Patent Description:
Typical processing of corrugated boxes includes cutting blanks to size; printing (if necessary); die cutting the sized blanks; and folding and gluing the die cut blanks into a completed box assembly. Printing of box blanks can be done using a variety of processes and equipment. The most common are silk screen, flexographic, and digital printing. Flexographic printing is far and away the most commonly used method for printing of secondary packaging and shippers. Rotary equipment that print and die cut/score blanks is the most cost effective method when high end graphics are not required. Through put speeds with corrugated are in excess of <NUM>,<NUM>-<NUM>,<NUM> per hour. Through put speeds in a flexographic print, and rotary die cut machine are in excess of <NUM>,<NUM>-<NUM>,<NUM> per hour.

Die cutting technology and equipment has been developed and refined for the production of paper corrugated boxes for over <NUM> years. Flatbed die cutting machines, with a straight up down cutting motion, provide the most precise and consistent die cut and scored blanks in both paper corrugated and plastic corrugated. Through put of top end flatbed die cut machines is in excess of <NUM> per hour when converting paper corrugated; slightly less for plastic corrugated. Flat Bed die cutters produce the best quality and most consistent boxes when compared to other die cutting processes.

Rotary Die cutting machines are the fastest commonly use machines to die cut and score blanks into boxes. Rotary machines typically combine printing and die cutting into a single machine so that both operations are completed in a single process step. The cutting and scoring of the blanks in these machines is done as the blanks are moved between two rotating cylinders: one with a cutting and scoring rule, and the other an anvil to cut into and compression score against. Rotary die cutting produces good quality paper corrugated boxes that will typically be a few cents per box less than boxes cut on a flat bed. This few cents per box can be important for large companies that purchase millions and millions of single use corrugated boxes per year. The few cents per box lower cost is less important for multiple use plastic corrugated boxes. <CIT> discloses a method for forming corrugated plastic blanks for forming boxes, using heated scoring rules and a rotary die cutter.

Additional converting machinery is used to form the box once the blank is formed. Folder Gluer machines take paper corrugated or plastic corrugated die cut and scored blanks and fold and glue them into a completed box.

The conventional approach of using converting equipment designed for paper corrugated to convert plastic corrugated results in an overall production process that is out of balance. In very simplified terms, the extrusion of plastic corrugated blanks is very slow and the equipment to convert blanks into boxes is very, very fast.

Using state of the art technology, a plastic corrugated extrusion and edge seal line can produce <NUM>,<NUM> - <NUM>,<NUM> blanks per week running <NUM> hours per day and seven days per week. A full week of production running <NUM>/<NUM> on a plastic corrugated extrusion line can be converted in less than one <NUM> hour shift using conventional paper corrugated converting equipment. The plastic corrugated box blanks produced by three state of the art extrusion/edge sealing lines running <NUM>/<NUM> could be converted into boxes in one day using conventional paper corrugated converting equipment.

However, the speed and size of conventional converting equipment and processes comes at a price. Such equipment and processes cannot consistently be utilized to convert plastic corrugated sheet.

The present invention provides an improved process for forming plastic corrugated material.

The present invention is directed to a process for forming plastic corrugated boxes in a plurality of steps at separate stations in an in-line system.

In accordance with one aspect of the invention, a balanced in-line process for forming blanks that can be used for forming boxes as claimed in claim <NUM> is provided. The process comprises sequencing a blank of corrugated plastic material having a first outer layer, a second outer layer and a plurality of flutes between the first outer layer and the second outer layer through a plurality of forming stations. This can be accomplished on a conveyor that moves the blank through each of the forming stations. The process includes forming a first body fold line separating a first box side wall and a second box side wall in the blank at a first forming station. Additionally, other body fold lines can be formed at this station as well. The process also includes forming a score line to create a first flap in the blank at a second forming station. Again, other score lines can be formed at this time for additional flaps.

The process includes the steps of forming a first slot between the first flap and a second flap in the blank at a third forming station (or between additional flaps), and can also include sealing the edges of the first slot. The process can further include forming a glue tab (or manufacturer's joint) at one end of the blank at a fourth forming station and cutting a hand hold into the blank at a fifth forming station.

The fold lines can be formed by joining the first outer layer of the blank to the second outer layer of the blank at each fold line. The score lines can be similarly formed.

The step of joining the first outer layer of the blank to the second outer layer of the blank can comprise contacting the blank with a die rule and a heated plate to weld the first outer layer to the second outer layer at the first fold line. Alternatively, this joining step can comprise contacting the blank with an ultrasonic emitter, which can be part of a plunge ultrasonic system or a rotary ultrasonic system. Further, the joining step can be contacting the blank with an impulse welding device.

The step of forming a glue tab at one end of the blank at a fourth forming station can comprise cutting the end of the blank to form a tab and joining the first outer layer of the tab to the second outer layer of the tab. Again, the joining can utilize a rule and heated plate, ultrasonics or an impulse welding device.

