APPARATUS FOR FOLDING PACKAGING MATERIAL

FIELD OF APPLICATION OF THE INVENTION

The present invention relates to an apparatus for folding packaging material, and more specifically, an apparatus using a method for folding packaging material into multiple packaging products having different sizes and/or dimensions.

BACKGROUND TO THE INVENTION

The packing industry utilizes paperboard material that has been subjected to a strict printing, cutting, folding, glueing and lamination process. Once finalized, this material is sent to a facility where packaging products are produced. While the process of producing these products was historically laboriously and time-intensive, modern day facilities now employ expensive carton folding machinery that can ensure a high product output, in addition to client-tailored packaging products. Accordingly, the carton folding industry has now evolved into a multi-billion US Dollar industry.

Modern day cartoning machines are tailored to provide either complete or partially completed products according to facility-specific goals. Often, the reason for this dependent on the product that would enter the final carton product. As such, some facilities will mass produce carton products have certain dimensions that could be utilized for products in a variety of industries (food, materials, components etc.), while some facilities will fill each carton with a desired product during the carton folding and final assembly process. A drawback for a majority of these cartoning machines are that they are limited to a single product line producing a very specific carton product. Furthermore, while some of these machines can be configured to produce different carton products, the steps necessary to reconfigure the machine is often difficult and time-consuming. Even further, some of these machines require a pickup tool for picking up cardboard material from a stack, and feeding same to a feed tool, which in turn feeds the cardboard material to the machines’ folding mechanism. The various components result in a comparatively complex process that is further susceptible to timeous breakdowns on account of the various components. Additionally, all of these components often result in a large or voluminous apparatus that is difficult to transport, assemble and perform routine maintenance on.

From the above, it is clear that there is a need for folding apparatus capable of multiple folding configurations, and wherein switching between different configurations is easy, short and user-friendly. Additionally, there exists a need for a folding apparatus that delivers a high carton product output, while the machine is also compact and capable of being easily assembled and transported.

OBJECT OF THE INVENTION It is accordingly an object of the present invention to provide a folding apparatus for folding packaging material that seeks to, at least partially, overcome or lessen the above disadvantages and/or will be a useful alternative to existing folding machines and apparatuses that produce a single packaging product.

SUMMARY OF THE INVENTION

According to a first aspect thereof, there is provided a folding apparatus which may include: a first folding section at one end having a first folding means for folding packaging material; a second folding section at the opposing end having a second folding means for folding packaging material; a displacement member capable of displacement in a substantially horizontal direction; and wherein the displacement member is displaced from a first position wherein the displacement member displaces the packaging material in the first folding section towards the first folding means to fold the packaging material, to a second position wherein the displacement member displaces the packaging material in the second folding section towards the second folding means to fold the packaging material.

The first folding section may include a first feeding section adjacent thereto for feeding packaging material to the first folding section. The second folding section may include a second feeding section adjacent thereto for feeding packaging material to the second folding section.

The packing material may be a resiliently deformable material.

The resiliently deformable material may be selected from a group consisting of carton material, plastic material, polymers, any suitable material used for packaging, and a combination thereof.

The first folding means and the second folding means may include one or more protrusions.

The one more protrusions of the first folding means and the second folding means may include cylinders.

The first folding means and the second folding means may be releasably securable to the first folding section and the second folding section, respectively.

The first folding means and the second folding means may both be replaced with differently sized, shaped and configured folding means, which allows for the folding of different packaging material.

The folding apparatus may include a first adjustment means for adjusting the configuration of the first folding section and the first folding means to fold different packaging material. The folding apparatus may include a second adjustment means for adjusting the configuration of the second folding section and the second folding means to fold packaging material.

In an embodiment of the invention, the first folding means of the first folding section and the second folding means of the second folding section may be a packaging folding aid including: one or more protrusions; a frame capable of receiving and securing the one or more protrusions, which is releasably securable to the folding apparatus for folding packaging material; and an adjustment means for adjusting the any one or more of the position, number, and orientation of the one or more protrusions in the frame; and wherein the packaging folding aid, when secured within the folding apparatus for folding packaging material serves as a template for folding packaging material, based on the number and configuration of the protrusions received and secured within the frame, as adjusted using the adjustment means.

The first feeding section and the second feeding section may feed the packaging material in a substantially vertical direction to the first folding section and the second folding section, respectively.

