trailing squaring arms and one or more leading squaring arms maintain the bottom trailing corner and the top leading corner of the box at a fixed angle.

In one embodiment of the present disclosure, a box forming machine includes a drive line. The drive line has a longitudinal direction and a drive mechanism configured to transport a blank forward on the drive line. The box forming machine also includes one or more fingers and one or more holders. The fingers are configured to lift and push down side flaps of the blank in an alternating fashion as the blank moves forward on the drive line. The one or more holders are configured to hold the side flaps of the blank in position as the blank moves forward on the drive line.

In one embodiment, a method for folding a box from a blank is performed on a feed line with an advancing direction of movement. The method includes supplying the blank on the feed line such that side panels of the blank extend transversely of the feed line. One or more goods are positioned on a middle panel of the blank. The blank is advanced with the one or more goods along the feed line. The side panels which lie diagonally of the middle panel are folded upward. A rear panel is folded upward and held in place as a rear wall of the box. Front panels are folded upward by moving an arm upward during forward movement of the blank. Folding the front panels upward includes folding the front panels from a first position under the feed line to a second position above the box, such that the box advances under the upward moved arm in order to form a front wall and an upper wall of the box with the front panels.

In one embodiment, a device is provided for folding a box from a blank while the blank advances in a direction of movement along a feed line. The device includes a supply section for supplying the blank on the feed line such that side panels of the blank extend transversely of the feed line. The device also includes positioning section for positioning one or more goods on a middle panel of the blank. The device includes a feed section for advancing the blank with the one or more goods along the feed line. A first folding section of the device is configured for folding upward side panels which lie diagonally of the middle panel. A second folding section of the device is configured for folding upward a rear panel and holding this panel in place as rear wall of the box. A third folding section of the device is configured for folding upward front panels by moving an arm upward from a first position under the feed line to a second position above the box, such that the box comes to lie under the upward moved arm in order to thus form a front wall and an upper wall of the box with the front panels.

Additional features and advantages of the disclosed embodiments will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the disclosure. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of the present disclosure.

The present invention relates to a box forming machine according to claim <NUM> and a method for folding a box blank according to claim <NUM>.

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 present disclosure relates to packaging machines. More specifically, the present disclosure relates to methods and apparatus for forming customized packaging boxes from generic fanfold material. For example, in one embodiment of the present disclosure, a method of forming a box from a blank includes providing a blank on a drive line. The blank can include a plurality of panels, including a leading panel, an intermediate panel, a bottom panel, and a trailing panel. Each panel has one or more side flaps extending therefrom. In addition, each blank may or may not include one or more false scores extending thereacross. In such an embodiment, the method further includes moving the blank forward on the drive line and folding the side flaps up and down in an alternating fashion.

Embodiments of the present disclosure solve one or more of the problems in the art discussed above by providing methods and apparatus for forming boxes from box templates (or "blanks") that may or may not have false scores extending thereacross. The methods and apparatus described herein include steps and devices that rigidify various panels and flaps of the blanks formed from fanfold material so that false scores do not negatively affect the folding process or the structural integrity of the final box.

Turning now to the figures, <FIG> illustrates an exemplary box forming machine and system <NUM>, including a material feeder system <NUM>, a blank cutting machine <NUM>, a product supply machine <NUM>, and a box forming machine <NUM>. As seen in <FIG>, the material feeder system <NUM> includes various stacks of fanfold material <NUM>, which may be fed into the blank cutting machine <NUM>. As noted above, the fanfold material <NUM> may include scores <NUM> where the material has been folded to form the stacks <NUM> of connected fanfold segments <NUM>.

The fanfold material <NUM> illustrated herein may comprise corrugate, cardboard, or other packaging materials, or a combination thereof. While the fanfold material may comprise corrugate/cardboard, one or more other embodiments of fanfold stacks <NUM> may comprise materials other than corrugate/cardboard that may be used to form packages and boxes. For example, fanfold materials may comprise various plastics, rubbers, papers, or other bendable materials, or combinations thereof, which are generally known in the art of packaging and box forming.

The fanfold material <NUM> is fed into the blank cutting machine to form a planar box template, or "blank," which is illustrated in more detail in <FIG>. First, turning to <FIG>, a closeup view of the blank cutting machine <NUM>, product supply machine <NUM>, and box forming machine <NUM> is shown. The blank cutting machine <NUM> transports a blank towards the box forming machine <NUM>, which folds the blank into a box for packaging one or more goods. In the exemplary system illustrated in <FIG>, the product supply machine <NUM> may comprise a conveyor belt <NUM> that feeds one or more goods onto the blank formed by the blank cutting machine <NUM> before the box forming machine <NUM> folds the blank into a box.

Additionally, the product supply machine <NUM> may include one or more scanners <NUM>, including one or more dimensional and/or bar code scanners that determine the size of the one or more goods being packaged. This size information may then be relayed to the blank cutting machine <NUM>, which in turn may cut a blank to optimal dimensions that minimize extra space around the one or more goods within the final box product. Once the one or more goods is/are placed on the proper area of the blank formed in the blank cutting machine <NUM>, the one or more goods and the blank are transported into the box forming machine <NUM>. As such, the box forming machine <NUM> may form a box around the one or more goods placed on the blank.

As noted above, a blank formed in the blank forming machine <NUM> may comprise a planar sheet of material having a plurality of panels, side flaps, and/or tabs that can be bent at various angles to form packaging boxes of various sizes and shapes. <FIG> shows one example of a blank <NUM> cut from a section of fanfold material <NUM> by the blank cutting machine <NUM>. For reference, the arrow on the right of <FIG> indicates the forward direction in which the blank <NUM> moves through the box forming machine <NUM>. In the illustrated example, the blank <NUM> comprises a leading panel A, an intermediate panel B, a bottom panel C, a trailing panel D, and a glue tab panel E. Each panel includes opposing side panels or flaps A'-E', respectively, which may extend transversely form either side of corresponding panels A-E.

The leading panel A is referred to as the "leading panel" because it is oriented in the forward direction as the blank <NUM> moves along through the box forming machine <NUM>. Likewise, the trailing panel D indicates a panel that trails behind other panels as the blank <NUM> moves forward through the box forming machine <NUM>. The bottom panel C is generally positioned where the one or more goods may be placed by the product supply machine <NUM>. The bottom panel C may form the bottom surface of the final box.

