TOOL FOR FORMING CONSTRUCT

Cross-Reference to Related Application [0001] This application claims the benefit of U.S. Provisional Application No.

61/017,850, which was filed on December 31, 2007. The entire contents of the above- referenced provisional application is hereby incorporated by reference for all purposes as if presented herein in their entirety.

Background of the Disclosure

[0002] The present disclosure generally relates to constructs and, more particularly, the present disclosure relates to tools and methods for forming containers.

Summary of the Disclosure

[0003] In general, one aspect of the disclosure is generally directed to a forming tool for forming a container from a blank. The forming tool has a cavity and a core. The cavity has an articulation portion moveably connected to a cavity base. The core has a nose moveably connected to a nose base. When the container is formed from the blank, the nose is moved relative to the nose base prior to fully receiving the core into the cavity to complete formation of the blank into the container.

[0004] In another aspect, the disclosure is generally directed to a tool for forming a construct from a blank. The tool comprises a cavity operable to receive a blank. The cavity comprises an articulating portion and a cavity base. The articulating portion is moveably connected to the cavity base. The cavity comprises at least one cavity spring for controlling movement of the articulating portion relative to the cavity base. A core is operatively connected to the cavity. The core is operable to enter the cavity to at least partially form the blank into a construct. The core comprising a core base and a nose that is moveably connected to the core base. The core comprises at least one core spring for controlling movement of the nose relative to the core base. The at least one cavity

spring has a first strength, and the at least one core spring has a second strength. The first strength is greater than the second strength.

[0005] In another aspect, the disclosure is generally directed to a method of forming a construct from a blank. The method comprises providing a blank and placing the blank in a forming tool. The forming tool comprises a cavity and a core. The cavity has an articulating portion, a cavity base, and at least one cavity spring for controlling movement of the articulating portion relative to the cavity base. The core comprises a core base, a nose, and at least one core spring for controlling movement of the nose relative to the core base. The method further comprising closing the tool while the blank is in the tool so that the core is at least partially received in the cavity. The closing the tool comprises pressing the core against the blank to compress the at least one core spring and further moving the core to cause the articulating portion to move relative to the cavity base. The at least one core spring is compressed prior to fully receiving the core into the cavity to complete formation of the blank into the construct.

[0006] Those skilled in the art will appreciate the above-stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

[0007] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure

Brief Description of the Drawings [0008] Fig. 1 is a schematic diagram of a forming tool of one embodiment of the present disclosure. [0009] Fig. 2 is a schematic diagram of the forming tool of Fig. 1 with the tool positioned to form a construct from a blank.

[0010] Fig. 3 is a schematic diagram of the forming tool of Fig. 2 further positioned to further form the construct. [0011] Fig. 4 is a schematic diagram of the forming tool of Fig. 3 further positioned to further form the construct.

[0012] Fig. 5 is an enlarged portion of Fig. 4.

[0013] Fig. 6 is a top view of the construct formed from the forming tool.

[0014] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

Detailed Description of the Exemplary Embodiment

[0015] Fig. 1 schematically illustrates a tool (e.g., mold assembly 130) that can be used in the manufacture of or forming of a container or construct 300 (Fig. 6), in accordance with one embodiment. The container 300 can have an injection-molded structure 305 with similar characteristics as the container and injection-molded structure described in co-assigned U.S. Patent Application No. 11/715,718 filed March 8, 2007 ("the '718 application"), the entire content of which is incorporated by reference herein for all purposes. Further, the container and injection-molded structure may be formed by similar methods, tools, apparatus, etc. as disclosed in the '718 application. Alternatively, the mold assembly 130 of the present disclosure may be used to form containers that do not have injection molded features without departing from the disclosure.

[0016] In the illustrated embodiment, the container 300 has a bottom wall 307, and four side walls 309 extending upwardly from the bottom wall. The injection-molded structure 305 can include a flange 310 that extends around the perimeter of the container and fingers 312 that extend downward from the flange 310 at respective corners 311 of the container. The container 300 and injection-molded structure 305 can be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure.

[0017] The mold assembly 130 is in an open configuration in Fig. 1 , and it includes a male mold 132 (e.g., core) and a female mold 134 (e.g., cavity). The female mold 134

includes a space 133 that is defined by a sidewall 135 that is generally shaped to correspond with the shape of the construct 300. In the illustrated embodiment, the male mold 132 is shaped to generally correspond to the shape of the space 133 to form the three-dimensionally-shaped construct 300 from a generally flat blank 22 that is pressed into the space. The male mold 132 and/or the female mold 134 may be otherwise shaped and/or arranged without departing from the disclosure.

