AGANOVIC, Amer (724 Hardwood Circle, Orlando, FL, 32828, US)
TEANY, Robert, Bradley (16500 Bay Ridge Drive, Clermont, FL, 34711, US)
GULIK, Gregory, Scott (508 Briar Oak Way, Deland, FL, 32724, US)
BUSCEMA, Craig, William (9971 Devonshire Street, Douglasville, GA, 30135, US)
GRAHAM, Thomas, Dean (11714 Flynn Court, Winter Garden, FL, 34787, US)
AGANOVIC, Amer (724 Hardwood Circle, Orlando, FL, 32828, US)
TEANY, Robert, Bradley (16500 Bay Ridge Drive, Clermont, FL, 34711, US)
GULIK, Gregory, Scott (508 Briar Oak Way, Deland, FL, 32724, US)
BUSCEMA, Craig, William (9971 Devonshire Street, Douglasville, GA, 30135, US)
| WHAT IS CLAIMED IS: 1. A method for forming a container from a blank of sheet material using a machine including a forming assembly and first and second minor flap folders, the forming assembly including at least one top clamp and at least one major flap folder, said method comprising: adjusting a width of the forming assembly using a first adjustment device; adjusting a depth of the forming assembly using a second adjustment device; inserting a first end of the blank into the forming assembly, the first end including a first pair of minor end flaps and a first major end flap; and activating the machine to form a first end wall of the container including: rotating the first pair of minor end flaps proximate the top clamp by extending the first and second minor flap folders inwardly toward the blank along a first substantially straight path; and rotating the first major end flap into contact with the first pair of minor end flaps by extending the at least one major flap folder upwardly along a second substantially straight path. 2. A method in accordance with Claim 1 further comprising rotating side panels of the blank to form the blank into a J-shape configuration before inserting the first end of the blank into the forming assembly. 3. A method in accordance with Claim 1 further comprising removing the blank from the forming assembly after the first end wall is formed. 4. A method in accordance with Claim 1 further comprising: inserting a second end of the blank into the forming assembly, the second end including a second pair of minor end flaps and a second major end flap; and activating the machine to form a second end wall of the container including: rotating the second pair of minor end flaps proximate the top clamp by extending the first and second minor flap folders inwardly toward the container along the first substantially straight path; and rotating the second major end flap into contact with the second pair of minor end flaps by extending the at least one major flap folder upwardly along the second substantially straight path. 5. A method in accordance with Claim 1, wherein activating the machine further comprises securing the blank within the forming assembly by moving the top clamps into contact with the blank. 6. A method in accordance with Claim 1, wherein the forming assembly includes an adhesive applicator, and wherein forming a first end wall of the container further comprises applying adhesive to the first major end flap using the adhesive applicator before the first pair of minor end flaps are rotated. 7. A method in accordance with Claim 1, wherein the forming assembly includes a rotatable finger, and wherein activating the machine further comprises rotating the finger downwardly to rotate the first major end flap downwardly before the first pair of minor end flaps are rotated. 8. A method in accordance with Claim 7, wherein activating the machine further comprises rotating the finger upwardly before the first major end flap is rotated. 9. A method in accordance with Claim 1, wherein activating the machine comprises pressing the first pair of minor end flaps and the first major end flap between the top clamp and the at least one major flap folder. 10. A method in accordance with Claim 1 further comprising resetting the machine to an initial configuration after the first end wall of the container is formed. 11. A method in accordance with Claim 1, wherein the forming assembly includes a backstop, and wherein inserting a first end of the blank into the forming assembly further comprises inserting the blank into the forming assembly until the first major end flap contacts the backstop. 12. A method in accordance with Claim 1, wherein the forming assembly includes a first forming module and a second forming module, the first forming module including a first top clamp, a first entrance plow, and a first major flap folder and the second forming module including a second top clamp, a second entrance plow, and a second major flap folder, and wherein adjusting a width of the forming assembly further comprises moving the first forming module and the second forming module relative to each other using the first adjustment device. 13. A method in accordance with Claim 1, wherein the forming assembly includes a beam assembly including a beam, a backstop coupled to the beam, and a finger coupled to the beam, and wherein adjusting a depth of the forming assembly further comprises moving the backstop and finger forward and rearward using the second adjustment device. 14. A machine for forming a container from a blank of sheet material, said machine comprising: a first forming module; a second forming module that is movable with respect to said first forming module for adjusting a width of said forming assembly, wherein each said forming module comprises: a top clamp configured to move in a substantially vertical direction to engage the blank; a major flap folder configured to move in a substantially vertical direction; and an entrance plow configured to direct the blank into said forming assembly; and first and second minor flap folders that are extendable inwardly toward the blank along a substantially straight path, said first minor flap folder positioned near said first forming module and said second minor flap folder positioned near said second forming module. 15. A machine in accordance with Claim 14, wherein each said forming module further comprises an adhesive applicator configured to move in a substantially horizontal direction toward and away from said entrance plow. 16. A machine in accordance with Claim 14, wherein each said forming module comprises a support assembly having said top clamp, said major flap folder, and said entrance plow coupled thereto. 17. A machine in accordance with Claim 14 further comprising a first adjustment device coupled to said first forming module and said second forming module and configured to move said first forming module and said second forming module with respect to each other for adjusting the width of said forming assembly. 18. A machine in accordance with Claim 14 further comprising: a first guide rail aligned along a width of said machine; and a second guide rail that is substantially parallel to said first guide rail, said first forming module and said second forming module slidably coupled to said first guide rail and said second guide rail for movement with respect to each other. 19. A machine in accordance with Claim 18 further comprising a width adjustment indicator comprising: a pointer coupled to said first guide rail; and a ruler coupled to said first forming assembly, said pointer and said ruler configured to indicate the width of said forming assembly. 20. A machine in accordance with Claim 14, wherein said forming assembly further comprises a beam assembly coupled between said first forming module and said second forming module, said beam assembly comprising: a beam; a backstop coupled to said beam for movement therewith; and a finger coupled to said beam for movement therewith, said finger rotatable with respect to said beam. 21. A machine in accordance with Claim 14 further comprising a second adjustment device coupled to said beam assembly and configured to adjust a depth- wise position of said backstop and said finger. 22. A machine in accordance with Claim 21, wherein said beam comprising a plurality of grooves defined in a surface thereof; and said second adjust device comprising a gear rack having a gear configured to engage said grooves for moving said beam along a depth of said forming assembly. 23. A machine in accordance with Claim 20 further comprising a center guide rail aligned along a depth of said forming assembly, said beam slidably coupled to said center guide rail for adjusting a depth- wise position of said backstop and said finger. 24. A machine in accordance with Claim 20 further comprising a depth adjustment indicator comprising: a pointer coupled to a frame of said machine; and a ruler coupled to said beam, said pointer and said ruler configured to indicate a depth of said forming assembly. 25. A machine in accordance with Claim 14 further comprising a third adjustment device coupled to said second minor flap folder and configured to move said second minor flap folder with respect to said first minor flap folder for adjusting a space between said first minor flap folder and said second minor flap folder. 26. A machine for forming a container from a blank of sheet material, said machine comprising: a frame; a forming assembly coupled to said frame, said forming assembly comprising: a first forming module; and a second forming module that is movable with respect to said first forming module for adjusting a width of said forming assembly, wherein each said forming module comprises: a top clamp configured to move in a substantially vertical direction to engage the blank; a major flap folder configured to move in a substantially vertical direction; and an entrance plow configured to direct the blank into said forming assembly; and first and second minor flap folders that are extendable inwardly toward the blank along a first substantially straight path, said first minor flap folder positioned near said first forming module and said second minor flap folder positioned near said second forming module. 27. A machine in accordance with Claim 26 further comprising an activation device coupled in communication with said forming assembly and said first and second minor flap folders for activating said machine to form the container. 28. A machine in accordance with Claim 26 further comprising a control system coupled in communication with said forming assembly and said first and second minor flap folders, said control system configured to form a first end wall of the container by: extending the first and second minor flap folders inwardly toward the blank along the first substantially straight path to rotate a first pair of minor end flaps of the blank against said top clamps; and extending said major flap folders upwardly along a second substantially straight path to rotate a first major end flap of the blank into contact with the first pair of minor end flaps. 29. A machine in accordance with Claim 26, wherein said top clamps each comprise a clamp actuator, said major flap folders each comprise a vertical actuator, and said minor flap folders each comprise a horizontal actuator, said machine further comprising an actuation assembly coupled to said clamp actuators, said vertical actuators, and said horizontal actuators for controlling movements thereof. 30. A machine in accordance with Claim 26, wherein each said forming module comprises an adhesive applicator configured to move horizontally toward and away from said entrance plows, said machine further comprising an adhesive unit coupled in flow communication with said adhesive applicators for supplying adhesive to said adhesive applicators. |
FROM A BLANK OF SHEET MATERIAL
BACKGROUND OF THE INVENTION
[0001] The embodiments described herein relate generally to a machine for forming a container and, more particularly, to a machine for forming an end wall of a container from a blank of sheet material.