The blank <NUM> illustrated in <FIG> is intended as a non-limiting example of one configuration of a blank. One will appreciate that the blank cutting machine <NUM> may form blanks of any number of shapes, sizes, and panel configurations to produce boxes that accommodate any number of product shapes and sizes. For example, in one or more embodiments, a blank may have more panels or less panels than those illustrated in <FIG>. Also, in one or more embodiments, a blank may comprise panels having only one side panel extending therefrom, more than two side panels extending therefrom, or no side panels extending therefrom. In one or more embodiments, a blank may be formed that includes no glue tabs or two or more glue tabs positioned at various locations on the blank.

However, for purposes of illustrating and describing various embodiments of a box forming machine according to the present disclosure, the blank <NUM> illustrated in <FIG> will be the blank <NUM> illustrated in subsequent <FIG>. The dotted lines shown on the blank <NUM> of <FIG> may be illustrative only of boundaries between panels and/or tabs where the box forming machine <NUM> may bend the blank <NUM> to form a box. In one or more embodiments of the present disclosure, the blank cutting machine <NUM> may score, depress, crease, or otherwise affect the material at the boundary lines of the blank <NUM> to form weaknesses in the material. In this way, the blank is more likely to bend at the boundary lines illustrated when the side panels A'-E' or panels A-E are manipulated by the box forming machine <NUM>. The illustrated blank <NUM> is configured to form a rectangular shaped box, as will be apparent from the following description and figures.

<FIG> illustrate various steps of a method of forming a box in the box forming machine <NUM> and components of the box forming machine <NUM> that fold the blanks into the boxes. In these figures, the blank <NUM> is shown moving forward through the box forming machine <NUM> without any goods or products placed thereon for illustrative purposes. However, it is understood, as discussed above, that one or more goods may be place onto the blank before the blank moves through the box forming machine <NUM> so that a box is formed around the goods. In particular, in the embodiment of the blank <NUM> illustrated herein, one or more goods may be place on the bottom panel C, which forms the bottom surface of the box being formed.

<FIG> illustrates an interior portion of the box forming machine <NUM> with the blank <NUM> entering the box forming machine <NUM> from the left. For reference, the direction referred to as the "forward" direction herein is illustrated from left to right in <FIG> and subsequent figures. The box forming machine <NUM> may comprise a drive line <NUM> that carries the blank <NUM> forward through the box forming machine <NUM>. To this end, the drive line <NUM> may comprise one or more drive mechanisms that carry the blank <NUM> forward along the drive line <NUM>. One or more embodiments may comprise different drive mechanisms, such as conveyor belts, chains, rolling surfaces, rails, or the like, or combinations thereof.

The box forming machine <NUM> may also comprise one or more arms <NUM>, holders <NUM>, and side panel fingers <NUM>, all of which will be described in more detail with reference to subsequent figures. As shown in <FIG>, the blank <NUM> may enter the box forming machine <NUM> in a planar fashion as it begins to move forward along the drive line <NUM>. For example, as shown in <FIG>, the leading panel A and associated side panels A' are generally planar as the blank <NUM> enters the box forming machine <NUM>.

However, the side panel fingers <NUM> may push the side panels A'-E' up and down in alternating fashion as the blank <NUM> moves forward along the drive line <NUM>. For example, as shown in <FIG>, the side panel fingers <NUM> may move up and down as the drive line <NUM> moves the blank <NUM> forward so that side panels A' and are pushed down and the side panel fingers <NUM> are positioned below side panels B'. Subsequently, as shown in <FIG>, the side panel fingers <NUM> may move up as the blank <NUM> moves forward on the drive line <NUM> to lift side panels B' at an angle relative to the intermediate panel B of the blank <NUM>. Once the side panel fingers <NUM> move up again, as shown in <FIG>, the side panel fingers <NUM> may then be positioned above side panels C'.

As described herein, folding the side flaps up and down in an alternating fashion means that alternating side flaps are folded up and down. In other words, one side flap is folded down and the adjacent or subsequent side flap is folded up, and so on. As a result, every other side flap is folded up and every other side flap is folded down.

When a side panel is pushed down or lifted up by the side panel fingers <NUM>, such as side panels A' and side panels B', shown in <FIG>, respectively, the panels from which the side panels extends may be rigidified. For example, because side panels B' are lifted up, the intermediate panel B from which side panels B' extend is rigidified. The intermediate panel B, being rigidly secured to side panels B', is less likely to bend or otherwise fail at a location other than the boundary therebetween because the side panels B' extending therefrom are folded and are no longer co-planar with the intermediate panel B. Likewise, the side panels A' that are folded/bent downward, may rigidify the leading panel A from which they extend. The same is true for the other panels A-E as the side panels A'-E' are bent up and down in alternating fashion as the blank <NUM> moves forward on the drive line <NUM>.

Rigidifying the panels A-E as the blank <NUM> moves forward on the drive line <NUM> may strengthen the panels A-E and ensure that the panels A-E are bent or folded at the proper boundary lines between adjacent panels during subsequent blank folding methods and steps of the box forming process described herein. Along these lines, rigidifying various panels of the blank <NUM> may reduce the risk of panels bending or folding along false scores that extend across the blank <NUM> at locations other than the boundaries between panels.

<FIG> illustrates an example of a false score <NUM> extending across the blank <NUM>. As seen in <FIG>, the blank <NUM>, which was cut from fanfold material <NUM>, extends across a fanfold score <NUM> creating a "false score" on the blank <NUM>. The false scores <NUM> of the blank <NUM> may form weaknesses in the blank material that causes panels A-E and side panels A'-E' to erroneously bend or fold during the box forming process. However, due to the side panels B' being lifted up at an angle by the side panel fingers <NUM>, the intermediate panel B and the side panels B' may be rigidified. That is, the intermediate panel B may tend to bend at the proper boundary between adjacent panels A and C, rather than bending along the false score <NUM>, due to the angle of the side panels B' relative to the intermediate panel B.

Likewise, as shown in <FIG>, the leading panel A is rigidified due to the side panels A' extending therefrom being bent down at an angle relative to the leading panel A. As the blank <NUM> moves forward along the drive line <NUM>, the holders <NUM> may maintain panels that have been folded down in their flat position. For example, the holder <NUM> illustrated in <FIG> comprises a bottom edge that sits atop the side panel A' as the blank <NUM> moves forward along the drive line <NUM>. In one or more embodiments, the holders <NUM> may be stationary. In one or more other embodiments, the holders <NUM> may be manipulated temporarily or permanently to adjust to the needs of various blanks and panel configurations. As will be apparent in subsequent figures, the holders <NUM> may also maintain the position of side panels A'-E' that have been folded upward as the blank <NUM> moves forward on the drive line <NUM>.