[0018] As shown in Fig. 1 , core 132 includes an outer mold or core base 136 to which a nose unit 138 (e.g., core plate or nose) is mounted. The nose 138 is moveably mounted to the core base 136 and is connected to the core base by a group of core springs 140, two of which are shown in Fig. 1. In alternative embodiments, a single core spring 140 could be provided. Optionally, four securing elements, such as securing pins 144, protrude from the core base 136 for aiding in the forming of the container. There can be a greater or lesser number of securing elements (e.g., securing pins 144), and in some situations they can be completely omitted without departing from the disclosure.

[0019] In one embodiment, a port 146 (e.g., with a valve gate) is optionally defined in the core base 136, or otherwise provided, for injecting fluid injection-molding material (e.g., resin) or the like, into the mold assembly 130 to form the injection-molded structure 305 of the construct 300. In one example, the port 146 is in the form of, or includes, a valve gate. The port 146 can be omitted such that the tool 130 forms the construct that is free from an injection-molded structure without departing from the disclosure.

[0020] In the illustrate embodiment, the cavity 134 includes a cavity base 150 to which an embossing unit 152 (e.g., cavity plate or articulating portion) is movably mounted. In one embodiment, a group of cavity springs 154, only two of which are schematically shown in Fig. 1, urge the articulating portion 152 toward the core 132. Alternatively, a single cavity spring 154 can be provided or the springs can be omitted without departing from the disclosure. A group of locating pins 156 can be mounted to the cavity base 150 in an arrangement that is for helping to position the blank 22 in a predetermined location. The cavity 134 includes a flange surface 164 that is generally perpendicular to the sidewall 135 and further at least partially defines the space 133.

[0021] In one embodiment of the disclosure, the core springs 140 in the male mold 132 and the cavity springs 154 in the female mold 134 are of different strength to prevent pinching the sidewalls 309 of the blank 22 when forming the construct. In the illustrated embodiment, the cavity springs 154 in the female mold 134 are stronger than the core springs 140 of the male mold 132 so that the cavity springs have a higher resistance to compression. The higher strength of the cavity springs 154 allows the core springs 140 to compress when the nose 138 presses the blank 22 against the articulating portion 152, prior to movement of the articulating portion 152 and corresponding compression of the cavity springs 154.

[0022] As shown in Fig. 1, the core springs 140 have a first end 143 in contact with a surface 145 of the core base 136. The core springs 140 have a second end 147 in contact with a surface 149 of the nose 138. The cavity springs 154 have a first end 155 in contact with a surface 157 of the cavity base 150. The cavity springs 154 have a second end 159 in contact with a surface 161 of the articulating portion 152. The core springs 140 and/or the cavity springs 154 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.

[0023] In one embodiment, the core springs 140 can have a diameter of at least approximately 0.75 inches (19 mm), and an overall, non-compressed length of at least approximately 1.25 inches (30 mm). In the illustrated embodiment, the cavity springs 154 can have a diameter of at least approximately 0.75 inches (20 mm), and an overall, non-compressed length of at least approximately 7.0 inches (175 mm). In one embodiment, the core springs 140 and the cavity springs 154 can be a medium heavy duty die spring of the type commercially available from Associated Spring Raymond of Maumee, OH. Alternatively, the core springs 140 and/or the cavity springs 154 could be otherwise shaped, arranged, and/or configured to be other types and/or sizes of springs. All dimensional information presented herein is intended to be exemplary and is not intended to limit the scope of the disclosure.

[0024] In the illustrated embodiment, the cavity springs 154 have a first strength, or resistance to linear compression, and the core springs 140 have a second strength, or

resistance to linear compression. The cavity springs 154 provide a resistance to the movement of the articulating portion 152 relative to the cavity base 150. The core springs 140 provide a resistance to the movement of the nose 138 relative to the core base 136. In the illustrated embodiment, the first strength of the cavity springs 154 is greater than the second strength of the cores springs 140 so that when the core 132 and cavity 134 are brought together, in contact with the blank 22 located therebetween, the core springs are compressed prior to the compression of the cavity springs. Accordingly, the surface 145 of the base 136 is moved closer to the surface 149 of the nose 138 when the base 136 is moved in the direction of arrow Al (Fig. 1) relative to the nose. The moving of the surface 145 occurs prior to the movement of the articulating portion 152 moving in the direction of arrow A2 (Fig. 1) resulting in the compression of the cavity springs 155. Alternatively, the resistance to movement of the articulating portion 152 could be maintained to be greater than the resistance to movement of the nose 138 by mechanisms other than the cavity springs 154. For example, the cavity springs 154 and/or the core springs 140 could be mechanisms other than coil springs (e.g., gas springs, reciprocating pistons, or other mechanism that provides resistance to linear compression). hi the illustrated embodiment, the core 136 has an external surface 171 for cooperating with the surface 135 of the cavity 134 to form the sidewalls 309 of the container 300. In one embodiment, the external surface 171 of the core 136 includes a first portion 171a on the base 136 and a second portion 171b on the nose 138. The first portion 171a and the second portion 171b are spaced apart by a gap 175. As shown in Fig. 1 and 2, the nose 138 is in an extended position such that the gap 175 has a maximum dimension Hl. As shown in Fig. 1, the articulating portion 152 of the cavity 134 is shown in an extended position wherein the articulating portion is spaced apart from the surface 157 of the cavity base 150 by a gap 179 having a maximum dimension H2. As will be discussed below in more detail, as the forming tool 130 is operated to form the container 300 from the blank 22, the gap 175 is first reduced by the movement

of the nose 138 in the direction of arrow Al and then the gap 179 is reduced by the movement of the articulating portion 152 in the direction of arrow A2.

[0026] A method of forming the construct 300 (Fig. 6) from the forming tool 130 will now be described. The blank 22 is first placed between the cavity 134 and the core 132 as generally shown schematically in Fig. 1. As shown in Fig. 2, the core 132 is moved in the direction of arrows A3 so that the nose 138 contacts the blank 22 that is held between the core and the cavity 134 and presses the blank against the articulating portion 152. Alternatively, the cavity 134 could be moved in a direction opposite to the arrows A3 so that the articulating portion 152 presses the blank 22 against the nose 138. As shown in Fig. 3, the core 132 is further moved in the direction of arrows A3 so that the gap 175 between the nose 138 and the base 136 is reduced to a minimum dimension H3. The gap 175 is reduced when the core springs 140 are compressed by the upward movement of the base 136 relative to the nose 138. At this point in the article forming process, the articulating portion 152 of the cavity 134 does not move because the force applied to the core 136 to move it toward the cavity is insufficient to overcome the resistance to compression of the cavity springs 154. As shown in Fig. 4, when sufficient force is applied to the core 136 to overcome the resistance to compression of the cavity springs 154, the articulating section 152 moves in the direction of arrow A2 to reduce the height of the gap 179 to a minimum distance of H5. Alternatively, the cavity springs 154 could be partially compressed (e.g., so that the height of the gap 179 has a dimension less than H3 and greater than H2).

[0027] In the illustrated embodiment, the blank 22 is formed into the container 200 by the configuration of the forming tool 130 shown in Fig. 4 with the external surface 171 of the core 132 pressing the portions of the blank corresponding with the sidewalls 309 of the container against the surface 135 of the cavity 134. The core springs 140 are compressed prior to fully receiving the core 132 into the cavity 134 to complete the formation or shaping of the blank 22 into the construct 300. The compression of the core springs 140 minimizes the height of the gap 179 prior to completion of the forming or shaping of the blank 22 into the shape of the construct 300.

[0028] The injection-molded structure 305 can be formed by injecting injection-molding material (e.g., polymeric material, resin, etc.) through the port 146 that fills an injection cavity 205 (Fig. 5) formed between the flange surface 164 of the cavity 134 and the blank 22. In the illustrated embodiment, the injection cavity 205 is shaped to form the injection-molded structure 305 that can include the flange 310 and fingers 312 but the injection cavity can be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure. In one embodiment, the injection molding occurs after completion of the formation or shaping of the blank 22 by fully receiving the core 132 into the cavity 134 so that the blank is pressed against the external surface 171 of the core and the surface 135 of the cavity.

[0029] In accordance with the exemplary embodiments of the present disclosure, the blanks can be formed from paperboard, corrugated cardboard or other materials having properties suitable for at least generally enabling respective functionalities described above. Paperboard is typically of a caliper such that it is heavier and more rigid than ordinary paper, and corrugated cardboard is typically of a caliper such that it is heavier and more rigid than paperboard. Typically, at least the side of the paperboard or cardboard that will be an exterior surface in the carton erected therefrom will be coated with a clay coating, or the like. The clay coating can be printed over with product, advertising, price-coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on one or both sides. The blanks can also be laminated to or coated with one or more sheet-like materials.

[0030] The foregoing description of the disclosure illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes

only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure without departing from the scope of the disclosure.