The first feeding section and the second feeding section may include gripping means for gripping the packaging material. The folding apparatus may include guiding means for guiding the packaging material from the first feeding section and the second feeding section to the first folding section and the second folding section, as required.

The guiding means may include one or more wheels for guiding the packaging material to the folding apparatus.

The guiding means may include one or more idler rollers for guiding the packaging material to the folding apparatus.

The folding apparatus may include an actuator means for actuating the first folding means and the second folding means.

The folding apparatus may include an actuator means for actuating the first feeding section and the second feeding section.

The folding apparatus may include an actuator means for actuating the displacement member.

The actuator means may be selected from a group consisting of a motor, a servo motor, a pneumatic apparatus or a hydraulic apparatus, and a combination thereof. The folding apparatus may include a human machine interface for programming the manner in which the first folding section and the second folding section folds packaging material, respectively.

The human machine interface may be used to control the actuating means.

The folding apparatus may include one or more pneumatic valves for controlling the manner in which packaging material is folded by the first folding means and the second folding means.

The folding apparatus may include a programmable logic controller which allows for communication between the human machine interface and the one or more pneumatic valves.

The folding apparatus may be mounted on a housing.

The housing may include a displacement means for displacing the folding apparatus.

The displacement means may be wheels or at least one wheeling assembly.

The displacement means may be a linear bearing guide assembly.

The folding apparatus may include an adhesive section for applying an adhesive to the packaging material. The adhesive may be a glue.

The folding apparatus may include a conveyor system for displacing folded packaging material from the folding section.

The conveyor system may include a conveyor belt.

According to a second aspect thereof, there is provided a folding apparatus, substantially as described according to the first thereof, wherein the folding apparatus may be modular and includes at least one opening at a side region thereof to allow for a second folding apparatus to be releasably secured thereto.

The folding apparatus may include: - a third folding section at one end having a third folding means for folding packaging material; a fourth folding section at an opposing end having a fourth folding means for folding packaging material; a third feeding section adjacent to the third folding section for feeding packaging material to the third folding section; a fourth feeding section adjacent to the fourth folding section for feeding packaging material to the fourth folding section; and a second displacement member capable of displacement in a substantially horizontal direction; and wherein the second displacement member is displaced from a first position; wherein the displacement member displaces the packaging material in the third folding section towards the third folding means to fold the packaging material, to a fourth position wherein the second displacement member displaces the packaging material in the fourth folding section towards the fourth folding means to fold the packaging material.

The packing material may be a resiliently deformable material.

The resiliently deformable material may be selected from a group consisting of carton material, plastic material, polymer material, any suitable material for packaging material, and a combination thereof.

The third folding means and the fourth folding means may be comprised of one or more protrusions.

The one or more protrusions may include cylinders.

The folding apparatus may include a third adjustment means for adjusting the configuration of the third folding section and the third folding means to fold different packaging material.

The folding apparatus may include a fourth adjustment means for adjusting the configuration of the fourth folding section and the fourth folding means to fold different packaging material. The third feeding section and the fourth feeding section may feed the packaging material in a substantially vertical direction to the third folding section and the fourth folding section, respectively.

The third feeding section and the fourth feeding section may both include gripping means for gripping the packaging material.

The second folding apparatus may include guiding means for guiding the packaging material from the third feeding section to the third folding section, and for guiding the packaging material from the fourth feeding section to the fourth folding section.

The guiding means may be comprised of one or more wheels for guiding the packaging material to the second folding apparatus.

The guiding means may be comprised of one or more idler rollers for guiding the packaging material to the second folding apparatus.

The second folding apparatus may include an actuator means for actuating any one of the third folding section, the fourth folding section, the third folding means, the fourth folding means, and the second displacement member.

The actuator means may be selected from a group consisting of a motor, a servo motor, a pneumatic apparatus or a hydraulic apparatus, and a combination thereof. The second folding apparatus may include a human machine interface for programming the manner in which the third folding section and the fourth folding section folds packaging material, respectively.

The human machine interface may be used to control one or more of the actuator means.

The second folding apparatus may include one or more pneumatic valves for controlling the manner in which packaging material is folded by the third folding means and the fourth folding means, respectively.

The second folding apparatus may include a programmable logic controller which allows for communication between the human machine interface and the one or more pneumatic valves.