<FIG> illustrates the blank <NUM> moved further down the drive line <NUM> from that shown in <FIG>. <FIG> illustrates the side panel fingers <NUM> pushing the side panels D' upward to rigidify trailing panel D. As shown, side panels A' have been folded down, side panels B' have been folded up, side panels C' have been folded down, side panels D' have been folded up, and side panels E' may be folded down. In this way, the side panel fingers <NUM> may fold the side panels A'-E' up and down in alternating fashion while the holders <NUM> maintain the positions of the side panels A'-E', either upward or downward (or flat), as the blank <NUM> moves forward along the drive line <NUM>.

Once the side panels A'-E' have been folded to rigidify respective panels A-E, the blank <NUM> may then undergo several bending/folding steps to form a box. As shown in <FIG>, once the leading panel A extends fully beyond the front edges of the holders <NUM>, one or more arms <NUM>-over which the leading panel A and the intermediate panel B have passed--may be raised up as the blank <NUM> moves forward along the drive line <NUM>. When the arms <NUM> lift the leading panel A and the intermediate panel B as shown, the blank <NUM> may be bent along the boundary between the intermediate panel B and the bottom panel C, rather than along the false score <NUM> shown. Thus, the rigidifying of the panels A-E due to the side panels A'-E' being folded up and down ensures that any false scores <NUM> that may extend transversely across the blank <NUM> do not negatively affect the folding steps of the box forming machine <NUM>.

Also, as shown in <FIG>, the trailing panel D and glue tab panel E may be lifted/folded upward by one or more trailing squaring arms that may rise above the drive line <NUM> from beneath the panels D and E. The trailing panel D and glue tab panel E may be lifted/folded upward simultaneously with, just prior to, or just after the leading panel A and intermediate panel B are lifted by the arms <NUM>.

The holders <NUM>, which may include upper and lower portions 404a and 404b, may maintain various side panels A'-E' in position during the folding step illustrated in <FIG>. In addition, the holders <NUM> may hold the bottom panel C down while the other panels A, B, D, and E are lifted by the arms <NUM> and trailing squaring arms. In this way, the blank <NUM> is not lifted off the drive line <NUM> during the folding steps described herein.

Also, in one or more embodiments of the present disclosure, the leading bottom corners of the holders <NUM> may be chamfered or angled. In such embodiments, the arms <NUM> may begin to lift the leading and intermediate panels A, B up before the leading panel A and/or intermediate panel B have moved completely beyond the front edge of the holders <NUM> by the drive line <NUM>. In such an embodiment, the chamfered corner of the holders <NUM> may increase the speed of forming a box from the blank <NUM> in the box forming machine <NUM> because the arms may begin lifting/folding the leading and intermediate panels A, B sooner than if the leading and intermediate panels A, B had to be completely past the holders <NUM> before the arms <NUM> could begin to lift/fold the leading and intermediate panels A, B.

The trailing squaring arms mentioned above with reference to <FIG>, which lift the trailing panel D and glue tab panel E, are not shown because of the blank <NUM> disposed on the drive line <NUM>. However, <FIG> illustrates the drive line <NUM> without the blank <NUM> thereon to show an embodiment of the trailing squaring arms <NUM>. Before the trailing squaring arms <NUM> lift the trailing panel D and glue tab panel E of the blank <NUM>, the trailing squaring arms <NUM> may lie flush with or below the drive line <NUM>. <FIG> illustrates the trailing squaring arms <NUM> as they begin to rise up above the drive line <NUM> to lift the trailing panel D and the glue tab panel E upward. In one or more embodiments, the trailing squaring arms <NUM> may extend upward until they are upright as shown in <FIG>.

In one or more embodiments, the box forming machine <NUM> may include only one trailing squaring arm <NUM> or more than two trailing squaring arms <NUM>. In addition, in one or more embodiments of the present disclosure, the trailing squaring arms <NUM> may extend upward at any number of angles, depending on the shape of the box being formed and the required angle of the trailing panel D relative to the bottom panel C. Along these lines, <FIG> illustrates a perspective view of a set of trailing squaring arms <NUM> extended upward with a blank <NUM> on the drive line <NUM>. As shown, the trailing squaring arms <NUM> extend upward above the drive line <NUM> to bend the trailing panel D and bottom panel C at an angle relative to each other along the border between the panels D, C. In one or more embodiments of the present disclosure, the trailing squaring arms <NUM> shown may move along the drive line <NUM> with the blank <NUM> to maintain the bottom trailing corner of the box as the blank <NUM> moves forward.

Turning now to <FIG>, the box forming machine <NUM> may also comprise a spatula <NUM> that extends downward to fold the glue tab panel E down as the blank moves forward along the drive line <NUM>. The spatula may fold the glue tab panel E downward simultaneously with the trailing panel D being lifted up. In one or more other embodiments, the spatula <NUM> may fold the glue tab panel E downward after the trailing panel D is lifted up. Also, the spatula <NUM> may comprise a leading edge <NUM> that extends transversely across the drive line <NUM>.

As shown in <FIG>, the leading edge <NUM> of the spatula <NUM>, which is hidden by panel A being lifted upward by the arms <NUM>, may extend toward and contact the boundary between the leading panel A and the intermediate panel B. As the blank <NUM> moves forward along the drive line <NUM>, as shown in <FIG>, the arms <NUM> may continue to raise upward over the boundary between the leading panel A and the intermediate panel B. As the arms <NUM> rise upward in this manner, the leading edge of the spatula <NUM> may contact the boundary between the leading panel A and the intermediate panel B so that the leading panel A bends relative to the intermediate panel B along the leading edge <NUM> at that boundary.

One will also appreciate that the bent side panels B' extending from the intermediate panel B may also facilitate the proper folding position between the leading and intermediate panels A, B. For example, as shown in <FIG>, the side panel B', which was folded upward, contacts the bottom panel C and/or the side panel C' to prevent the intermediate panel B from bending any further as the arms <NUM> push down on the leading panel A. The same is true for the side panel D' extending from the trailing panel D as the trailing panel D is pushed upward, and the glue tab panel E is pushed downward by the spatula <NUM>, as described above. Thus, bending the side panels A'-E' as described herein may also function to ensure proper bending of the blank <NUM> as the arms <NUM>, the trailing squaring arms <NUM>, and the spatula <NUM> push on the various panels A-E.