The process can include other steps preformed at other forming stations. For example, the process can include forming smooth sealed edges on the blank, adding latch and hook material to a portion of the blank, and/or printing one or both surfaces of the blank.

Typical operating speeds for forming paper corrugated material are <NUM>-<NUM> blanks per hour. At this rate, there is not enough time to transfer heat from a heated plate to the plastic layers in a plastic corrugated material. Accordingly, the process is preferably run at a slower rate, for example, the blanks can be processed at a speed of approximately <NUM>-<NUM> blanks per hour. This slower rate provides more dwell time for transferring heat.

The process can further include moving each of the plurality of blanks through a third forming station by the conveyor and forming slots between flaps in each blank at the third forming station. The process can also include sealing edges of the slots formed in each blank.

The process can also include moving each of the plurality of blanks through a third (or fourth) forming station by the conveyor and forming a glue tab at an end of each blank by joining the first outer layer to the second outer layer at the glue tab. The joining step can be accomplished by contacting each blank with a die rule and a heated plate to weld the first outer layer to the second outer layer at the fold lines. Alternatively, the joining can be accomplished by ultrasonics or impulse welding.

Further aspects of the invention are discussed herein and are shown in the Figures.

To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:.

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

The conventional approach of using box converting equipment designed for paper corrugated material, to convert plastic corrugated material, results in an overall production process that is out of balance. In very simplified terms, the extrusion of plastic corrugated blanks is very slow and the conventional equipment to convert paper corrugated blanks into boxes is very, very fast.

As discussed herein, both paper and plastic corrugated boxes have been mass produced at high speed using flatbed or rotary die cutters as shown in <FIG>, respectively. In each instance, all (or most) of the features needed in the blanks is formed in a single pass by each cutter. While this works well for paper corrugated material, it can cause issues with plastic corrugated material, leaving such plastic blanks less desirable or unuseable.

Plastic corrugated material is typically extruded to include a first outer layer, a second outer layer, and a plurality of internal parallel flutes or ribs connecting the first outer layer to the second outer layer. Forming features in such material can be problematic because plastic has an inherent memory. That is, over time (in some cases immediately or in merely minutes) the plastic partially or completely returns to its pre-formed shape. Accordingly, scoring or fold lines, or other features tend to disappear if formed simply by compression.

One method for overcoming the tendency of the plastic to return to its original state, is to utilize heat (or heat plus pressure) when reforming the plastic. In particular, it is necessary in many instances to, in effect, weld the first outer layer of the corrugated material to the second outer layer when forming score or fold lines, or flattening portions of the material.

This "welding" of the plastic can be accomplished by heating elements of the die cutter. However, it is challenging and perhaps impossible to keep a full size plate of steel (i.e., as used in a conventional die cutter) perfectly flat when heated. This inability will affect the blanks produced. Moreover, the speed such conventional die cutting machinery uses is not conducive to forming good welds in the plastic.

The present invention provides an in-line process which utilizes a slower speed and modifies the blanks in smaller increments or portions (i.e., as opposed to a single pass by a conventional die cutter). It is much easier to keep small cutting/sealing platens flat at elevated temperatures. Additionally, the slower speed of the in-line process allows more dwell time to seal edges and weld the plastic where necessary.

<FIG> illustrates an in-line processing system <NUM> for converting plastic corrugated material into blanks <NUM> for forming boxes. The system <NUM> removes individual blanks from a stack <NUM>. The blanks <NUM> are singulated for transfer through a number of steps to impart features onto each blank <NUM> in a series of operations.

One optional first step, shown in <FIG>, is sealing the edges of the plastic corrugated blank <NUM>. Each blank <NUM> is drawn past a first die <NUM> that contacts a first edge <NUM> of the blank <NUM>, and a second die <NUM> that contacts the second edge <NUM> of the blank <NUM>. The dies <NUM>, <NUM> seal the edge and form a rounded, smooth edge surface. A typical edge sealer can form <NUM>-<NUM> blanks <NUM> per hour - this is much slower than traditional die cutting equipment.

The blank <NUM> can then be indexed on a continuous belt <NUM> through an in-line series of additional operations at separate stations <NUM> of the system <NUM> to form the typical features needed for the blank <NUM> to be converted into a box. These include: (<NUM>) die cutting of glue tab (i.e., formation of manufacturer's joint connecting one end of the blank to the other); (<NUM>) die cutting of slots between bottom and top flaps; (<NUM>) flap scores; and (<NUM>) body scores or fold lines). The in-line process can also be used to impart other cuts and features to the blank, such as print or labels, or latch and hook material (e.g., Velcro®). After one step is performed, the blanks <NUM> are then transferred to the next station <NUM> for another operation.

Box flap and body scores can be imparted to the blank using several methods. These include using standard die rule to compress the material against a hard rigid plate (as is done with paper corrugated material). Using steel die rule or a steel bar to compress the plastic corrugated material against a heated steel plate to bond the upper and lower skins together. Using plunge type ultrasonic technology to impart the scores. Or using score rules to compress the plastic corrugated material against a steel plate. The plate could be heated to bond the upper and lower skins of the material for consistent score.