The second folding apparatus may be mounted on a second housing.

The second housing may include a second displacement means for displacing the folding apparatus.

The second displacement means may be wheels or at least one wheeling assembly.

The second displacement means may be a linear bearing guide assembly. The second folding apparatus may include an adhesive section for applying an adhesive to the packaging.

The adhesive may be a glue.

The second folding apparatus may include a conveyor system for displacing folded packaging material from the third folding section and the fourth folding section, respectively.

The conveyor system may include a conveyor belt.

According to a third aspect thereof, there is provided a method of folding packaging material by utilizing a folding apparatus which may comprise the steps of: adding packaging material to a first feeding section and a second feeding section of the folding apparatus; feeding the packaging material from the first feeding to a first folding section having a first folding means at one end of the folding apparatus; feeding the packaging material from the second feeding section to a second folding section having a second folding means at the opposing end of the folding apparatus; and displacing a displacement member towards the packaging material in the first folding section, such that the first folding means folds the carton material, and wherein the displacement member is further displaceable towards packaging material in the second folding section, such that the second folding means folds the packaging material. The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawing which illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

One embodiment of the invention is described below, by way of a non-limiting example only, and with reference to the accompanying drawings in which:

Figure 1 is a perspective overview of the full assembly of the folding apparatus;

Figure 2 is a partial perspective overview of section A of the folding apparatus;

Figure 3 is a partial perspective overview of the feeding section and folding section of section A of the folding apparatus;

Figure 4 is a partial and rear perspective overview of the feeding section and folding section of section A of the folding apparatus; Figure 5 is partial perspective overview of an actuator and first displacement member operating between section A and section B, and wherein a second displacement member operates between section C and D.

Figure 6 is partial perspective overview of an actuator and first displacement member operating between section A and section B, in addition to a further actuator and second displacement member operating between section C and D.

Figure 7 is a front view of the modular configuration of the invention, wherein a first folding apparatus and a second folding apparatus are configured to operate between section A and B, in addition to being configured to operate between section C and D;

Figure 8 is a top view of the modular configuration of the invention, wherein the second folding apparatus is not releasably secured to the first folding apparatus;

Figure 9 is a top view of the modular configuration of the invention, wherein the second folding apparatus is releasably secured to the first folding apparatus, and wherein the configuration allows for the first folding apparatus to operate between section A and B, in addition to the second folding apparatus being configured to operate between section C and D; Figure 10 is a top view of the modular configuration of the invention, wherein the second folding apparatus is disconnected from the first folding apparatus; and

Figure 11 is a perspective view of the folding apparatus, which illustrates how the folding section is removed and replaced with another folding section for folding different packaging material.

The presently disclosed subject matter will now be described more fully hereinafter with reference to the accompanying Example, in which representative embodiments are shown and discussed. The presently disclosed subject matter can, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the embodiments to those skilled in the art.

DETAILED DESCRIPTION OF THE INVENTION

A non-limiting example of a preferred embodiment of the invention is described in more detail below, with reference to Figures 1 to 1 1 .

Example:

With reference to Figure 1 , a folding apparatus 2 is shown having a housing 4 including supporting members 6. Additionally, the housing 4 includes base support members 8 and vertical support members 10. The folding apparatus 2 includes two operational sections, namely section A and section B, wherein the various components of the folding apparatus 2 are duplicated and mirrored. Section A of the folding apparatus 2 includes a feeding section 12 wherein packaging material (not shown) is received and gripped by gripping means 14. An actuator 16 actuates a roller member 18 to guide packaging material gripped by the gripping means 14 to a folding section 20.

The folding section 20 includes folding protrusions 22 for folding the packaging material in the folding section 20. A human machine interface 24 together with a programmable logic controller 26 are mounted on the folding apparatus 2 for programming and controlling the various components of the folding apparatus 2 function in accordance with programmable instructions. The human machine interface 24 together with the programmable logic controller 26 are in communication with a pneumatic valve system 28, which in turn provides pneumatic members 30 to the feeding section 12 and the folding section 20. In use, the human machine interface 24, programmable logic controller 26, pneumatic valve system 28, and pneumatic members 30 control and determine how the components of the feeding section 12 and the folding section 20 function to produce packaging products from packaging material. For example, a different set of programmable instructions could be utilized in order for the human machine interface 24, programmable logic controller 26, pneumatic valve system 28, and pneumatic members 30 to fold packaging material into packaging products of varying shapes and sizes. It will be appreciated by a person skilled in the art that the detail regarding the representation and configuration of the human machine interface 24, programmable logic controller 26, and pneumatic valve system 28 have been excluded from the drawings in the specification, for the sake of clarity. In a further embodiment of the invention, the folding section 20 and the folding protrusions 22 include pistons, cylinders and/or pneumatic actuators to cooperate with the folding protrusions 22 to fold the packaging material into different packaging products.