[0002] At least some known machines are adjustable to form containers of various sizes from blanks of sheet material, such as boxes made of corrugated paper or paperboard. However, at least some of these known adjustable machines include several components that must be individually adjusted for each different sized container being formed. For example, one known machine for forming a container without an integrated lid includes seven fingers that are adjusted based on the width of the container. However, the fingers of this known machine would interfere with forming a container having an integrated lid. Another known machine includes four columns that are each adjusted depending on the dimensions of the container being formed. Yet another known machine includes four corner modules that are each required to be adjusted separately based on the dimensions of the container being formed. Still another known machine includes four stabilizing bars and a mandrel that are each adjusted separately based on the dimensions of the container being formed.
[0003] As such, it is desirable to provide an adjustable container- forming machine that can be adjusted in fewer steps than known machines for forming various sized containers. Further, it is desirable to provide a machine that can form at least a portion of a container having an integrated lid.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one aspect, a method for forming a container from a blank of sheet material using a machine is provided. The machine includes a forming assembly and first and second minor flap folders. The forming assembly includes at least one top clamp and at least one major flap folder. The method includes adjusting a width of the forming assembly using a first adjustment device, adjusting a depth of the forming assembly using a second adjustment device, and inserting a first end of the blank into the forming assembly. The first end includes a first pair of minor end flaps and a first major end flap. The machine is activated to form a first end wall of the container including rotating the first pair of minor end flaps proximate the top clamp by extending the first and second minor flap folders inwardly toward the blank along a first substantially straight path, and rotating the first major end flap into contact with the first pair of minor end flaps by extending the at least one major flap folder upwardly along a second substantially straight path.
[0005] In another aspect, a machine for forming a container from a blank of sheet material is provided. The machine includes a first forming module and a second forming module that is movable with respect to the first forming module for adjusting a width of said forming assembly. Each forming module includes a top clamp configured to move in a substantially vertical direction to engage the blank, a major flap folder configured to move in a substantially vertical direction, and an entrance plow configured to direct the blank into the forming assembly. The machine further includes first and second minor flap folders that are extendable inwardly toward the blank along a substantially straight path. The first minor flap folder is positioned near the first forming module, and the second minor flap folder is positioned near the second forming module.
[0006] In yet another aspect, a machine for forming a container from a blank of sheet material is provided. The machine includes a frame and a forming assembly coupled to the frame. The forming assembly includes a first forming module and a second forming module that is movable with respect to the first forming module for adjusting a width of said forming assembly. Each forming module includes a top clamp configured to move in a substantially vertical direction to engage the blank, a major flap folder configured to move in a substantially vertical direction, and an entrance plow configured to direct the blank into the forming assembly. The machine further includes first and second minor flap folders that are extendable inwardly toward the blank along a substantially straight path. The first minor flap folder is positioned near the first forming module, and the second minor flap folder is positioned near the second forming module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Figures 1-14 show exemplary embodiments of the blank, container, and machine described herein.
[0008] Figure 1 is a top plan view of a blank of sheet material for constructing a container.
[0009] Figure 2 is a perspective view of a container formed from the blank shown in Figure 1.
[0010] Figure 3 is a side view of an exemplary machine for forming a container from a blank.
[0011] Figure 4 is a front view of the machine shown in Figure 3.
[0012] Figure 5 is a perspective view of the machine shown in Figure 3.
[0013] Figure 6 is a perspective view of an exemplary forming assembly that may be used with the machine shown in Figures 3 and 4.
[0014] Figure 7 is a front view of the forming assembly shown in Figure 6.
[0015] Figure 8 is a side view of the forming assembly shown in Figure 6.
[0016] Figure 9 is a perspective view of the forming assembly shown in Figure 6. [0017] Figure 10 is a bottom perspective view of the forming assembly shown in Figure 6.
[0018] Figure 11 is an enlarged bottom perspective view of the forming assembly shown in Figure 6.
[0019] Figure 12 is an enlarged front perspective view of the forming assembly shown in Figure 6.
[0020] Figure 13 is an enlarged top perspective view of the forming assembly shown in Figure 6.
[0021] Figure 14 is a flowchart of a method that may be used with the machine shown in Figures 3-13 for forming the container shown in Figure 2 from the blank shown in Figure 1.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.
[0023] A container formed from a single sheet of material and a method and machine for constructing the container is described herein. The container may be constructed from a blank of sheet material using a machine. In one embodiment, the container is fabricated from a cardboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided. [0024] In an example embodiment, the container includes at least one marking thereon including, without limitation, indicia that communicates the product stored in the container, a manufacturer of the product and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. "Printing," "printed," and/or any other form of "print" as used herein may include, but is not limited to including, ink jet printing, laser printing, screen printing, giclee, pen and ink, painting, offset lithography, flexography, relief print, rotogravure, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings herein provided. In another embodiment, the container is void of markings, such as, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product.
[0025] The machine described herein is relatively simple to adjust to form containers of various dimensions by performing two adjustments based on the dimensions of a container to be formed. More specifically, a first adjustment device is used to adjust the width of a forming assembly of the machine and a second adjustment device is used to adjust the depth of the forming assembly. As such, the two-step process described herein simplifies the component-by-component adjustments required by known adjustable container- forming machines. In one embodiment, a third step is performed when minor end flaps have unequal widths.
[0026] As used herein, the terms "forward," "front," and variations thereof refer to a direction or relative location along a Z-axis of the machine in a positive direction; the terms "rearward," "rear," and variations thereof refer to a direction or relative location along the Z-axis of the machine in a negative direction; the terms "upward," "top," and variations thereof refer to a direction or relative location along a Y-axis of the machine in a positive direction; the terms "downward," "bottom," and variations thereof refer to a direction or relative location along the Y- axis of the machine in a negative direction; the terms "inward," "inner," and variations thereof refer to a direction or relative location along an X-axis of the machine toward a centerline of the machine that is parallel to the Z-axis; and the terms "outward," "outer," and variations thereof refer to a direction or relative location along the X-axis of the machine away from the centerline of the machine that is parallel to the Z-axis.
[0027] Referring now to the drawings, Figure 1 , which is a top plan view of an example embodiment of a blank 10 of sheet material. A container 150 (shown in Figure 2) is formed from blank 10. Blank 10 has a first or interior surface 12 and an opposing second or exterior surface 14. Further, blank 10 defines a leading edge 16 and an opposing trailing edge 18. In one embodiment, blank 10 includes, in series from leading edge 16 to trailing edge 18, a front panel 20, a bottom panel 22, a rear panel 24, a top panel 26, an outer front flap 28, and an inner front flap 30 coupled together along preformed, generally parallel, fold lines 32, 34, 36, 38, and 40, respectively. Front panel 20 and rear panel 24 are also considered to be side panels. The container formed from blank 10 may be referred to as lidded shoe box, although it will be understood the container can be used to contain any suitable product(s).