As shown in <FIG>, as the blank <NUM> moves forward along the drive line <NUM>, the arms <NUM> may travel along the leading panel A of the blank <NUM> and press the leading panel A down against the glue tab panel E, which has been folded down by the spatula <NUM>. As this occurs, the spatula <NUM> may be withdrawn from between the glue tab panel E and the leading panel A. In one embodiment, the spatula <NUM> may retreat just prior to the leading panel A contacting the glue tab panel E. In another embodiment, the spatula <NUM> may retreat just after the leading panel A contacts the glue tab panel E. In yet another embodiment, the spatula <NUM> may retreat simultaneously with the leading panel A contacting the glue tab panel E.

As shown in <FIG>, once the leading panel A has been folded downward by the arms <NUM>, the leading panel A may form the top surface of a box <NUM>. Along these lines, the intermediate panel B may form the front surface of the box <NUM>, the bottom panel C may form the bottom surface of the box <NUM>, and the trailing panel D may form the rear surface of the box <NUM>.

Also, as shown in <FIG>, the box forming machine <NUM> may comprise a leading squaring arm <NUM>. Once the leading panel A has been pushed down to form the top surface of the box <NUM>, the leading squaring arm <NUM> may extend downward and contact the top surface and front surface of the box <NUM>. Accordingly, in one embodiment, the leading squaring arm <NUM> may comprise a first component 1502a configured to contact the top surface and a second component 1502b configured to contact the front surface. In the illustrated embodiments, which shows a rectangular shaped box <NUM> formed from the blank <NUM>, the first and second components 1502a, 1502b are disposed at a <NUM>-degree angle relative to one another. In such an embodiment, the leading squaring arm <NUM> may maintain the top leading corner of the box <NUM> at a <NUM>-degree angle as the blank moves forward along the drive line <NUM>.

However, one will appreciate that the first and second components of the leading squaring arm <NUM> may be disposed at various other angles relative to one another depending on the shape of the box being formed. For example, in one or more embodiments, the box forming machine <NUM> may form boxes that are not rectangular shaped. In such embodiments, the leading squaring arm <NUM> may have first and second components 1502a, 1502b that are angled greater or less than <NUM>-degrees relative to one another. In addition, while the embodiment illustrated in the figures shows one leading squaring arm <NUM>, one or more other embodiments of the box forming machine <NUM> may comprise more than one leading squaring arm <NUM>.

Likewise, as discussed above, the trailing squaring arms <NUM> may extend upward from the drive line <NUM> vertically to maintain the trailing bottom corner of the box <NUM> at a <NUM>-degree angle as the blank <NUM> moves forward along the drive line <NUM>. However, as with the leading squaring arm <NUM>, the trailing squaring arms <NUM> may be disposed at angles other than <NUM>-degrees relative to the drive line <NUM> to form corners of boxes other than rectangular shaped boxes.

The box forming machine <NUM> may also comprise upper and lower side arms configured to fold the remaining side panels of the blank <NUM> to form right and left side surfaces of the box <NUM>. <FIG> and <FIG> illustrate upper and lower side arms <NUM>, <NUM>, respectively. The upper side arm <NUM> may move down while contacting the side panel A' extending from the leading panel A to fold the side panel A' down to form at least a portion of the right surface of the box <NUM>. Likewise, the lower side arm <NUM> of the box forming machine <NUM> may extend upward while contacting the side panel C' extending from the bottom panel C to fold the side panel C' to form at least a portion of the right surface of the box <NUM>. Likewise, opposing upper and lower side arms <NUM>, <NUM> may form the left surface of the box <NUM> by similarly folding various side panels to form the left surface of the box <NUM>.

One will appreciate that during the various folding steps described herein, one or more methods may be provided to adhere the various panels together while forming the box <NUM>. For example, in one or more embodiments, the box forming machine <NUM> may include the step of applying glue or other adhesive material to the glue tab panel E. Additionally or alternatively, the box forming machine <NUM> may include means to apply glue or other adhesive material to at least a portion of the leading panel A. In such embodiments, the leading panel A and glue tab panel E may adhere to one another when they are brought into contact.

Likewise, one or more embodiments of the box forming machine <NUM> of the present disclosure may comprise means to apply glue or other adhesive materials to the various side panels that form the left and right surfaces of the box <NUM>. In this way, the box may remain intact after the panels of the blank are bent/folded into position along the drive line <NUM> of the box forming machine <NUM>, as described herein.

One will appreciate that the various components of the box forming machine <NUM> described herein may comprise components, shapes, and configurations, or be disposed at different angles or distances relative to one another, other than those described herein, while maintaining their proper functions described herein. For example, the arms <NUM> extending transversely across the drive line <NUM> are illustrated as elongated, rectangular bars. However, one or more other embodiments of the arms <NUM> may include one or more rod shaped bars, planar plates, or irregularly shaped components.

Also, for example, while the arms <NUM> are illustrated as extending transversely across the drive line <NUM> in a perpendicular fashion, one or more embodiments may include arms <NUM> that extend across the drive line <NUM> in a non-perpendicular fashion.

Also, for example, while the present disclosure illustrates the side panel fingers <NUM> comprising generally circular rods tapering towards the trailing ends thereof, one or more other embodiments may comprise side panel fingers <NUM> of other shapes and/or sizes. For example, in one or more other embodiments, the side panel fingers may comprise rectangular rods, plates, or other irregularly shaped components that are capable of performing the same functions described herein.

Also, for example, the drive line, spatula, trailing squaring arms, leading squaring arms, and holders of the present disclosure may comprise shapes and components other than those described herein or be positioned at angles other than those shown. These components of other embodiments may perform the same functions as those described herein.

For example, the spatula <NUM> and leading squaring arms <NUM> are illustrated as extending downward from above the drive line <NUM>. However, in one or more embodiments, the spatula <NUM> and/or leading squaring arms <NUM> may extend from below or to the side of the drive line <NUM> to perform their described functions. Also, for example, the spatula <NUM> and/or leading squaring arms <NUM> may extend at an angle relative to the drive line <NUM>, rather than parallel in the longitudinal direction of the drive line <NUM> as illustrated herein.

