AN ERECTED CARTON

FIELD OF INVENTION

The invention relates to a packaging device and system. More particularly, the invention relates to a device for manipulating end closure flaps of an erected carton and a system for executing a folding process to bring the end closure flaps into a closed condition using the mentioned device.

BACKGROUND OF THE INVENTION

Conventionally in the glove packaging industries, the flaps of glove-filled boxes are still manually closed by the production workers. This is undesirable as the gloves are commonly used for medical purposes in hospital and clinics, the gloves should be sterilized and are preferred to be processed by automated machinery to minimize the risk of contaminating the gloves. Moreover, manual box closing is not feasible for large scale production lines as the process is time consuming and labour intensive.

Over the years, there are a few patented technologies over the prior art attempt to solve the abovementioned problem. Of interest in respect to a packaging machine with pivoting minor flap retainer and rotating glue gun assembly is US20080110135A1. This patent discloses an automated packaging process includes a packaging apparatus that is capable of closing cartons of various configurations, using a rotating glue gun assembly, and by providing a cycle stop operation finishing capability that allows completion of packaging processes in progress when the cycle stop operation is initiated. For cartons that have minor flaps that are substantially overlapped by a bottom end flap, a pivoting minor flap retaining guide holds the minor flaps closed while the bottom end flap is folded upwardly and over the minor flaps. The rotating glue gun assembly allows rotation of the glue nozzles to allow selective placement, spacing, and timing of the application of glue beads for gluing cartons having various configurations. By rotating the glue nozzles, the distance between the applied glue beads can be adjusted according to desired specifications, and without disabling specific glue guns for extended periods of time during the packaging run.

The main drawback of this patent is that the boxes are sealed by glue, tearing off the seal will damage the cartons during the inspection process. Instead of securing the cartons by gluing, the flaps of the cartons are provided with tongue and groove locking mechanism to secure the closing of the cartons. To date, there is still no cartons closing machine and system capable of closing a tongue and groove locking mechanism effectively.

Accordingly, it would be desirable to provide a device and system that capable of closing tongue and groove locking mechanism of a carton. This invention provides such a device and system thereof.

SUMMARY OF INVENTION

In a first aspect of the invention, there is provided a device for manipulating end closure flaps of an erected carton, the device comprises a shaped plate which is engageable with an end closure flap and movable to press against the end closure flap and folds the end closure flap from an opened condition to a closed condition while keeping in abutment with the end closure flap during a folding process; wherein the shaped plate includes a first projection extending from a leading edge of the shaped plate to engage and guide an elongated tab or a locking tab of the end closure flap into a complementary slot formed in the carton as the end closure flap is brought into its closed condition by the shaped plate. Preferably, the first projection of the leading edge curves out of the general plane of the shaped plate.

Alternatively, the shaped plate may further comprise a trailing edge that includes a second projection extending from the trailing edge of the shaped plate.

Either the first projection, the second projection or both have extending projections to engage with the complementary slot on the carton and to guide the locking tab into the slot. Preferably, each of the extending projections can be in the form of a relatively short tongue as compared to the length of the respective leading or trailing edge.

Preferably, the shaped plate may have at least one elongate slot for receiving the elongated tab or the locking tab of the end closure flap so that the elongated tab or the locking tab of the end closure flap can be pre-folded prior to the folding process.

Preferably, the shaped plate may further comprise at least one suction unit for holding at least one side of the carton during a carton erection process.

In a second aspect of the invention, there is provided a system for use in closing end closure flaps of an erected carton, the system comprises the device as mentioned above and a mechanized arm which carries the device and which can be actuated to cause the device to execute the folding process to bring the end closure flaps into a closed condition;

Preferably, the system may further comprise a base coupled with at least one holding means for holding the carton in position during the erection process or the folding process.

One skilled in the art will readily appreciate that the invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments described herein are not intended as limitations on the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the invention, its construction and operation and many of its advantages would be readily understood and appreciated.

Fig. 1A illustrates a first exemplary of a conventional carton box. Fig. IB illustrates a second exemplary of a conventional carton box.

Fig. 2A-2D illustrates a first embodiment of a device for manipulating the end closure flaps of an erected carton which embodies therein the principle features of the invention.

Fig. 3A-3D illustrates a second embodiment of the device.

Figs. 4 to 6 illustrates a first pre-folding process for folding an elongated tab of a first main flap into a designated shape prior to its closure process.

Figs. 7 to 9 illustrates a first folding process for closing the first end closure flap.

Figs. 10 to 11 illustrates a second pre-folding process for folding a locking tab of a second end closure flap into a designated shape prior to its closure process.

Figs. 12 to 14 illustrates a second folding process for closing the second end closure flap.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described in greater detail, by way of example, with reference to the drawings.