<FIG> show components and process steps for forming flap and/or body scores. Flap scores <NUM> are shown being formed using steel rollers <NUM> in <FIG>. The steel rollers <NUM> compress, or compress and bond the plastic material as the sheet moves through the process sequence. If bonding (i.e., welding of the top and bottom skin) is desired, it can be accomplished by compressing the material against a heated steel plate, or using rotary ultrasonic equipment.

Body scores <NUM> can also be imparted to the plastic corrugated blank using simple up and down compression of a steel scoring rule <NUM> against a steel plate as shown in <FIG>. Alternatively, "plunge" ultrasonic technology can be used.

<FIG> also shows fold lines being formed in a blank <NUM>. The blank <NUM> is on a heated steel plate <NUM>. A plurality of scoring rules <NUM> compress the blank <NUM> against the steel plate <NUM>.

By using a heated steel cutting plate <NUM>, it is possible to bond the two outer skins of the plastic corrugated material together to form a clear fold line <NUM>. When scored in this way the blank <NUM> will fold in the intended location and follow the imparted score line <NUM> rather than following the path of least resistance and jump to the area between the flutes adjacent to imparted score and the intended fold line <NUM>.

A separate station <NUM> can be used to form and seal slots <NUM> between flaps <NUM> of the blank <NUM>. As illustrated in <FIG> and <FIG>, a first die <NUM> and a second die <NUM> are each arranged to cut a slot <NUM> between adjacent flaps <NUM>, and to seal the edges <NUM> of the slot <NUM>. As blanks <NUM> are transferred and indexed through the sequential process steps, the flap slots <NUM> can be cut and sealed by a simple vertical press with mirror image cutting and sealing features on opposing sides of the transfer line. By using plunge ultrasonic technology or using steel rule to compress the plastic corrugated material to a heat steel plate <NUM> a quality cut and edge seal of slots <NUM> can be achieved.

Other stations - using similar dies, can be used to form other features, such as the glue joint <NUM> (i.e., manufacturer's joint). The glue joint <NUM> is shown, for example, in <FIG> and <FIG>. Additionally, such stations can cut out portions of the blank <NUM>, such as hand holds <NUM> as shown in <FIG>.

The in-line balanced process is designed for slower speeds (e.g., formation of <NUM>-<NUM> blanks <NUM> per hour). At such speeds, there is more dwell time for the heated steel plate to transfer enough heat to the blank <NUM> to get a good bond between the outer skins or layers of the material. At the <NUM>+ per hour rate of conventional converting equipment there simply isn't enough dwell time to get consistent quality bonded score lines.

The process of indexing blanks in an in-line series of operations has the added benefit of imparting features on smaller areas of the blank <NUM> in any single operational step. This allows doing things that are very challenging to do when doing all of the cutting and scoring in a single stroke as typically done in the converting of paper corrugated boxes.

The balanced in-line process indexes the sheet through a series of operations. Only the area for each individual step needs to have the heated cutting area.

Prior to the present invention, substantially all of the processing steps would have been done in a single pass of a die cutter, such as the flatbed die cutter <NUM> of <FIG> or the rotary die cutter <NUM> of <FIG>. Because of the difficulty of heating the entire die cutter (which can distort the die), such prior processing did not result in consistently satisfactory blanks <NUM>.

Instead of heating a large die cut plate (platen or striker plate) typical on a production flatbed die cutter <NUM>, individual heated plates and vertical presses are used at the multiple stations <NUM>. Such plates and presses are small when compared to the traditional flatbed die cutter <NUM>. For boxes with <NUM> inch flaps, the heated cutting plate could be as small as <NUM> inches by <NUM> inches. For a box with <NUM> inch flaps the heated cutting plate could be as small as <NUM> inches by <NUM> inches. There is significantly less warp and distortion issues in heating a sequence of small plates as opposed to the large <NUM> inch x <NUM> inch platen of a flatbed die cut machined designed for paper corrugated material.

The order in which sequence steps are conducted is not important in the in-line process. Moreover, the in-line process allows for modular sequential operational steps. That is, not all boxes will require all features and not all modules of the in-line process needs to be used in the production of every box.

Claim 1:
A balanced in-line process for forming blanks (<NUM>) for forming boxes comprising:
sequencing a blank of corrugated plastic material having a first outer layer, a second outer layer and a plurality of flutes between the first outer layer and the second outer layer through a plurality of separate forming stations (<NUM>);
forming a first body fold line (<NUM>) separating a first box side wall and a second box side wall in the blank at a first forming station;
moving the blank to a second forming station that is separate from the first forming station;
forming a score line (<NUM>) to create a first flap in the blank at the second forming station;
moving the blank to a third forming station that is separate from the first forming station and the second forming station; and
forming a first slot between the first flap (<NUM>) and a second flap (<NUM>) in the blank at the third forming station (<NUM>).