Additionally, the folding apparatus 2 includes adjustment means 32 that allows for manual adjustment of the folding protrusions 22 in the folding section 20, which is required when packaging products having different configurations are required. Alternatively, the human machine interface 24 and the programmable logic controller 26 can be used in order to automatically adjust the folding protrusions 22 in the folding section 20 to produce different packaging products.

With reference to Figure 2, the figure provides a partial view of section A with section B excluded for clarity. A second actuator 34 for actuating and displacing a displacement member 36 having a first plate 38 and a second plate 40 is provided and located between section A and section B of the folding apparatus. In an even further embodiment, the human machine interface 24, programmable logic controller 26, and pneumatic valve system 28 can also be connected to the second actuator 34 in order to control the speed and displacement of the displacement member 36.

With reference to Figures 1 and 2, the folding apparatus, where in operation, the displacement member 36 is displaced towards the folding protrusions 22 in section A, wherein the packaging material is folded by the folding protrusions 22 and the force exerted by the displacement member 36 and the first plate 38. Additionally, and when in operation, the displacement member 36 is further capable of being displaced towards the folding protrusions 22 in section B (see Figure 1 ), wherein packaging material is folded by the folding protrusions 22 and the force exerted by the displacement member 36 and the second plate 40. The displacement between section A and B can be repeated in order to fold multiple packaging products, and the speed of the gripping means 14, folding protrusions 22, displacement member 36 and other components of the folding apparatus can be adjusted and programmed by the human machine interface 24, programmable logic controller 26, and pneumatic valve system 28 in order to produce more or less packaging products, in addition to packaging products having different sizes and/or configurations.

Figure 3 and Figure 4 provide a closer view of components in section A, wherein packaging material (not shown) is gripped by the gripping means 14 in the feeding section 12; and guided to the folding section 20 by the actuator 16 and the roller member 18. The folding means 22 in the folding section 20 is configured to fold the packaging material into a specific packaging product. The human machine interface 24, programmable logic controller 26, pneumatic valve system 28, and pneumatic members 30 are utilized in order to provide programmable instructions to the feeding section 12, and the folding section, such that a desired packaging product can be obtained in either section A or section B.

Figure 5 provides a closer view of the displacement member 36 located between section A and section B. Here, the second actuator 34 actuates and displaces the displacement member 36 and the first plate 38 towards the folding means 22 in section A and is further capable of displacement of the displacement member 36 and the second plate 40 is displaced towards the folding means 22 in section B, such that the packaging material is folded in both section A and section B. With reference to Figure 2 and Figure 5, it is noted that the force applied by the displacement member 36, together with either the first plate 38 or the second plate 40, will result in packaging material being folded by the folding means 22 in the folding section 20.

In an alternative configuration, the folding apparatus 2 is modular in configuration. As such a configuration will be complimentary with another folding apparatus 2 defining section C and section D. To this end, Figure 6 shows a third actuator 42 used for actuating and displacing a second displacement member 44 having a third plate 46 and a fourth plate 48 between section C and D.

Figure 7 illustrates a configuration having a first folding apparatus 2' and a second folding apparatus 2", in addition to the relative positions of section A, section B, section C and section D.

Figure 8 provides a top view of the configuration wherein the first folding apparatus 2' and the second folding apparatus 2" define the relative positions of section A, section B, section C and section D. Here the second folding apparatus 2" is not operational as it has not releasably secured to the first folding apparatus 2'. Figure 9 provides an operational configuration wherein the second folding apparatus 2" is releasably secured to the first folding apparatus 2'. In this configuration, the second folding apparatus 2" having a section C and D can be implemented in order to utilize the second displacement member 44. To this end, and when in operation, the second displacement member 44 can be actuated and displaced by the fourth actuator 42, such that the second displacement member is displaced towards the folding protrusions 22 in section C, wherein the carton material is folded by the folding protrusions 22 and the force exerted by the second displacement member 44 and the third plate 46. Additionally, and when in operation, the second displacement member 44 is further capable of being displaced towards the folding protrusions 22 in section D, wherein the packaging material is folded by the folding protrusions 22 and the force exerted by the second displacement member 44 and the fourth plate 48.