One will also appreciate that the various steps and folding processes carried out by the box forming machine <NUM> described herein may vary in other embodiments. Again, the blank <NUM> shown herein for illustrative purposes may be altered to form boxes of various other shapes and sizes. Accordingly, the steps, folding processes, and order with which these steps are carried out may be rearranges, altered, or discarded in one or more other embodiments of the present disclosure.

For example, in one or more embodiments, the blank <NUM> may not comprise a glue tab panel E. In such an embodiment, the box forming machine <NUM> may or may not comprise a spatula as described herein. Also, for example, in one or more embodiment of the present disclosure, the box being formed by the box forming machine <NUM> may be an open box having one or more surfaces open. In such an embodiment, the box forming machine <NUM> may or may not include one or more upper and lower side arms to form left and/or right surfaces of the box. Likewise, in such an embodiment, the box forming machine <NUM> may or may not raise a leading panel over the top of the one or more goods to form an open top of the box <NUM>.

Attention is now directed to <FIG>, while illustrate another box blank and methods and devices for folding the box blank into a box. For instance, <FIG> shows a blank <NUM>. Blank <NUM> is shown in top view in <FIG>. The blank <NUM> is similar or identical in many respects to blank <NUM>. For instance, the blank <NUM> has four central panels A, B, C and D. Each of the four central panels is provided to form a wall of the box. In the configuration of <FIG>, panel B forms the lower wall of the box, panels A and C form upright walls of the box, and panel D forms the upper wall of the box. The Figure also indicates how the length <NUM>, width b, and height h of the box follow from the dimensions of blank <NUM>. This will be apparent to the skilled person and will not be further elucidated.

Each of the panels A, B, C and D has two side flaps, designated respectively with A', B', C' and D'. These side flaps are provided to form the two side walls of the box. In the present embodiment, a closing flap A" is further provided on panel A in the direction of movement <NUM> or longitudinal direction of blank <NUM>. This closing flap A" serves to connect panel A to panel D when the box is being formed. This will be further elucidated with reference to the following figures. In <FIG>, closing flap A" is formed as a flap which protrudes in the longitudinal direction of panel A. Alternatively, closing flap A" can also be provided with corresponding side flaps so that closing flap A" extends over the whole width of the blank. The advantage hereof is that no waste pieces need to be discharged.

In <FIG>, a wedge-shaped piece of material has been cut away between adjacent side flaps. In practice this is advantageous in some cases in the folding of the side flaps. This is the embodiment which is shown in <FIG>, since it clearly illustrates the side flaps. A method according to the present disclosure also allows use to be made of a blank <NUM> in which the adjacent side flaps are separated from each other only by a single cut, and wherein a wedge of material has not been cut away. In other words, the side flaps in blank <NUM> can be formed by a straight cut in the transverse direction of blank <NUM>, starting at an edge of the blank and extending toward a central axis of the blank over a length equal to the length of the side flaps. The skilled person will further appreciate that the side flaps A', B', C' and D' can be dimensioned to fully form or partially form the side panel. When the side panel has been only partially formed, the side panel will typically have an opening in the centre, whereby the box is not fully closed. This is advantageous in some situations. When the side panel has been fully formed, the side flaps can be adjoining or overlapping. Different combinations hereof are possible.

A blank can be created in order to form a box with predetermined dimensions. The creating of the blank itself may for performed in a variety of ways. Blanks as shown in <FIG> can be made to the size of the goods to be packaged. The blank shown in <FIG> will be referenced in the following description for how to fold a blank. It will be appreciated, however, that the blanks <NUM> and the following discussion are merely exemplary.

<FIG> shows the folding upward of side panels of the blank <NUM>. This folding upward may take place during a forward movement in the direction of movement <NUM> of blank <NUM>. The blank is for this purpose positioned on a feed line with its longitudinal direction in the feed direction. Provided on either side of the feed line are fingers <NUM> which can be positioned relative to the blank via a finger arm <NUM>. By moving the blank in the direction of movement <NUM>, the four side panels D', C', B' and A' will pass finger <NUM>. Finger <NUM> can be positioned relative to the side panels. More particularly, the distance between finger <NUM> and a central axis of blank <NUM> is adjustable, such that finger <NUM> can be positioned relative to blank <NUM> in the transverse direction. This allows finger <NUM> to be positioned in the transverse direction, at the position of the side panels. More particularly, finger <NUM> may be positioned overlapping with the side panels and in the vicinity of the central panels.

Finger <NUM> may be oriented with a distal end which extends counter to the direction of movement <NUM>, and the distal end points at least slightly downward. Pointing slightly downward is defined as the finger forming, at least at the position of the distal end, an angle with the horizontal plane of a maximum of <NUM> degrees, preferably a maximum of <NUM> degrees, more preferably a maximum of <NUM> degrees.

Finger arm <NUM> is further provided to control the height of finger <NUM>. This is shown in <FIG> with arrow <NUM>. The height of finger <NUM> may be controlled such that the distal end is situated above a side flap D' when side flap D' arrives at the distal end of finger <NUM> due to the forward movement in the direction of movement <NUM>. The finger can then be moved downward <NUM> so as to lie with a distal end of the finger under side flap C' when side flap C' arrives at finger <NUM>. The result hereof is that the finger will engage under side flap C' and will fold side flap C' upward as illustrated with arrow <NUM>. The distal end of the finger can here press on side flap D', without this being a drawback. On the basis of this description, and in combination with <FIG>, the skilled person will appreciate that forming and controlling of a finger <NUM> relative to the flaps allows side flaps to be folded upward or to not be folded upward in an extremely simple manner. Because of the adjustability in the transverse direction, side flaps can even be folded upward or not folded upward irrespective of the width b of the box. This construction allows a device for folding boxes with different dimensions to be formed in simple manner. This construction also provides for a simple method.

A side flap holder <NUM> is further provided which is mounted on a side flap holder arm <NUM> for the purpose of holding the upward folded side flap in place during the forward movement of the blank over the feed line. The side flap holder <NUM> is not shown in the further figures, but is deemed preferably present for holding the side flaps in the folded position during further folding steps.