Referring to Fig. 1A, a first exemplary of an industrial standard carton box in its erected configured is illustrated. The carton includes a body 12 with two opened ends, each end has a first end closure flap 7 with an elongated tab 6 extended from the free end of the first end closure flap 7, two side flaps 8 connected to the sides of the first end closure flap 7 and a second end closure flap 10 with a locking tab 9 extended from the free end of the second end closure flap 10. A tongue and groove locking mechanism is formed by the locking tab 9 and a complementary slot 11 located on a section of the carton’s body 12 at the edge of the first end closure flap 7.

Referring to Fig. IB, a second exemplary of an industrial standard carton box is illustrated. The difference between the designs in Fig. 1A and Fig. IB is that the side flaps 8 in Fig. IB is not connected to the first end closure flap 7, this allows the side flaps 8 to operate independently.

Referring to Figs. 2A-2D, a device for manipulating the first and second end closure flaps 7, 10 of the carton as illustrated therein comprises a shaped plate 1 to cradle and guide the first or second end closure flap 7, 10 during the folding of the first or second end closure flap 7, 10 from an opened condition to the closed condition. The shaped plate 1 includes a first projection 4A extended from a leading edge of the shaped plate 1 to engage and guide the locking tab 9 of the second end closure flap 10 into the complementary slot 11 as the second end closure flap 10 is brought into its closed condition by the shaped plate 1. The first projection 4A can be in the form of an extended portion that curves outwardly from the leading edge of the shaped plate 1.

Alternatively, the shaped plate 1A as shown in Figs. 3A-3D may further comprises a trailing edge of like configuration to the leading edge, the trailing edge includes a second projection 4B extended from the trailing edge to engage and guide the first end closure flap 7 into its closed condition. The first and second projections 4A, 4B form a curved surface profile that allows the first or second end closure flap 7, 10 to move smoothly along the curved surface while keeping in abutment with the first or second end closure flaps 7, 10 during a folding process. Both the first and second projections 4A, 4B have tongues 5A, 5B. Preferably, the tongues 5A, 5B are relatively short as compared to the length of the respective first and second projections 4A, 4B. Each tongue 5A, 5B can be configured to enlarge the opening of the complementary slot 11 and acts as a boundary for the elongated tab 6 or the locking tab 9 to be easily guided into their designated positions.

In addition to that, an elongate slot 3 is provided between the leading edge/trailing edge and the shaped plate 1A. Each elongate slot 3 is configured to receive the elongated tab 6 or the locking tab 9 so that the elongated tab 6 or the locking tab 9 can be pre-folded at a substantially right angle to the first or second end closure flaps 7, 10 prior to the folding process. Preferably, the elongated tab 6 and the locking tab 9 are pre-folded by the elongate slot 3. At least one suction unit is provided on the other side of the shaped plate 1A for holding at least one side of the carton during a carton erection process.

In one embodiment of the invention, the mentioned device is coupled to a robotic arm programmed to facilitate different movements for the device to fold the first and second end closure flaps 7, 10 from the opened condition to the closed condition. In operation, the device is firstly directed by the robotic arm to pick up a carton from a stack of flat cartons via the suction unit of the device. Secondly, the carton is transferred to a table with suction units. While one side of the carton is held by the device and the opposite side of the carton is held firmly on the table, the carton erection process can be performed by moving the device away from the table. Once the carton is in the erected configuration, the robotic arm then performs a set of processes for closing the carton box.

Preferably, the closing processes include: 1) a first pre-folding process, 2) a first folding process, 3) a second pre-folding process and 4) a second folding process.

In the first pre-folding process as shown in Figs. 4-6, the device is directed to pre-fold the elongated tab 6 of the first end closure flap 7 using the elongate slots 3. The purpose of the pre-folding is to fold the elongated tab 6 into a designated shape so that the closing of the first end closure flap 7 and the elongated tab 6 can be performed in a smoother manner.

In the first folding process as shown in Figs. 7-9, the first end closure flap 7 will be pushed to its closed configuration by the projection 4B and the tongue 5B of the device. Preferably, when the elongated tab 6 substantially reaches the opened end, a rocking movement can be performed to fit the elongated tab 6 into its designated position. Alternatively, the first folding process can be further assisted by introducing lateral forces to push the side flaps 8 inwardly to its closed configuration.

In the second pre-folding process as shown in Figs. 10 & 11, the device is directed to pre-fold the locking tab 9 of the second end closure flap 10 using the elongate slot 3. The purpose of the pre-folding is to fold the locking tab 9 into a designated shape so that the closing of second end closure flap 10 and the fitting of the locking tab 9 into the complementary slot 11 can be performed in to smoother manner.

In the second folding process as shown in Figs. 12-14, the second end closure flap 10 will be pushed to its closed configuration by the projection 4A and the tongue 5A of the device. Prior to insertion of the locking tab 9 into the complementary slot 11, the tongue 5A of the device will firstly engage and further enlarge the opening of the complementary slot 11. The enlarged opening of the complementary slot 11 will allow the locking tab 9 to be inserted thereinto with an effortless manner and the tongue 5A can also act as a boundary for guiding the locking tab 9 into the complementary slot 11.

The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the invention.