[0028] More specifically, front panel 20 extends from leading edge 16 to fold line 32, bottom panel 22 extends from front panel 20 along fold line 32, rear panel 24 extends from bottom panel 22 along fold line 34, top panel 26 extends from rear panel 24 along fold line 36, outer front flap 28 extends from top panel 26 along fold line 38, and inner front flap 30 extends from fold line 40 to trailing edge 18. Fold lines 32, 34, 36, 38, and/or 40, as well as other fold lines and/or hinge lines described herein, may include any suitable line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided. When container 150 is formed from blank 10, fold line 32 defines a bottom edge of front panel 20 and a front edge, or first side edge, of bottom panel 22; fold line 34 defines a rear edge, or second side edge, of bottom panel 22 and a bottom edge of rear panel 24; fold line 36 defines a top edge of rear panel 24 and a rear edge of top panel 26; fold line 38 defines a front edge of top panel 26 and a top edge of outer front flap 28; and fold line 40 defines a bottom edge of outer front flap 28 and a bottom edge of inner front flap 30. As used through this description, front edges and rear edges are also considered to be side edges.
[0029] In the exemplary embodiment, trailing edge 18 includes two pairs 42 of notches 44 defined therein. More specifically, each pair 42 of notches 44 defines a locking tab 46 therebetween. A free edge 48 of each locking tab 46 extends slightly beyond trailing edge 18 to facilitate securing front flaps 28 and 30 in position, as described in more detail below. Although two pairs 42 of notches 44 defining two locking tabs 46 are included in the exemplary embodiment, blank 10 may include any suitable number of notches 44 and/or locking tabs 46 that enable blank 10 to function as described herein.
[0030] A first minor end flap 50 extends from a first end edge of front panel 20 at a fold line 52, and a second minor end flap 54 extends from a second end edge of front panel 20 at a fold line 56. A first major end flap 58 extends from a first end edge of bottom panel 22 at a fold line 60, and a second major end flap 62 extends from a second end edge of bottom panel 22 at a fold line 64. Further, a third minor end flap 66 extends from a first end edge of rear panel 24 at a fold line 68, and a fourth minor end flap 70 extends from a second end edge of rear panel 24 at a fold line 72. First minor end flap 50 has a width W 1 , second minor end flap 54 has a width W 2 , third minor end flap 66 has a width W 3 , fourth minor end flap 70 has a width W 4 , first major end flap 58 has a width W 5 , and second major end flap 62 has a width W 6 .
[0031] In the exemplary embodiment, width W 5 is approximately equal to width W 6 . Further, widths Wi and W 3 are approximately equal to width W 5 such that free edges 74 and 76 of minor end flaps 50 and 66 are in contact when container 150 is formed, and widths W 2 and W 4 are approximately equal to width W 6 such that free edges 78 and 80 of minor end flaps 54 and 70 are in contact when container 150 is formed. Alternatively, minor end flaps 50 and 66 and/or minor end flaps 54 and 70 overlap and/or are not in contact when container 150 is formed. In the exemplary embodiment, width Wi is longer than width W 3 , and widths W 2 and W 4 are substantially equal. It should be understood that widths Wi and W 3 may be substantially equal and/or widths W 2 and W 4 may be other than substantially equal.
[0032] Each of first minor end flap 50, second minor end flap 54, third minor end flap 66, fourth minor end flap 70, first major end flap 58, and second major end flap 62 has a height H 1 . In the exemplary embodiment, minor end flaps 50, 54, 66, and 70 have a height slightly shorter than height Hi to account for clearances, however, the height of minor end flaps 50, 54, 66, and 70 is approximately height H 1 . Alternatively, first minor end flap 50, second minor end flap 54, third minor end flap 66, fourth minor end flap 70, first major end flap 58, and/or second major end flap 62 has a height other than height H 1 . In the exemplary embodiment, front panel 20 and rear panel 24 each have height H 1 , however, front panel 20 and/or rear panel 24 may have a height other than height H 1 .
[0033] In the exemplary embodiment, second major end flap 62 has a cutout 82 defined therethrough, and fourth minor end flap 70 has a cutout 84 defined therethrough. Cutout 82 and cutout 84 are substantially congruent and configured to define and aperture 160 through container 150 when formed, as described in more detail below. Alternatively, any or none of minor end flaps 50, 54, 66, and/or 70 and/or major end flaps 58 and/or 62 include cutout 82 and/or 84.
[0034] A first top end flap 86 extends from a first side edge of top panel 26 at a fold line 88, and a second top end flap 90 extends from a second side edge of top panel 26 at a fold line 92. A first front tab 94 extends from a front edge of first top end flap 86 at a fold line 96, and a second front tab 98 extends from a front edge of second top end flap 90 at a fold line 100. Front tabs 94 and 98 are adjacent to front flaps 28 and 30 and are separated from front flaps 28 and 30 by a cut line 102 or 104, respectively. Cut lines 102 and 104 define bottom edges of respective front tabs 94 and 98 and end edges of front flaps 28 and 30. A first locking flap 106 extends from first front tab 94 along a bottom edge 108 thereof at a pair of fold lines 110 and 112 into inner front flap 30, and a second locking flap 114 extends from second front tab 98 along a bottom edge 116 thereof at a pair of fold lines 118 and 120 into inner front flap 30. As such, end edges of inner front flap 30 are notched when container 150 is formed from blank 10. In the exemplary embodiment, a slot 122 is defined between each locking flap 106 and 114 and an adjacent front tab 94 and 98 between fold lines 110 and 112, and 118 and 120. Each slot 122 is sized to receive a respective locking tab 46.
[0035] Figure 2 is a perspective view of a container 150 formed from blank 10 (shown in Figure 1). Referring to Figures 1 and 2, to construct container 150 from blank 10, front panel 20 is rotated about fold line 32 toward bottom panel 22 to be substantially perpendicular to bottom panel 22 to form a front wall 152, also referred to herein as a first side wall. Rear panel 24 is rotated about fold line 34 toward bottom panel 22 to be substantially perpendicular to bottom panel 22 to form a rear wall 154, also referred to herein as a second side wall.
[0036] First minor end flap 50 is rotated about fold line 52 to be substantially perpendicular to front panel 20 and substantially aligned along fold line 60. Third minor end flap 66 is rotated about fold line 68 to be substantially perpendicular to rear panel 24 and substantially aligned along fold line 60. Adhesive is applied to exterior surface 14 of first minor end flap 50, exterior surface 14 of third minor end flap 66, and/or interior surface 12 of first major end flap 58. In a preferred embodiment, adhesive is applied to interior surface 12 of first major end flap 58. First major end flap 58 is then rotated about fold line 60 toward minor end flaps 50 and 66 to be substantially perpendicular to bottom panel 22. Interior surface 12 of first major end flap 58 is secured to exterior surface 14 of first minor end flap 50 and third minor end flap 66 to form a first end wall 156.
[0037] Similarly, second minor end flap 54 is rotated about fold line 56 to be substantially perpendicular to front panel 20 and substantially aligned along fold line 64. Fourth minor end flap 70 is rotated about fold line 72 to be substantially perpendicular to rear panel 24 and substantially aligned along fold line 64. Adhesive is applied to exterior surface 14 of second minor end flap 54, exterior surface 14 of fourth minor end flap 70, and/or interior surface 12 of second major end flap 62. In a preferred embodiment, adhesive is applied to interior surface 12 of second major end flap 62. Second major end flap 62 is rotated about fold line 64 toward minor end flaps 54 and 70 to be substantially perpendicular to bottom panel 22. Interior surface 12 of second major end flap 62 is secured to exterior surface 14 of second minor end flap 54 and fourth minor end flap 70 to form a second end wall 158. Overlapping cutouts 82 and 84 define aperture 160 through second end wall 158. Aperture 160 is configured to facilitate removing container 150 from a shelf and/or a stack of containers 150 by allowing a person to insert a finger into aperture 160 to remove container 150.
[0038] Bottom panel 22 forms a bottom wall 162 of container 150. First side wall 152, second side wall 154, first end wall 156, second end wall 158, and bottom wall 162 form a tray portion 164 and define a cavity 166 of container 150.
[0039] To form a lid portion 168 of container 150, first top end flap 86 is rotated about fold line 88 toward top panel 26 to be substantially perpendicular to top panel 26. Similarly, second top end flap 90 is rotated about fold line 92 toward top panel 26 to be substantially perpendicular to top panel 26. First front tab 94 is rotated about fold line 96 to be substantially perpendicular to first top end flap 86, and first locking flap 106 is rotated about fold lines 110 and 112 to be substantially perpendicular to first front tab 94. As such, exterior surface 14 of first locking flap 106 is adjacent interior surface 12 of top panel 26. Similarly, second front tab 98 is rotated about fold line 100 to be substantially perpendicular to second top end flap 90, and second locking flap 114 is rotated about fold lines 118 and 120 to be substantially perpendicular to second front tab 98. Exterior surface 14 of second locking flap 114 is adjacent interior surface 12 of top panel 26.
[0040] Outer front flap 28 is rotated about fold line 38 toward top panel 26 to be substantially perpendicular to top panel 26. In such a position, interior surface 12 of outer front flap 28 is adjacent to exterior surface 14 of front tabs 94 and 98. Inner front flap 30 is rotated about fold line 40 toward outer front flap 28 to be substantially parallel to outer front flap 28. When positioned, interior surface 12 of inner front flap 30 is adjacent interior surface 12 of front tabs 94 and 98. As such, front tabs 94 and 98 are positioned between outer front flap 28 and inner front flap 30 and are substantially parallel to outer front flap 28 and inner front flap 30. Locking tabs 46 are inserted into slots 122 to secure inner front flap 30 in position with respect to front tabs 94 and 98 and outer front flap 28. Accordingly, lid portion 168 is assembled without the use of adhesive, although adhesive may be used in addition to locking tabs 46 and slots 122.
[0041] Front tabs 94 and 98, outer front flap 28, and inner front flap 30 form a front closure wall 170 of lid portion 168, also referred to herein as a side closure wall. First top end flap 86 forms a first end closure wall 172 of lid portion 168, and second top end flap 90 forms a second end closure wall 174 of lid portion 168. When lid portion 168 is in such a position as described above, container 150 is in the open configuration.
[0042] To close container 150, top panel 26 is rotated about fold line 36 toward bottom panel 22 to rotate lid portion 168 toward tray portion 164. As top panel 26 is moved toward tray portion 164, first end closure wall 172 overlaps first end wall 156, side closure wall 170 overlaps first side wall 152, and a second end closure wall 174 overlaps second end wall 158. When top panel 26 is substantially parallel to bottom panel 22, container 150 is in the closed configuration and top panel 26 forms a top wall 176 of container 150.
[0043] The above-described method for forming container 150 from blank 10 can be performed manually and/or automatically. In the exemplary embodiment, at least end walls 156 and 158 are formed automatically using a machine.
[0044] Figure 3 is a side view of an exemplary machine 200 for forming container 150 (shown in Figure 2) from blank 10 (shown in Figure 1). Figure 4 is a front view of machine 200. Figure 5 is a perspective view of machine 200. [0045] In the exemplary embodiment, machine 200 includes a frame 202 that supports a forming assembly 204, a control system 206, an actuation assembly 208, and an adhesive unit 210. Actuation assembly 208 includes, for example, pneumatic system controls and/or hydraulic fluid system controls, and is operatively coupled to the actuators described herein. Control system 206 is coupled in communication with, such as operational control communication with, forming assembly 204, actuation assembly 208, and adhesive unit 210. As used herein, "operational control communication" refers to a link, such as a conductor, a wire, and/or a data link, between two or more components of machine 200 that enables signals, electric currents, and/or commands to be communicated between the two or more components. The link is configured to enable one component to control an operation of another component of machine 200 using the communicated signals, electric currents, and/or commands. Forming assembly 204 is configured to be adjustable such that machine 200 can form containers having different dimensions, as described in more detail with respect to Figures 6-13.
[0046] In the exemplary embodiment, control system 206 is shown as being centralized within machine 200, however control system 206 may be a distributed system throughout machine 200, within a structure housing machine 200, and/or at a remote control center. Control system 206 includes a processor (not shown) configured to perform the methods and/or steps described herein. Further, many of the other components described herein include a processor. As used herein, the term "processor" is not limited to integrated circuits referred to in the art as a computer, but broadly refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. It should be understood that a processor and/or control system can also include memory, input channels, and/or output channels.
[0047] In the embodiments described herein, memory may include, without limitation, a computer-readable medium, such as a random access memory (RAM), and a computer-readable non-volatile medium, such as flash memory. Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, input channels may include, without limitation, sensors and/or computer peripherals associated with an operator interface, such as a mouse and a keyboard. Further, in the exemplary embodiment, output channels may include, without limitation, a control device, an operator interface monitor and/or a display.
[0048] Processors described herein process information transmitted from a plurality of electrical and electronic devices that may include, without limitation, sensors, actuators, compressors, control systems, and/or monitoring devices. Such processors may be physically located in, for example, a control system, a sensor, a monitoring device, a desktop computer, a laptop computer, a PLC cabinet, and/or a distributed control system (DCS) cabinet. RAM and storage devices store and transfer information and instructions to be executed by the processor(s). RAM and storage devices can also be used to store and provide temporary variables, static (i.e., non-changing) information and instructions, or other intermediate information to the processors during execution of instructions by the processor(s). Instructions that are executed may include, without limitation, machine control commands. The execution of sequences of instructions is not limited to any specific combination of hardware circuitry and software instructions.
[0049] Frame 202 includes an upper portion 212 coupled to a lower portion 214. More specifically, upper portion 212 has a width W F1 , a height Hpi, and a depth Dpi, and lower portion 214 has a width W F2 , a height Hp 2 , and a depth Dp 2 . In the exemplary embodiment, depth Dp 2 is larger than depth Dpi by a depth Dp 3 , and widths Wpi and Wp 2 are approximately equal. Alternatively, frame 202 has any suitable dimensions that enable machine 200 to function as described herein. In the exemplary embodiment, a back 216 of upper portion 212 is substantially flush with a back 218 of lower portion 214, but a front 220 of upper portion 212 is offset from a front 222 of lower portion 214 by depth D F3 such that a portion 224 of a top 226 of lower portion 214 is exposed at a front 228 of machine 200. Further, in the exemplary embodiment, a table surface 230 is coupled to top 226 of lower portion 214 and extends between front 222 of lower portion 214 and front 220 of upper portion 212. Alternatively, machine 200 does not include table surface 230.
[0050] Machine 200 may optionally include transparent, semi- transparent, semi-opaque, and/or opaque guard panels 232 coupled to frame 202 to facilitate preventing objects from contacting components of machine 200 during operation. In a particular embodiment, transparent guard panels 232, such as guard panels formed from LEXAN® sheet material (Lexan is a registered trademark of SABIC Innovative Plastics IP B. V. Company of Bergen op Zoom, The Netherlands), are coupled to upper portion 212 of frame 202, and opaque guard panels 232, such as metal guard panels, are coupled to lower portion 214 of frame 202. When guard panels 232 are coupled to front 220 of upper portion 212, an opening is defined through the guard panel to allow access to forming assembly 204. When a guard panel is coupled to a top 234 of upper portion 212, the guard panel forms a top surface of machine 200 upon which a stack of blanks 10 (shown in Figure 1) can be positioned.
[0051] Machine 200 further includes an activation device 236 coupled in communication with control system 206. In the exemplary embodiment, activation device 236 is a foot pedal that can be depressed by an operator 238 of machine 200 to activate machine 200. Activation device 236 is movable with respect to frame 202 such that operator 238 can select a position of activation device 236. In a particular embodiment, activation device 236 includes a guard and/or a cover to facilitate preventing accidental activation of machine 200. Further, in the exemplary embodiment, machine 200 includes a status indicator 240 coupled to frame 202 at any suitable location, such as at back 216 of upper portion 212. Status indicator 240 is coupled in communication with control system 206 to indicate a status of machine 200, such as power on, power off, glue level, glue temperature, and/or a fault. In a particular embodiment, status indicator 240 indicates status by using lights. Alternatively, status indicator 240 indicates the machine status using any suitable display. In an alternative embodiment, machine 200 does not include status indicator 240.
[0052] Referring to Figures 1-5, to operate machine 200, operator 238 adjusts forming assembly 204 based on dimensions of blank 10, as described in more detail below. Operator 238 rotates first side panel 20 and second side panel 24 of blank 10 to be substantially perpendicular to bottom panel 22. Such a configuration of blank 10 is referred to herein as a J-configuration. Operator 238 positions at least first major end flap 58 within forming assembly 204 at a predetermined location. Alternatively, second major end flap 62 is initially positioned within forming assembly 204. Activation device 236 is then depressed, or otherwise activated, to initiate formation of container 150 (shown in Figure 2) by machine 200. In the exemplary embodiment, operator 238 taps activation device 236 with his/her foot to activate machine 200.
[0053] Forming assembly 204 forms first end wall 156 (shown in Figure 2) of container 150, as described in more detail below. Operator 238 removes the partially formed container (not shown) from forming assembly 204 inserts at least second major end flap 62 into forming assembly 204 at the predetermined location. By using activation device 236, operator 238 activates machine 200. Forming assembly 204 then forms second end wall 158 (shown in Figure 2) of container 150 such that tray portion 164 of container 150 is formed. A product is positioned within tray portion 164 and/or lid portion 168 is formed manually and/or by using another machine.
[0054] Figure 6 is a perspective view of an exemplary forming assembly 204 that may be used with machine 200 (shown in Figures 3-5). Figure 7 is a front view of forming assembly 204. Figure 8 is a side view of forming assembly 204. Figure 9 is a perspective view of forming assembly 204. Figure 10 is a bottom perspective view of forming assembly 204. Figure 11 is an enlarged bottom perspective view of forming assembly 204. Figure 12 is an enlarged front perspective view of forming assembly 204. Figure 13 is an enlarged top perspective view of forming assembly 204.
[0055] Machine 200 includes a front guide rail 242, a rear guide rail 244, a center guide rail 246, a side support rail 248, a first minor flap folder 258, and a second minor flap folder 260. Forming assembly 204 includes a first adjustment device 250, a second adjustment device 252, a first forming module 254, a second forming module 256, and a beam assembly 257.
[0056] Guide rails 242 and 244 extend along the width of machine 200 and include brackets 262 at each end 264 thereof to couple guide rails 242 and 244 to frame 202. More specifically, guide rails 242 and 244 are coupled to an upper rail 266 (shown in Figures 3-5) of lower portion 214 (shown in Figures 3-5), which is also a lower rail of upper portion 212, using brackets 262. Side support rail 248 is coupled to guide rails 242 and 244 and is substantially perpendicular to guide rails 242 and 244; however, side support rail 248 may be at any suitable orientation to guide rails 242 and/or 244. In the exemplary embodiment, side support rail 248 is coupled to an upper surface 268 of guide rails 242 and 244 adjacent brackets 262. Center guide rail 246 is coupled to guide rails 242 and 244 at approximately a center of guide rails 242 and 244 between sides 270 and 272 (shown in Figures 3-5) of frame 202. Center guide rail 246 is substantially perpendicular to guide rails 242 and 244. In the exemplary embodiment, center guide rail 246 is coupled to a bottom surface 274 of guide rails 242 and 244.
[0057] First forming module 254 includes a pair of sliding supports 276 and 278 that are coupled to front guide rail 242 and rear guide rail 244, respectively, such that first forming module 254 is moveable in a direction 280 substantially parallel to guide rails 242 and 244. Similarly, second forming module 256 includes a pair of sliding supports 282 and 284 that are coupled to front guide rail 242 and rear guide rail 244, respectively, such that second forming module 256 is moveable in direction 280 substantially parallel to guide rails 242 and 244. In the exemplary embodiment, first forming module 254 and second forming module 256 are moveable toward and away from each other along guide rails 242 and 244 using first adjustment device 250, as described in more detail below.
[0058] Beam assembly 257 includes a beam 286 having a plurality of grooves 288 defined in an upper surface 290 thereof is coupled to center guide rail 246 via a sliding support 292. Grooves 288 are substantially parallel to guide rails 242 and 244 and are configured to engage a gear 294 of second adjustment device 252, as described in more detail below. In the exemplary embodiment, at a front end 296 of beam 286, a backstop 298 and a cylinder 300 having a finger 302 are coupled to beam 286 for movement therewith. Further, in the exemplary embodiment, first minor flap folder 258 is coupled to side support rail 248 at a front end 304 thereof. As such, first minor flap folder 258 is at a fixed position with respect to guide rails 242 and 244 and frame 202. Second minor flap folder 260 is coupled to frame 202 and/or table surface 230 at a location that enables forming modules 254 and/or 256 to be adjusted as described herein. In the exemplary embodiment, second minor flap folder 260 is coupled to frame 202 and/or table surface 230 via a third adjustment device 306; however, second minor flap folder 260 may be fixedly coupled to frame 202 and/or table surface 230.
[0059] When coupled within frame 202, forming assembly 204 is positioned within upper portion 212 and lower portion 214. Minor flap folders 258 and 260 and first adjustment device 250 are located at front 220 of upper portion 212 adjacent table surface 230. When third adjustment device 306 is included in forming assembly 204, third adjustment device 306 is located at front 220 of upper portion 212. Forming modules 254 and 256 are generally centrally located within frame 202 and are movable along the width of frame 202. Beam assembly 257, including backstop 298, cylinder 300, and finger 302, is generally centrally located within frame 202 between first forming module 254 and second forming module 256 and is movable along the depth of frame 202. Second adjustment device 252 is located adjacent a back 308 (shown in Figures 3 and 5) of frame 202, which is also a back of machine 200. [0060] First forming module 254 is generally a mirror image of second forming module 256 and, as such, first forming module 254 is described herein, but it should be understood that the description also applies to second forming module 256 unless otherwise indicated. Forming module 254 includes an entrance plow 310, a vertical upright 312 having a top clamp 314 coupled thereto, a major flap folder 316, and an adhesive applicator 318 coupled to a support assembly 320. Sliding supports 276 and 278 are coupled to a bottom surface 322 of support assembly 320 for moving forming module 254 along guide rails 242 and 244. When a width- wise position of forming module 254 is adjusted, width-wise positions of entrance plow 310, vertical upright 312, top clamp 314, major flap folder 316, and adhesive applicator 318 are adjusted. In an alternative embodiment, one forming module 254 or 256 includes major flap folder 316.
[0061] In the exemplary embodiment, entrance plow 310 is coupled to support assembly 320 and extends forward from support assembly 320. In the exemplary embodiment, entrance plow 310 extends forward along table surface 230. Entrance plow 310 is configured to support side panel 20 and/or 24 (shown in Figures 1 and 2) to maintain the J-shape configuration of blank 10 (shown in Figures 1 and 3) during forming of end wall 156 and/or 158 (shown in Figure 2). More specifically, entrance plow 310 is generally L-shaped and has a width portion 324 and a depth portion 326. Width portion 324 extends substantially parallel to the width of machine 200, and depth portion 326 extends substantially parallel to the depth of machine 200. Width portion 324 is coupled to support assembly 320, and depth portion 326 extends substantially perpendicularly to width portion 324. An angled portion 328 extends from depth portion 326 and is configured to facilitate positioning J-shaped blank 10 between forming modules 254 and 256.
[0062] Vertical upright 312 is coupled to support assembly 320 and is aligned substantially parallel to the height of machine 200. Vertical upright 312 has any suitable height that enables machine 200 to form containers of various heights and/or other dimensions. In the exemplary embodiment, at a top end 330 of vertical upright 312, an upper guide plate 332 is coupled to vertical upright 312. Upper guide plate 332 is configured to guide at least top panel 26 (shown in Figure 1) into forming assembly 204 and/or support at least top panel 26 within forming assembly 204 when top panel 26 is adjacent vertical upright 312. More specifically, an outer surface 334 of upper guide plate 332 is configured to guide and/or support at least top panel 26. A clamp actuator 336 is coupled to an inner surface 338 of upper guide plate 332. Clamp actuator 336 is configured to move top clamp 314 relative to vertical upright 312. In the exemplary embodiment, clamp actuator 336 is controlled by control system 206 (shown in Figures 4 and 5) and/or actuation assembly 208 (shown in Figures 3 and 4) to move upwards and downwards relative to frame 202. In one embodiment, actuation assembly 208 provides a fluid, such as air, to clamp actuator 336 to move top clamp 314 relative to frame 202.
[0063] Top clamp 314 is coupled to a bottom 340 of clamp actuator 336 and is configured to secure bottom panel 22 (shown in Figure 1) within forming assembly 204 and/or machine 200 during formation of end wall 156 and/or 158. Top clamp 314 includes an arm 342 and a presser block 344 coupled to a front surface 346 of arm 342 at a bottom end 348 of arm 342. A top end 350 of arm 342 is coupled to clamp actuator 336. A rear surface 352 of arm 342 is configured to contact interior surface 12 of minor end flap 50, 54, 66, and/or 70 (shown in Figure 1) when end wall 156 or 158 is being formed by forming assembly 204. In the exemplary embodiment, arm 342 is sized to form containers, such as container 150 (shown in Figure 2), having various dimensions. Presser block 344 is configured to contact interior surface 12 of bottom panel 22 adjacent fold line 60 or 64 (shown in Figure 1) when blank 10 is positioned within forming assembly 204. In the exemplary embodiment, presser block 344 is sized to form containers, such as container 150, having various dimensions. Further, when clamp actuator 336 is in a first or top position, a bottom surface 354 of presser block 344 is positioned above table surface 230 and/or entrance plow 310. When clamp actuator 336 is in a second or bottom position, bottom surface 354 of presser block 344 is adjacent to, or in contact with, table surface 230 and is adjacent to depth portion 326 of entrance plow 310. [0064] Forming module 254 further includes major flap folder 316 coupled to support assembly 320. Major flap folder 316 includes a support 356 that extends downward from support assembly 320 into lower portion 214 of frame 202. At a bottom end 358 of support 356, a vertical actuator 360 is coupled thereto. A major folding plow 362 is coupled to a top end 364 of vertical actuator 360 adjacent to support 356. Vertical actuator 360 is configured to move major folding plow 362 upwards and downwards with respect to support assembly 320 and/or frame 202 along a substantially straight line. In the exemplary embodiment, vertical actuator 360 is controlled by control system 206 (shown in Figures 4 and 5) and/or actuation assembly 208 (shown in Figures 3 and 4) to move upwards and downwards relative to frame 202. In one embodiment, actuation assembly 208 provides a fluid, such as air, to vertical actuator 360 to move major folding plow 362 relative to frame 202.
[0065] Major folding plow 362 includes a vertical face 366, an angled face 368, and a horizontal face 370. Vertical face 366, angled face 368, and horizontal face 370 are formed integrally as one-piece, however, it should be understood that major folding plow 362 can be fabricated using any suitable techniques and/or methods. In the exemplary embodiment, major folding plow 362 is positioned rearward of top clamp 314 and forward of front guide rail 242. Further, when vertical actuator 360 is at a first or bottom position, horizontal face 370 is positioned at or below table surface 230 and/or entrance plows 310. When vertical actuator 360 is at a second or top position, horizontal face 370 is within upper portion 212 of frame 202 and vertical face 366 is adjacent rear surface 352 of arm 342.
[0066] Adhesive applicator 318 is movably coupled to support assembly 320 along an inner surface 372 thereof and is in flow communication with adhesive unit 210. More specifically, an applicator actuator 374 is coupled to a top 376 of support assembly 320 adjacent inner surface 372. Applicator actuator 374 is configured to move adhesive applicator 318 forward and rearward with respect to support assembly 320. Specifically, when applicator actuator 374 is in a first or front position, adhesive applicator 318 is positioned adjacent to and rearward from major folding plow 362 and forward of vertical upright 312. When applicator actuator 374 is in a second or rear position, adhesive applicator 318 is positioned rearward from vertical upright 312.
[0067] In the exemplary embodiment, adhesive applicator 318 is coupled at a front end 378 of applicator actuator 374 and extends downward therefrom. A nozzle 380 is located at a bottom 382 of adhesive applicator 318. Nozzle 380 is positioned to apply adhesive to interior surface 12 of major end flap 58 and/or 62 when inserted into forming assembly 204. A lower guide plate 384 is coupled to an outer surface 386 of adhesive applicator 318 and is configured to prevent at least top panel 26 from contacting adhesive applicator 318 and/or nozzle 380 when blank 10 is inserted into forming assembly 204. More specifically, lower guide plate 384 is configured to direct at least top panel 26 between an outer surface 388 of lower guide plate 384 and an inner surface 390 of vertical upright 312.
[0068] Control system 206 is coupled in communication with adhesive applicator 318 and applicator actuator 374 for applying a predetermined glue pattern to major end flap 58 and/or 62. In the exemplary embodiment, operator 238 inputs a selected glue pattern into control system 206 for controlling adhesive applicator 318 and applicator actuator 374. Further, applicator actuator 374 is controlled by control system 206 (shown in Figures 4 and 5) and/or actuation assembly 208 (shown in Figures 3 and 4) to move forward and rearward relative to frame 202. In one embodiment, actuation assembly 208 provides a fluid, such as air, to applicator actuator 374 to move adhesive applicator 318 relative to frame 202.
[0069] First adjustment device 250 is coupled to first forming module 254 and second forming module 256 for moving first forming module 254 and second forming module 256 relative to each other and frame 202. First adjustment device 250 includes a threaded rod 392 and a handle 394 coupled to a first end 396 of threaded rod 392. In one embodiment, handle 394 is a ratchet. In the exemplary embodiment, a second end 398 of threaded rod 392 is positioned within a support block 400 that is coupled to front guide rail 242 and/or frame 202. Threaded rod 392 extends through a first module support 402, a second module support 404, and a center support 406 coupled to a front end 408 of center guide rail 246. Threaded rod 392 is sized such that handle 394 is positioned outside of frame 202. In the exemplary embodiment, when operator 238 rotates handle 394 in a first direction, threaded rod 392 rotates to move forming modules 254 and 256 outwardly toward frame 202 to widen forming assembly 204. When operator 238 rotates handle 394 in a second direction, threaded rod 392 rotates to move forming modules 254 and 256 inwardly toward each other to narrow forming assembly 204. In one embodiment, first adjustment device 250 includes a lock 410 for securing first adjustment device 250 at a desired width setting.
[0070] In the exemplary embodiment, vertical upright 312 of first forming module 254 includes a width adjustment indicator 412 coupled thereto. Width adjustment indicator 412 includes a pointer 414 and a ruler 416. Ruler 416 includes any suitable indicator of width, such as English units, metric units, and/or custom units based on dimensions of the containers formed using machine 200. Pointer 414 is coupled to front guide rail 242 and is stationary with respect to frame 202, and ruler 416 is coupled to vertical upright 312 to move with first forming module 254 as first forming module 254 is moved along front guide rail 242. As such, width adjustment indicator 412 facilitates adjusting a width of forming assembly 204 by operator 238 using first adjustment device 250.
[0071] Forming assembly 204 further includes beam assembly 257 that includes beam 286 having backstop 298 coupled to front end 296 thereof. Backstop 298 is vertically oriented plate configured to contact a free edge 124 (shown in Figure 1) of major end flap 58 or 62 when blank 10 is inserted into forming assembly 204. Upper surface 290 of beam 286 includes grooves 288 defined therein, and a lower surface 418 of beam 286 is coupled to sliding support 292. Adjacent to and rearward from backstop 298, finger 302 is coupled to beam 286 via cylinder 300. Cylinder 300 is configured to rotate finger 302 from a first or bottom position to a second or top position. Finger 302 is generally positioned along a centerline of beam 286 and is configured to contact interior surface 12 of major end flap 58 and/or 62. In the exemplary embodiment, when in the bottom position, finger 302 extends over a top 420 of backstop 298 to contact major end flap 58 and/or 62. For example, finger 302 is contoured to arch over backstop 298 and have a substantially horizontal contact surface 422 at a front end 424 thereof. In a particular embodiment, beam assembly 257 includes at least one sensor (not shown) that detects the presence of blank 10 against backstop 298. Alternatively, at least one sensor is coupled to forming assembly 204 and/or frame 202 for detecting the presence of blank 10 within machine 200.
[0072] In the exemplary embodiment, at a rear end 426 of beam 286 a gear rack 428 is coupled to rear guide rail 244 and/or center guide rail 246. Gear rack 428 includes gear 294 having teeth 430 configured to engage grooves 288 on beam 286. Second adjustment device 252 is coupled to gear 294 for adjusting a depth- wise position of backstop 298 and finger 302. In the exemplary embodiment, a depth adjustment indicator 432 is coupled at rear end 426 of beam 286. Depth adjustment indicator 432 includes a pointer 434 that is coupled to frame 202 and a ruler 436 that is coupled to beam 286. As such, ruler 436 moves with beam 286 as beam 286 is moved along center guide rail 246. Ruler 436 includes any suitable indicator of width, such as English units, metric units, and/or custom units based on dimensions of the containers formed using machine 200. Depth adjustment indicator 432 facilitates adjusting a depth of backstop 298 and finger 302 by operator 238 using second adjustment device 252.
[0073] Second adjustment device 252 includes a rod 438 and a handle 440 coupled to a first end 442 of rod 438. First end 442 is coupled to frame 202, and handle 440 is positioned outside of frame 202. In one embodiment, handle 440 is a ratchet. In the exemplary embodiment, a second end 444 of rod 438 is coupled to gear rack 428 and, more specifically, to gear 294. When operator 238 rotates handle 440 in a first direction, rod 438 rotates gear 294 to move backstop 298 and finger 302 forward toward major folding plows 362. When operator 238 rotates handle 440 in a second direction, rod 438 rotates gear 294 to move backstop 298 and finger 302 rearward, away from major folding plows 362. In one embodiment, second adjustment device 252 includes a lock 446 for securing second adjustment device 252 at a desired depth setting.
[0074] Machine 200 includes first minor flap folder 258 coupled to side support rail 248 at front end 304 thereof. As such, first minor flap folder 258 is at a fixed position with respect to guide rails 242 and 244 and frame 202. Second minor flap folder 260 is coupled to frame 202 and/or table surface 230 at a location that enables forming modules 254 and/or 256 to be adjusted as described herein. In the exemplary embodiment, second minor flap folder 260 is coupled to frame 202 and/or table surface 230 via third adjustment device 306. Alternatively, second minor flap folder 260 is coupled to frame 202 and/or table surface 230 at a fixed location and machine 200 does not include third adjustment device 306. In the exemplary embodiment, first minor flap folder 258 is substantially a mirror image of second minor flap folder 260 and, as such, first minor flap folder 258 is described herein, but it should be understood that the description also applies to second minor flap folder 260 unless otherwise indicated.
[0075] Minor flap folder 258 includes a horizontal actuator 448 and a minor folding plow 450 coupled to horizontal actuator 448. Horizontal actuator 448 includes at least one rod 452 coupled to minor folding plow 450 for moving minor folding plow 450 inward and outwardly along a substantially straight line. More specifically, minor folding plow 450 is movable along a substantially straight line that is substantially perpendicular to a direction of movement of top clamp 314 and/or major flap folder 316. In the exemplary embodiment, when horizontal actuator 448 is at a first or outward position, minor folding plow 450 is positioned adjacent frame 202 and outwardly of entrance plows 310. When horizontal actuator 448 is at a second or inward position, minor folding plows 450 are located adjacent each other, rear surface 352 of respective arm 342, and/or a rear surface 458 of width portion 324 of entrance plow 310.
[0076] Minor folding plow 450 is generally L-shaped and includes a depth portion 454 and a width portion 456. Depth portion 454 and width portion 456 are formed integrally as one-piece, however, it should be understood that minor folding plow 450 can be fabricated using any suitable techniques and/or methods. In the exemplary embodiment, depth portion 454 is substantially parallel to depth portion 326 of entrance plow 310, and width portion 456 is substantially parallel to width portion 324 of entrance plow 310, rear surface 352 of arm 342, and vertical face 366 of major folding plow 362. An inner end 460 of width portion 456 is configured to contact minor end flap 50, 54, 66, and/or 70 to rotate minor end flap 50, 54, 66, and/or 70 toward a respective side panel 20 or 24, as described in more detail herein.
[0077] In the exemplary embodiment, second minor flap folder 260 is coupled to third adjustment device 306 for adjusting a width-wise position of second minor flap folder 260. Alternatively, second minor flap folder 260 is coupled at a fixed location with respect to forming assembly 204 and/or frame 202. In an alternative embodiment, first minor flap folder 258 and/or second minor flap folder 260 are coupled to an adjustment device for adjusting a width-wise position thereof.
[0078] In the exemplary embodiment, third adjustment device 306 is coupled to a sliding support 462 that is coupled to second minor flap folder 260 for moving second minor flap folder 260 relative to frame 202. Third adjustment device 306 includes a threaded rod 464 and a handle 466 coupled to a first end 468 of threaded rod 464. First end 468 of threaded rod 464 is coupled to frame 202 such that handle 466 is positioned outside of frame 202. In one embodiment, handle 466 is a ratchet. In the exemplary embodiment, a second end 470 of threaded rod 464 is positioned within sliding support 462.
[0079] In the exemplary embodiment, a width adjustment indicator 472 is coupled to second minor flap folder 260 and table surface 230. Width adjustment indicator 472 includes a pointer 474 that is coupled to table surface 230 and a ruler 476 that is coupled to second minor flap folder 260. As such, ruler 476 moves with second minor flap folder 260 as second minor flap folder 260 is moved along threaded rod 464. Ruler 476 includes any suitable indicator of width, such as English units, metric units, and/or custom units based on dimensions of the containers formed using machine 200. Width adjustment indicator 472 facilitates adjusting a width of second minor flap folder 260 by operator 238 using third adjustment device 306.
[0080] In the exemplary embodiment, when operator 238 rotates handle 466 in a first direction, threaded rod 464 rotates to move sliding support 462 outwardly toward frame 202 to widen forming assembly 204. When operator 238 rotates handle 466 in a second direction, threaded rod 464 rotates to move sliding support 462 inwardly toward first minor flap folder 258 to narrow forming assembly 204. In one embodiment, third adjustment device 306 includes a lock 478 for securing third adjustment device 306 at a desired width setting. In the exemplary embodiment, the width-wise position of second minor flap folder 260 is adjusted when minor end flaps have differing widths, such as width Wi of first minor end flap 50 (shown in Figure 1) and width W 3 of third minor end flap 66 (shown in Figure 1).
[0081] Figure 14 is a flowchart of a method 500 that may be used with machine 200 (shown in Figures 3-13) for forming container 150 (shown in Figure 2) from blank 10 (shown in Figure 1). It should be understood that method 500 may be used to form any suitable container having major and minor end flaps, such as container 150, using machine 200. Method 500 is performed by control system 206 (shown in Figures 4 and 5) sending commands and/or instructions to components of machine 200. Control system 206 is programmed with code segments configured to perform method 500. Alternatively, method 500 is encoded on a computer-readable medium that is readable by control system 206. In such an embodiment, control system 206 is configured to read computer-readable medium for performing method 500.
[0082] Referring to Figures 1-14, an initial configuration of machine 200 includes top clamp 314 in the top position, major flap folder 316 in the bottom position, adhesive applicator 318 in the front position, finger 302 in the top position, and minor flap folders 258 and 260 in the outward position. Method 500 is initiated when machine 200 is in the initial configuration. Further, as described herein, first major end flap 58, first minor end flap 50, and third minor end flap 66 are formed into first end wall 156 first, and then second major end flap 62, second minor end flap 54, and fourth minor end flap 70 are formed into second end wall 158; however, it should be understood that first end wall 156 and second end wall 158 may be formed in any order.
[0083] Operator 238 begins by adjusting 502 machine 200 based on the dimensions of blank 10. More specifically, to adjust 502 a width of forming assembly 204, operator 238 uses first adjustment device 250 to adjust the width-wise position of first forming module 254 and second forming module 256. To adjust 502 the depth of forming assembly 204, operator 238 uses second adjustment device 252 to move beam assembly 257 to set the depth-wise positions of backstop 298 and finger 302. As such, only two devices 250 and 252 are usually used to adjust 502 machine 200 to form container 150. When minor end flaps 50, 54, 66, and/or 70 of a first end 126 of blank 10 have differing widths, operator 238 uses third adjustment device 306 to adjust 502 a width- wise position of second minor flap folder 260.
[0084] Operator 238 rotates side panels 20 and 24 relative to bottom panel 22 to form 504 blank 10 into the J-shaped configuration. Operator 238 then inserts 506 first end 126 of blank 10 into forming assembly 204 of machine 200. More specifically, bottom panel 22 is positioned on table surface 230 and slid between entrance plows 310 into forming assembly 204. Exterior surface 14 of side panels 20 and 24 is in contact with inner surfaces 480 of depth portions 326 of entrance plows 310. Interior surface 12 of top panel 26 is positioned against outer surfaces 334 and 388 of upper guide plate 332 and lower guide plate 384, respectively, of first forming module 254 or second forming module 256. In the exemplary embodiment, blank 10 is inserted 506 into forming assembly 204 until free edge 124 of major end flap 58 contacts backstop 298. In a particular embodiment, machine 200 cannot be activated until a sensor detects that blank 10 is positioned against backstop 298. After blank 10 is properly positioned, end wall 156 of container 150 is formed 508 using machine 200. [0085] More specifically, in the exemplary embodiment, to form 508 end wall 156 using machine 200, activation device 236 is used to activate 510 machine 200. Upon activation 510 of machine 200, top clamps 314 are moved 512, such as extended, downwardly by clamp actuators 336 until bottom surfaces 354 of presser blocks 344 are in contact with and/or proximate to interior surface 12 of bottom panel 22. In the exemplary embodiment, top clamps 314 exert a force on bottom panel 22 such that blank 10 is secured in position with respect to machine 200. Adhesive applicator 318 is then moved rearward, or retracted, by applicator actuator 374 to apply 514 adhesive to blank 10 and, more specifically, to major end flap 58. As described herein, control system 206 controls adhesive applicator 318 and/or applicator actuator 374 to apply a predetermined glue pattern.
[0086] Finger 302 is rotated 516 downwardly to the bottom position by cylinder 300 to rotate major end flap 58 downwardly. More specifically, finger 302 holds major end flap 58 at a position that facilitates preventing a bottom edge of minor end flaps 50 and 66 from contacting interior surface 12 of major end flap 58 and adhesive applied thereto. Minor end flaps 50 and 66 are rotated 518 toward side panels 20 and 24, respectively, using minor flap folders 258 and 260. More specifically, minor folding plows 450 are moved inwardly toward each other and/or blank 10, or extended, to inward positions by horizontal actuators 448 such that inner ends 460 of minor folding plows 450 contact exterior surface 14 of minor end flaps 50 and 66 to force minor end flaps 50 and 66 to rotate 518 about fold lines 52 and 68, respectively. When minor end flaps 50 and 66 are rotated 518 by minor folding plows 450, interior surface 12 of minor end flaps 50 and 66 is positioned against rear surfaces 352 of top clamp arms 342, and arm 342 facilitates preventing over-rotation of minor end flaps 50 and 66. Minor folding plows 450 are then moved outwardly away from each other, or retracted, to the outward positions by horizontal actuators 448. Finger 302 is then rotated 520 upwardly to the top position.
[0087] Major flap folders 316 are then moved 522, or extended, to rotate major end flap 58 about fold line 60. More specifically, vertical actuators 360 force major folding plows 362 upward such that horizontal faces 370 contact exterior surface 14 of major end flap 58. As major folding plows 362 continue to move upward, or extend, major end flap 58 rotates about fold line 60, and vertical faces 366 contact exterior surface 14 of major end flap 58. When major folding plows 362 are at top position, interior surface 12 of major end flap 58 is forced into contact with exterior surface 14 of minor end flaps 50 and 66. Further, vertical faces 366 press 524 major end flap 58 and minor end flaps 50 and 66 together against rear surface 352 of top clamp arms 342. When the adhesive sets, or has begun to set, top clamps 314 are moved 526 upward to release blank 10 from machine 200. Control system 206 then re-sets 528 machine 200 to the initial configuration by moving, or retracting, major folding plows 362 downwardly to bottom position and moving, or extending, adhesive applicator 318 forward to the front position.
[0088] After adhesive has secured major end flap 58 to minor end flaps 50 and 66 to form end wall 156, top clamps 314 are moved 526 upward, or retracted, to the top position to release partially formed container 150 from machine 200. Operator 238 removes 530 partially formed container 150 from machine 200. Operator 238 then inserts 532 a second end 128 of blank 10 into forming assembly 204 and/or machine 200. Second end wall 158 is formed 534 using machine 200, as described above. After machine 200 forms 534 second end wall 158, operator 238 removes 536 container 150 from machine 200. More specifically, container 150 removed 536 from machine 200 includes a formed tray portion 164. Lid portion 168 may be formed after tray portion 164 is formed. Alternatively, lid portion 168 is formed before tray portion 164 is formed.
[0089] The above-described embodiments facilitate providing a machine that is adjustable to form containers of various dimensions. More specifically, the machine described herein can be adjusted using two adjustment devices, rather than adjusting each component separately as is required with known adjustable machines. Further, the forming modules described herein enable the two- step adjustment of the machine by allowing an operator to adjust many of the components of the machine with a single adjustment device. [0090] The above-described minor end flap folders are not adjusted to accommodate containers of differing widths because the minor folding plows are moved the same distance regardless of container width. More specifically, the minor folding plows are moved horizontally in a substantially straight line to rotate the minor end flaps, in contrast to rotating to contact the minor end flaps as minor end flap folders do in known machines. Moreover, the guide plates and/or vertical uprights described herein enable the machine to form a container from a blank having a top panel. Additionally, the above-described top clamps secure the blank within the machine such that the operator can remove his/her hands from the blank prior to activating the machine.
[0091] A technical effect of the apparatus and methods described herein includes at least one of: (a) forming a first end wall of a container by extending first and second minor flap folders inwardly toward a blank along a first substantially straight path to rotate a first pair of minor end flaps of the blank proximate top clamps; (b) forming a first end wall of a container by extending at least one major flap folder upwardly along a second substantially straight path to rotate a first major end flap of the blank into contact with the first pair of minor end flaps; (c) applying glue to the first major end flap to form the first end wall; and (d) pressing the first pair of minor end flaps and the first major end flap together to secure the first major end flap to the first pair of minor end flaps.
[0092] Exemplary embodiments of a machine for forming a container from a blank of sheet material are described above in detail. The methods and apparatus are not limited to the specific embodiments described herein, but rather, components of apparatus and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the machine may also be used in combination with other container forming systems and methods, and are not limited to practice with only the containers described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other container forming applications. [0093] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
[0094] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
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