The result of the folding upward of side flap C', and of side flap A', as will be further elucidated hereinbelow, is that the stiffness of segment C and segment A, for the benefit of the folding upward of these segments for the purpose of forming the upright walls of the box, increases considerably. Because side flaps C' and A' are folded upward, central panels C and A are also strengthened in that the flexibility of panels C and A decreases considerably at the position of the connection to side flap C' and A'. The skilled person will appreciate that the stiffness of sections C and A is high once side flaps C' and A' have been folded upward. This allows segments C and A to be folded upward in a less controlled, even rough manner, without this being detrimental to the reliability of the folding upward. After side flaps C' and A' have been folded upward, side flap B' can optionally also be folded at least partially upward. Folding side flap B' upward through for instance about <NUM> degrees prevents undesired unfolding of side flaps C' and A', i.e. this is prevented by the partially upward folded side flap B'.

The skilled person will appreciate that when plate-like material is handled for folding, it is easy for an undesired fold to be created when the plate-like material is not wholly supported to sufficient extent during the folding movement. Such situations are avoided by first folding side flaps C' and A' upward. It will be almost impossible for an undesired fold to be created in the A-segment and C-segment as long as side flaps A' and C' form an angle with the respective central panels A and C. This is particularly advantageous when boxes with different dimensions are folded in one device. This is because the box can be folded considerably more easily, and the method of folding is considerably more robust when segments A and C are allowed to be handled more roughly and/or in less controlled manner. This makes it possible to provide an arm or pressing element or folding element which does not necessarily support the whole panel A and/or C during folding upward of the respective panel.

<FIG> shows blank <NUM>. In the situation of <FIG>, a good or goods <NUM> has/have already been placed on the panel B of blank <NUM>. Side flaps C' and A' have further already been folded upward. In the situation of <FIG>, the central panels A, B, C, D have not been folded upward yet, and still lie on the feed line (not shown in <FIG>). The direction of movement is illustrated in <FIG> with arrow <NUM>. When blank <NUM> moves in the direction of movement <NUM>, glue <NUM> is applied at a front end of blank <NUM>, to panel D, via a glue gun <NUM>. <FIG> further shows that an arm <NUM> extends under the feed line, and thus under blank <NUM>, in an initial phase of the method.

<FIG> shows a further step wherein arm <NUM> moves upward from a position under the feed line. This upward movement of arm <NUM> is illustrated with an arrow <NUM>. During the upward movement <NUM> of arm <NUM>, blank <NUM> can still be advanced in the direction of movement <NUM>. On the rear side, the rear wall is folded upward via an actuator <NUM>. Folding upward of the rear wall is illustrated with arrow <NUM>. Actuator <NUM> can be embodied in different ways. Because side flaps A' and C' have already been folded upward, segments A and C of the blank are stiff and can be folded upward in a simple manner by arm <NUM> and actuator <NUM>. Depending on the size of the blank, undesired folding of first segment D may occur as a result of the upward movement <NUM> of arm <NUM>. As a result of the direction of movement <NUM> and as a result of the force of gravity the fold will typically be directed forward (in clockwise direction in <FIG>), such that arm <NUM> always comes to lie under segment D. Because of the upward movement of the arm, the arm will still be able to move the segment D upward, even when it has an undesired forward fold. The applied glue <NUM> will not be able to bump against arm <NUM> or against another part of blank <NUM> due such an uncontrolled movement either.

The skilled person will appreciate that the exact order of the application of the glue, the folding upward of side flaps A' and C' and the placing of the goods on the blank can vary from one embodiment to another.

<FIG> shows a further phase of the folding. Rear panel A of blank <NUM> has been folded completely upward so as to form the rear wall of the box. Actuator <NUM> follows the advancing movement <NUM> of the blank in order to keep rear wall A positioned correctly. When rear wall A is folded upward, a positioning finger <NUM> is moved, from above, forward and downward, as illustrated with arrow <NUM>, up to the upper side of the box. With this forward and downward movement <NUM>, the positioning finger <NUM> will fold closing flap A", which forms the overlap as described above, forward.

Positioning finger <NUM> further has the function of catching the first segment D. First segment D is folded over the goods by arm <NUM> so as to form the upper side of the box. As described above, upper segment D can have undesired folds, and the movement of the folding of this front segment D is not wholly controlled. Depending on the size of the box, the strength of the sheet material and the speed of the folding, the front segment D will drop downward as the upper wall of the box more quickly or more slowly, optionally considerably forced by arm <NUM>. This dropping down is illustrated with arrow <NUM>. The dropping down <NUM> of first segment D is stopped by positioning finger <NUM>. When a false crease is present in first segment D, first segment D may drop down early and sharply. It will therefore be advantageous to have the positioning finger <NUM> extend to a position substantially at the front of the box so as to enable first segment D to be caught correctly in all cases. The skilled person will appreciate that the shape of positioning finger <NUM> is not crucial to application of the principles disclosed herein. The most important consideration in shaping the finger is the complementarity in the transverse direction with the applied glue. The fingers and the glue will preferably not overlap, as seen in the transverse direction. The skilled person will thus appreciate that it is also possible for two or more fingers to be formed, wherein glue is applied between the fingers, as seen in the transverse direction. This prevents glue <NUM>, which is situated on first segment D, from coming into undesired contact, contact at an incorrect location or premature contact with goods and/or with closing flap A". In order to prevent glue <NUM> from coming into contact with positioning finger <NUM>, the positioning finger <NUM> may take a narrow form, as seen in the transverse direction, and may be placed centrally relative to the box, while the glue is applied eccentrically, as seen in the width direction, and is thus not applied in the center.

<FIG> shows a further phase in the method for the folding. In <FIG>, rear wall A has been folded upward and rear wall A is held in position by actuator <NUM>. At this point, front wall C has also been folded upward by the movement of arm <NUM>. Front wall C is preferably held in position by a further actuator <NUM>. The upward front wall, formed by the C-segment of the blank, can be held in position optimally by actuator <NUM>. This is illustrated with arrow <NUM>. Actuator <NUM> may be provided at the position of an upper side of the box with a finger (not shown) which forms the angle between side panel and upper panel in order to make this a right angle. A similar finger can be provided on actuator <NUM> so that actuators <NUM> and <NUM> are able to hold the box perpendicularly and at right angles. By positioning front wall C and real wall A, the upper wall D is also positioned correctly relative to closing flap A". This allows arm <NUM> to press front segment D against closing flap A" so that glue <NUM> comes to lie between the front and rear parts D and A of blank <NUM>. Positioning finger <NUM> may be retracted here. Retracting can be done by actively moving positioning finger <NUM> rearward, as illustrated with arrow <NUM>. Alternatively, and/or additionally, positioning finger <NUM> can be retracted in a relative sense by an advancing movement in the direction of movement <NUM> of the box. After the pressing <NUM> has been carried out, the box is formed with an underside formed by the B-segment of the blank, a front wall formed by the C-segment of the blank, a rear wall formed by the A-segment of the blank and an upper wall formed by the D-segment of the blank. The side walls have already been partially formed by the upward folded side flaps A' and C'.

In <FIG>, the box is completed by folding downward <NUM> of side flap D' and folding upward <NUM> of side flap B'. Glue can be provided on one of the side flaps, so that side flap B' can be secured to side flap D'. Alternatively, side flaps B' and D' can be glued to the side flaps A' and C', which have already been folded upward. The skilled person will appreciate that the order of folding upward of side flap B' and folding downward of side flap D' can also be altered without having noticeable influence on the above described folding principles. <FIG> further illustrates how arm <NUM> can finally press <NUM> the upper side of the box D with closing flap A". <FIG> also shows that the positioning finger has been retracted.

<FIG> shows a top view of a device for folding boxes from blanks. The device is provided to package different goods with different dimensions in boxes made to a custom size. The device has for this purpose a supply section <NUM> for supplying blanks <NUM>. The blanks are positioned on feed line <NUM> at the position of the supply section, with the side panels transversely of feed line <NUM>. The feed line <NUM> is provided to advance the blank in the direction of movement <NUM>. The device is further provided with a positioning section <NUM>. In the positioning section <NUM>, goods <NUM> are positioned correctly on the blank <NUM>. In practice, a supply <NUM> is provided for the goods. Supply <NUM> may be linked operationally to supply section <NUM> so that blanks <NUM> which are supplied via supply section <NUM> have a shape and dimensions corresponding to a shape and dimensions of the goods <NUM>, <NUM>' which are supplied via the supply. More particularly, successive goods <NUM> and <NUM>' which are supplied have different dimensions, and corresponding blanks <NUM> which are supplied via supply section <NUM> have corresponding different dimensions.

At the position of positioning section <NUM>, the goods <NUM> are positioned on a central panel B of blank <NUM>. The skilled person will appreciate on the basis of the above elucidation that the goods could also be positioned on the central panel C. In some operations, for instance, the moving of arm <NUM> and positioning fingers <NUM>, would have to be performed differently therein. The movement of arm <NUM> will become slightly more complex as a result of the direction of movement of the blank <NUM>, but the skilled person will appreciate that such a device can be constructed on the basis of the same operating principles. It is then possible to opt to have the closing flap A" connect onto an outer side of the box, or to move the closing flap to panel D.

When closing flap A" is formed at the position of panel D, the method can be performed as described above and as shown in the Figures. The closing flap D" will then overlap with panel A at the position of the upright side wall of the box. Arm <NUM> can then further be provided to press the closing flap and the panel A against the side wall.

After goods <NUM> have been positioned on blank <NUM>, blank <NUM> is advanced by feed line <NUM> to the first folding section <NUM>. At the position of first folding section <NUM>, the fingers <NUM>, which were elucidated above with reference to <FIG>, provide for the upward folding of the side flaps which are positioned diagonally relative to the goods <NUM>. <FIG> shows how two fingers <NUM> are provided on either side of the blank for the purpose of folding upward side flaps on either side of feed line <NUM>. The skilled person will appreciate that, depending on the width of the blank, this depending on the size of goods <NUM>, fingers <NUM> may be moved closer to or further away from feed line <NUM> by means of finger arms <NUM>.

In the embodiment of <FIG>, the first folding section further comprises the glue guns <NUM> for applying glue to the front segment of the blank <NUM>. It will be apparent that glue guns <NUM> can also be provided at a different location on the feed line.

<FIG> further illustrates the second folding section <NUM> and the third folding section <NUM>. In order to simply explain the operation of the device, the second folding section <NUM> and the third folding section <NUM> are illustrated as different parts of the device. In practice, these segments or sections <NUM> and <NUM> can be formed integrally or be mutually integrated. Furthermore, other sections <NUM> and <NUM> can also be formed integrally or be mutually integrated. At the position of the second folding section <NUM>, the rear wall is folded upward. The positioning finger <NUM> will typically also be provided at the position of this folding section <NUM>. <FIG> illustrates that the positioning finger is narrow and that glue guns <NUM> are provided in order to apply glue eccentrically, while positioning finger <NUM> extends centrically.

Provided in the third folding section <NUM> is the arm <NUM> which, as elucidated above with reference to <FIG>, moves from a position under feed line <NUM> to a position above the box. Because of this movement and because of the forward movement in the direction of movement of the blank, the arm can perform the functions described above with reference to <FIG> in a simple manner. Positioning finger <NUM> may be mounted on an actuator which allows positioning finger <NUM> to be moved in the direction of movement <NUM>. Positioning finger <NUM> may also be movable in the height. Arm <NUM> can be provided from two parts which are provided on either side of the feed line. This allows the arm to move to a position under the feed line in simple manner without the arms colliding with feed line <NUM>.

The device can comprise yet another folding section (not shown) for folding upward and downward of side flaps B' and D'. Side flaps B' and D' can be provided here with glue in order to connect them to each other or to connect them to side flaps A' and/or C'. The device can also comprise yet another packing section, for instance, for securing a fixing one or more straps around the box. The device can further comprise a section for labelling of the box. Alternatively, the blanks can be supplied already labelled on the basis of the operational link between supply device <NUM> and supply <NUM>.

One will appreciate that altering the order, number, and types of folding steps and processes described herein may allow a manufacturer and/or distributor to form any number of box shapes and sizes. These various box shapes and sizes may be altered, designed, and customized to accommodate any number of product shapes and sizes that are to be packaged within the box. Accordingly, box forming machines of the present disclosure are configured to form customized boxes that fit around products without wasted box material or added packaging materials. In addition, box forming machines of the present disclosure are configured to form such boxes without fanfold scores (or "false scores") negatively affecting the box forming steps and/or processes described herein. As such, the methods, processes, and apparatus described herein may successfully form customizable boxes from generic fanfold material having fanfold scores.

In light of the disclosure herein, embodiments may take a variety of forms or may include a variety of different combinations of the features described herein. By way of exemplary disclosure, not forming part of the invnetion, a method of forming a box from a blank can include:.

In the disclosure, the method also includes lifting the trailing panel upward to form a back surface of the box. In some embodiments, the method also includes holding the trailing panel at a first angle relative to the bottom panel to maintain a bottom trailing corner of the box as the blank moves forward on the drive line.

In some the disclosure, the method also includes:.

In the disclosure, the method also includes holding the bottom panel down while the leading panel and intermediate panel are folded up over the one or more goods. Similarly, in some embodiments, the method also includes holding the bottom panel down while the trailing panel is lifted up to from the back surface of the box.

In the disclosure, a horizontally extending spatula folds the glue tab downward and a leading edge of the spatula engages a boundary between the leading panel and the intermediate panel so that the leading panel bends relative to the intermediate panel at the boundary when lifting the leading panel and intermediate panel up and over the one or more goods.

In the disclosure, the method also includes folding the side panels to form left and right surfaces of the box as the blank moves forward on the drive line. In the disclosure, the side panels that have been folded up are held in position with a holder. In some embodiments, a bottom leading corner of the holder is chamfered. In the disclosure, the leading panel and the intermediate panel begin to be lifted up and over the one or more goods before the intermediate panel has completely passed a leading edge of the holder as the blank moves forward on the drive line. In the disclosure, the holder is stationary as the blank moves forward on the drive line.

In the disclosure, the side panels are folded up and down in an alternating fashion by one or more fingers that move up and down as the blank moves forward on the drive line. In the disclosure, the side panels extending from the bottom panel are folded downward to rigidify the bottom panel.

In another disclosure not forming part of the invention, a method of forming a box from fanfold material includes:.

In the disclosure, the method also includes folding the leading panel and the intermediate panel up and over the bottom panel to form a top and front surface of a box, respectively. In the disclosure, the method also includes folding the trailing panel up and maintaining the trailing panel at an angle relative to the bottom panel to form a trailing bottom corner of a box. In the disclosure, the method also includes pushing a glue tab extending from the trailing panel down with a spatula, wherein the spatula comprises a leading edge that contacts a boundary between the leading panel and the intermediate panel as the intermediate panel and leading panel are folded up and over the bottom panel to form a front and top surface of a box, respectively.

In the disclosure, the method also includes holding the side panels in position as the blank moves forward on the drive line after the side panels have been folded up and down in an alternating fashion. In the disclosure, the method also includes holding the bottom panel down as the leading panel, intermediate panel, and trailing panel are folded to form the top, front, and rear surfaces of a box, respectively.

In another embodiment, a box forming machine includes:.

In some embodiments, the box forming machine also includes one or more trailing squaring arms disposed on the drive line. In some embodiments, the one or more trailing squaring arms have a downward position and a raised position, wherein the one or more trailing squaring arms in the raised position maintain an angle of a bottom trailing corner of a box made from the blank as the blank moves forward on the drive line.

In some embodiments, the box forming machine also includes one or more leading squaring arms disposed at least partially above the drive line. In some embodiments, the one or more leading squaring arms are configured to maintain an angle of a top leading corner of a box formed from the blank as the blank moves forward on the drive line.

In some embodiments, the box forming machine also includes a spatula having a leading edge facing forward in the longitudinal direction of the drive line. In some embodiments, at least a portion of the spatula comprises a surface that is parallel to the drive line. In some embodiments, at least a portion of the spatula is disposed above the drive line.

In some embodiments, the one or more fingers each comprise an elongate member tapering down toward a trailing end thereof. In some embodiments, the elongate member of each of the one or more fingers is disposed parallel to the drive line in the longitudinal direction of the drive line.

In another embodiment, a method is provided for folding a box from a blank. The method is performed on a feed line with an advancing direction of movement. The method includes:.

In some embodiments, the folding upward of the side panels is performed during forward movement of the blank on the feed line, by positioning fingers under the side panels.

In some embodiments, the blank has at least four central panels extending successively in the direction of movement of the feed line, wherein the middle panel is formed by the third of the at least four central panels.

In some embodiments, the method also includes:.

In some embodiments, prior to the pressing, a positioning finger is placed between the areas, adjacently of the glue zone, in order to prevent premature contact between the areas, after which the areas are positioned relative to each other so as to thereby at least partially form the box, after which the positioning finger is removed from between the areas.

In some embodiments, the positioning finger extends above the box in the direction of movement, such that the upper wall of the box comes to lie on the positioning finger when the arm folds the front panels upward.

In some embodiments, the method also includes folding downward side panels which are connected to the upper wall and folding upward side panels which are connected to the lower wall, so that the latter stated side panels form the side walls of the box.

In another embodiment, a device is provided for folding a box from a blank. The device includes:.

In some embodiments, the first folding section comprises fingers which are movable in the transverse direction relative to the feed line so as to adjust the distance between opposite fingers to a width of the blank, and wherein the fingers extend in a direction opposite to the direction of movement with a distal end which can be moved upward and downward in order to grip under said side panels which lie diagonally of the middle panel.

In some embodiments, the device also includes:.

In some embodiments, the device includes a positioning finger situated above the feed line, which positioning finger is movable in the direction of movement so as to extend between the areas in order to prevent premature contact between the areas, after which the areas are positioned relative to each other so as to thereby at least partially form the box, after which the positioning finger is removable from between the areas.

In some embodiments, the pressing element is formed by the arm, which is further provided to move in the direction of movement during pressing of the blank at the position of the glue zone.

In some embodiments, the device further comprises a fourth folding section for folding downward side panels which are connected to the upper wall and folding upward side panels which are connected to the lower wall, so that the latter stated side panels form the side walls of the box.

Claim 1:
A box forming machine (<NUM>), comprising:
a drive line (<NUM>, <NUM>) having a longitudinal direction and a drive mechanism that transports a blank (<NUM>, <NUM>) forward longitudinally on the drive line (<NUM>, <NUM>);
one or more fingers (<NUM>, <NUM>) disposed next to the drive line (<NUM>, <NUM>), the one or more fingers (<NUM>, <NUM>) configured to move up and down to bend side panels (A', B', C', D') of the blank (<NUM>, <NUM>) up and down in an alternating fashion; and
one or more holders (<NUM>, <NUM>) positioned forward from the one or more fingers (<NUM>, <NUM>), the one or more holders (<NUM>, <NUM>) positioned so that the side panels (A', B', C', D') of the blank (<NUM>, <NUM>) are held in position by the one or more holders (<NUM>, <NUM>) as the blank (<NUM>, <NUM>) moves forward on the drive line (<NUM>, <NUM>).