Figure 10 further illustrates the modular configuration of the invention, wherein the second folding apparatus 2" can be releasably disconnected from the first folding apparatus 2'.

With reference to Figure 1 1 , there is provided a folding apparatus 50 including a first operational section A’ consisting of a first feeding section 52’ and a first folding section 54’. The first feeding section 52’ includes a frame 56 which allows for the displacement and removal of the first operational section A’. The first feeding section 52’ includes a first feeding means 58’ for feeding the packaging material (not shown) to the first folding section 54’, which includes the first folding protrusions 60’ for folding the packaging material. The folding apparatus 50 allows for the first operational section A’ to be removably replaced with a second operational section A”.

The second operational section A” includes a second feeding section 52’ and a second folding section 54”. The second feeding section 52” includes a second feeding means 58” for feeding the packaging material (not shown) to the second folding section 54”, which includes the first folding protrusions 60” for folding the packaging material. The replacement of the first operational section A’ with a second operational section A” allows for the folding apparatus 50 to fold differently sized and shaped packaging material, which is illustrated by the first carton box 62 and the second carton box 64.

ADVANTAGES OF USING THE FOLDING APPARATUS

A prototype of the folding apparatus showed surprising advantages over existing folding methods and instruments.

Typically, several carton folding companies make use of workers for the manual folding of carton boxes; a folding apparatus utilizing glue for folding carton boxes; and a folding apparatus not requiring any glue for folding carton boxes.

Typically, a shift consists of 9 hours whereby the working or the machine would continuously fold the packaging material into carton boxes.

1 . At a facility using workers and manual folding, the following costs are incurred:

22 x Workers earning R4100 per month: R90 200.00

2 x Supervisor earning R5000 per month: R10 000.00

Total salary expenditure: R100 200.00

Approximately 9000 carton boxes are folded in one shift.

As such, 18 9000 carton boxes are folded over 21 days. The cost per carton box: R.53 or 53 cents. (This excludes accommodation and transport of workers and the transportation of the boxes).

2. At a facility fit with a folding apparatus utilizing glue for folding carton boxes:

2 x Workers earning R5000 per month: R10 000.00

1 x Supervisor earning R12000 per month: R12 000.00

Total salary expenditure: R22 000.00

The cost of glue per box: R.96 or 96 cents.

Approximately 7 020 carton boxes are folded in one shift.

As such, 147 420 carton boxes are folded over 21 days.

The costs per carton box: R1 .11 (This excludes accommodation and transport of workers and the transportation of the boxes).

3. At a facility fit with a folding apparatus that does not require glue for folding carton boxes:

1 x Operator earning R15 000 per month: R15 000.00

2 x General Workers earning R5 000 per month: R10 000.00

Total salary expenditure: R25 000.00

Approximately 6 480 carton boxes are folded in one shift.

As such, 136 080 carton boxes are folded over 21 days. The costs per carton box: R0.90 or 90 cents (This excludes accommodation and transport of workers and the transportation of the boxes).

4. At a facility fit with a quattro (Figures 8, 9 and 10 where there are 4 folding sections) folding apparatus that does not require glue for folding carton boxes:

1 x Operator earning R15 000 per month: R15 000.00

4 x General Workers earning R5 000 per month: R20 000.00

Total salary expenditure: R35 000.00

Approximately 12 960 carton boxes are folded in one shift.

As such, 272 160 carton boxes are folded over 21 days.

The costs per carton box: R0.90 or 90 cents (This excludes accommodation and transport of workers and the transportation of the boxes).

Considerations:

The costs per carton box provided above all relate to one specific size. As such, the costs would vary if different sized boxes and/or packaging material are utilized. The example above was merely utilized to illustrate how costs are saved. This particular example and comparison were in respect of typical grape carton boxes. See image below:

Importantly, the costs vary according to style of the carton box, the size thereof, and the items packaged therein. Some typical cost variations are provided below: