Moran, Robert John (12 The Esplanade, Narrabeen, New South Wales 2101, AU)
Hamblin, Ron Geoffrey (52 Hector Road, Willoughby, New South Wales 2068, AU)
Moran, Robert John (12 The Esplanade, Narrabeen, New South Wales 2101, AU)
Munt, Gregory Richard (Griffith Hack, 509 St. Kilda Road Melbourne, VIC 3004, AU)
| 1. | A method of forming a box from a blank, which method inclues the steps of: (a) forming the blank into a partiallyerected box having a base, upright side walls, upright end walls, gusset corners that are outside the interior of the box, side flaps that extend upwardly from the side walls and/or end flaps that extend upwardly from the end walls ; (b) applying an adhesive material to the partiallyerected box ; (c) outwardly and downwardly folding the side flaps against the side walls or outwardly and downwardly folding the end flaps against the end walls so that: (i) the gusset corners are sandwiche between the folded down side flaps and the side halls or between the folded down end flaps and the end walls ; and (ii) the folded down side flaps are adhered to the side walls or the folded down end flaps are adhered to the end halls. |
| 2. | The method defined in claim 1 wherein the blank inclues a series of panels separated by fold lines and step (a) inclues folding the blank about the fold lines so that the panels form the base, the side walls ; the end walls, the gusset corners, the side flaps and/or the end f laps. |
| 3. | The method defined in claim 2 inclues forming each gusset corner from two adjacent panels. |
| 4. | The method defined in claim 2 or claim 3 wherein step (a) inclues forcing the blank into a forming chamber and thereby causing the blank to fold about the fold lines and form the partiallyerected box with the base, upright side walls, upright end walls, gusset corners that are outside the interior of the box, and side and/or end flaps that extend upwardly from the side and/or end walls. |
| 5. | The method defined in any one of the preceding claims wherein step (c) inclues outwardly folding the side and/or end flaps by contacting the side and/or end flaps with flap folding members that swing outwardly in a flicking motion and contact and fold outwardly the side and/or end flaps. |
| 6. | The method defined in claim 5 further inclues downwardly folding the side and/or end flaps by moving the flap folding members downwardly at the same time as the members move outwardly in the flicking motion, with the downward movement of the flap folding members casing the side and/or end flaps to fold downwardly against the side and/or end walls. |
| 7. | A method of producing a food product which inclues the steps of: (a) forming a box in accordance with the method defined in any one of the preceding claims; (b) placing a food product mix in the box ; and (c) baking the food product in the box in an oven. |
| 8. | An apparats for forming a box from a blank which inclues: (a) a box forming station for forming the blank into a partiallyerected box shaving a base, upright side walls, upright end walls, gusset corners outside the interior of the box, side flaps extending upwardly from the side walls and/or end flaps extending upwardly from the end walls ; (b) an adhesive material application station for applying an adhesive material to the partiallyerected box ; and (c) a flap folding station for outwardly and downwardly folding the side flaps against the side walls or for outwardly and downwardly folding the end flaps against the end walls so that: (i) the gusset corners are sandwiche between the folded down side flaps and the side walls or between the folded down end flaps and the end wallsj and (ii) the folded down side flaps are adhered to the side walls or the folded down end flaps are adhered to the end walls. |
| 9. | The apparats defined in claim 8 inclues a transfer means for moving the blank to the box forming station and then moving the partiallyerected box successively to the adhesive material application and flap folding stations. |
| 10. | The apparats defined in claim 9 further inclues a means for contacting the upwardly extending side flaps or the upwardly extending end flaps and outwardly folding the side or end flaps as the partiallyerected box is moved by the transfer means from the box forming station. |
| 11. | The apparats defined in any one of claims 8 to 10 wherein the flap forming station inclues an assembly for folding each flap. |
| 12. | The apparats defined in claim 9 wherein each assembly inclues an inner downwardly extending member, an outer downwardly extending member, a means which couples together upper sections of the members so that the outer member can swing about the coupling outwardly and inwardly relative to the inner member, and a means: (a) for moving the members downwardly towards and upwardly away from the box at the station; and (b) for moving the outer member outwardly and inwardly relative to the inner member; whereby in use of the assembly, when a partiallyerected box with upwardly extending side or end flaps is at the flapforming station, each assembly: (a) initially moves downwardly to a position at which the outer member is located inwardly of one of the side flaps or the end flaps; (b) the outer member then swings outwardly in a flicking motion and contacts and folds the side flap or the end flap outwardly; (c) simultaneously with step (b) the assembly moves downwardly and the outer member folds the side flap or the end flap downwardly and positions the downwardlyfacing side flap or end flap between the outer and inner members; and (d) as the assembly continues to move downwardly, the outer member swings inwardly and forces the side flap or the end flap against one of the side walls or the end walls. |
| 13. | A method of forming a box from a blank substantially as hereinbefore described with reference to the accompanying drawings. |
| 14. | An apparats for forming a box from a blank substantially as hereinbefore described with reference to the accompanying drawings. |
The present invention relates particularly, although by no means exclusively, to a method and an apparats for forming a box having a base, upright side walls and end walls, gusset corners that are folded against outer surfaces of the side walls or the end walls, and outwardly folded side flaps and end flaps that are adhered to the side walls and end walls and retain the gusset corners in position.
The above-described box is suited particularly for use in the production of baked food products, such as cakes.
In this context, the present invention also relates to a method of producing a food product which inclues the steps of forcing the above-described box, placing a food product mix in the box, and then baking the food product in the box. one known and widely used method of forming a box from a blank is based on applying glue to appropriate panels of the blank and then folding the blank to erect the box and to glue together overlapping panels which hold together the erected box.
This method is not well suited to making boxes that have outwardly folded gusset corners. Gusset corners are important in constructing leak-proof boxes. Outwardly folded gusset corners are important in situations where unhindered access to the interior of a box is required.
One such situation is the manufacture of baked food products.
Another known but less widely used method of forming a box from a blank is based on folding a blank to erect the box and using mechanical interlocks formed in the blank to retain the corners in position and thereby hold together the erected box.
This method is also not well suited to making boxes that have outwardly facing gusset corners. In particular, the method is not well suited to making such boxes at high rates of production.
An object of the present invention is to provide an improved method and apparats for forcing a box with outwardly folded gusset corniers.
According to the present invention there is provided a method of forming a box from a blank, which method inclues the steps of: (a) forming the blank into a partially-erected box having a base, upright side walls, upright end walls, gusset corners that are outside the interior of the box, side flaps that extend upwardly from the side walls and/or end flaps that extend upwardly from the end walls ; (b) applying an adhesive material to the partially-erected box ; (c) outwardly and downwardly folding the side flaps against the side walls or outwardly and downwardly folding the end flaps against the end walls so that: (i) the gusset corners are sandwiche between the folded down side flaps and
the side walls or between the folded down end flaps and the end walls; and (ii) the folded down side flaps are adhered to the side walls or the folded down end flaps are adhered to the end walls.
Preferably the blank inclues a series of panels separated by fold lines and step (a) inclues folding the blank about the fold lines so that the panels form the base, the side walls, the end walls, the gusset corniers, the side flaps and/or the end flaps.
Each gusset corner may be formed from any suitable number of adjacent panels.
Preferably each gusset corner is formed from two adjacent panels.
Step (a) may be carried out with any suitable means.
Preferably step (a) inclues forcing the blank into a forming chamber and thereby casing the blank to fold about the fold lines.
The adhesive material may be any suitable adhesive material.
Suitable adhesive materials include glue and double-sided adhesive tape.
According to the present invention there is also provided a method of producing a food product which inclues the steps of: (a) forming a box as described above;
(b) placing a food product mix in the box; and (c) baking the food product in the box in an oven.
According to the present invention there is also provided an apparats for forming a box from a blank which inclues: (a) a box forming station for forming the blank into a partially-erected box having a base, upright side walls, upright end walls, gusset corners outside the interior of the box, side flaps extending upwardly from the side walls and/or end flaps extending upwardly from the end walls ; (b) an adhesive material application station for applying an adhesive material to the partially-erected box ; and (c) a flap folding station for outwardly and downwardly folding the side flaps against the side walls or for outwardly and downwardly folding the end flaps against the zend halls so that: (i) the gusset corners are sandwiche between the folded down side flaps and the side walls or between the folded down end flaps and the end walls ; and (ii) the folded down side flaps are adhered to the side walls or the folded down end flaps are adhered to the end walls.
It is preferred that the apparats inclues a transfer means for moving the blank to the box forming station and then moving the partially-erected box successively to the adhesive material application and flap folding stationsa It is preferred that the apparats further inclues a means for contacting the upwardly extending side flaps or the upwardly extending end flaps as the partially- erected box leaves the box forming station and outwardly folding the side or end flaps.
It is preferred that the flap forming station inclues an assembly for folding each flap.
It is preferred that each assembly inclues an inner downwardly extending member, an outer downwardly extending member, a means which couples together upper sections of the members so that the outer member can swing about the coupling outwardly and inwardly relative to the inner member, and a means for moving: (a) the members downwardly towards and upwardly away from the box at the station ; and (b) the outer member outwardly and inwardly relative to the inner member.
In use of the above-described assembly, when a partially-erected box with upwardly extending side or end flaps is at the flap-forming station, each assembly: (a) initially moves downwardly to a position at which the outer member is located inwardly of one of the side flaps or the end flaps ; (b) the outer member then swings outwardly in a
flicking motion and contacts and folds the side flap or the end flap outwardly; (c) simultaneously with step (b) the assembly moves downwardly and the outer member folds the side flap or the end flap downwardly and positions the downwardly-facing side flap or end flap between the outer and inner members; and (d) as the assembly continues to move downwardly, the outer member swings inwardly and forceß the side flap or the end flap against one of the side walls or the end walls.
The present invention is described further by way of example with reference to the accompanying drawings, of which: Figure 1 is a top plan view of a blank for forming a box in accordance with a preferred embodiment of the method and the apparats of the present invention; Figure 2 is a perspective view of a partially- erected box formed from the blank shown in Figure 1 at a box forming station of the apparatus ; Figure 3 is a perspective view of the finished box as produced in a flap forming station of the apparatus ; and Figure 4 illustrates the sequence of steps carried out at the flap forming station.
The blank shows in Figure 1 inclues a series of panels separated by fold lines.
The preferred embodiment of the method of the present invention folds and glues the panels of the blank and forms the finished box shown in Figure 3.
The panels in Figure 1 are marked with reference numerals. When folded to form the finished box shown in Figure 3, the panel 3 shown in Figure 1 forms the base 3', the panels 5 form the side walls 5', the panels 7 form the end walls 7', the pairs of adjacent panels 9 form the outwardly facing gusset corners 9', the panels 11 form the outwardly and downwardly facing side flaps 11', and the panels 15 form the outwardly and downwardly facing end flaps 15'.
The blank is formed from corrugated board with a bleached lining on the surfaces that form the interior of the box and a polyolefin facing on the bleached lining.
The purpose of the polyolefin lining is to provide a barrier to water and oil. This treated corrugated board is particularly suitable for the production of baked food products and the preferred embodiment is described in this context. The blank may be formed from any other suitable material.
In the finished box shown in Figure 3 the gusset corners 9'are outwardly facing and are sandwiched between the side flaps 11'and the side walls 5'. It can readily be appreciated that an alternative arrangement is one in which the outwardly facing gusset corners are sandwiche between the end flaps 15'and the end walls 7'.
The first step of the preferred embodiment of the method for forming the box shown in Figure 3 from the blank shown in Figure 1 is to fold the panels 15 through 180° to contact the panels 7 and to glue together the panels 7,15.
In effect, this step pre-forms what will become the outwardly and downwardly facing end flaps 15'of the
finished box.
The blank is then folded and glued by a box forming apparats and thereby formed into the box shown in Figure 3. The apparats inclues a series of stations at which the blank is successively folded and glued to form the box.
The blank is positioned first at an inlet end of the apparats and is transported by means of a pneumatic ram along a horizontal slide to a box-erecting station and is positioned to extend horizontally across an open forming chamber. A forming member, such as a punch, then moves downwardly and contacts the blank and forces the blank into the forming chamber and thereby partially erects the box with the side walls 5', the end halls 7', and the gusset corner 9'folded against the side walls 5'. In this partially erected state the side flaps 11'extend upwardly from the side walls 5'.
The partially erected box is then moved by means of a second pneumatic ram through a gluing station (not shown) and glue is applied to the side walls 5'as the side walls 5'move past fixed gluing guns (not shown). The applied glue is illustrated by the numeral 21 in Figure 2.
The glue inclues hot melt glue and cold glue. In an alternative arrangement the partially-erected box is stationary at the gluing station and the glue guns move past the stationary box.
The glued, partially-erected box is then moved by the second pneumatic ram to a side flap folding station and a flap folding assembly on each side of the box moves down and folds the side flaps 11'outwardly and downwardly against the side halls 5'and sandwiches the corner gussets 9'between the side flaps 11'rand the side walls 5'.
Whist at the side flap folding station the hot melt glue
provides an initial tack weld to hold the side flaps against the side walls. Progressively, the cold glue sets and provides a full strength bond. The use of a combination of hot melt glue and cold glue is particularly suited to baking food products.
The formed box is discharged from an outlet end of the box forming apparats.
The above-described box forming apparats also inclues an indexing means which controls movement of blanks through the apparats.
With reference to Figure 4, the assembly (shown in very diagrammatic form) on each side of the box inclues an inner and an outer flap-folding member in the form of plates 17a, 17b which are coupled together at upper sections of the plates.
Figure 4 illustrates the operation of the assembly to fold the side flap 11'shown in the Figure outwardly and downwardly against the side wall 5'shown in the Figure. Firstly, with reference to the left hand sketch, the assembly moves downwardly to a position at which the outer member 17a is located inwardly of the side flap 11'. Secondly, the outer member 17a swings outwardly in a flicking motion and contacts and folds outwardly the side flap 11'. Simultaneously, the assembly moves downwardly and the outer member 17a folds the side flap 11' downwardly. Finally, as the assembly continues to move downwardly, the outer member 17a swings inwardly and forces the side flap 11'towards and ultimately against the side wall 5'rand holds it in this position for a sufficient time for the hot glue to establish a tack weld. In this sequence of steps the inner member 17b acts as a rection surface against which the side flap 11'is folded.
When the completed box is used in the production of baked food products, the box is then moved to a food product line and food product mix is placed in the box and the box is transported to an oven (typically a convection oven) and the product is baked in the box.
Any modifications may be made to the preferred embodiment described above without departing from the spirit and scope of the present invention.