AU777628B2 - A method and an apparatus for forming a box - Google Patents

Description

31/08 2004 15:03 FAX 51 3 92438333 GRIFFITH HACK -IPAUSTRALIA [0008 Inla A MEfTHOD AND AN APPARATUS FOR FORMING A BOX The present invention relates to a method and an apparatus for forming a box.

S

The present invention relates particularly, although by no means exclusively, to a method and an apparatus 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 includes the steps of forming the above-described box, placing a food product mix in the box, and then baking the food product in the box.

25 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 *see.:box and to glue together overlapping panels which hold r* ~:together the erected box.

O 0 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 5 unhindered access to the interior of a box is required.

One such situation is the manufacture of baked food products.

COMSID No: SBMI-00893021 Received by IPAustratia:flme 15:13 Date 2004-08-31 09/09 '04 THU 13:03 FAX 61 3 9243 8333 GRIFFITH HACK Q) 006 -2- Another known but less widely used method of forming a box f ran a blank is based on f olding 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 apparatus for forming a box with outwardly folded gusset corners.

According to the present invention there is provided a method of forming a box from a blank using a box forming apparatus, the blank having a series of panels separated by fold lines, which method includes the steps of: forcing the blank into a forming chamber at a box forming station of the apparatus and thereby causing the blank to fold about the 000 25 fold lines and form a partially- erected box having a base, upriLght side walls, upright .00000end walls, gusset corners that are outside 0* the interior of the box, side flaps that extend upwardly from the side walls and/or end flap. that extend upwardly from the end 00.0 walls; (b0plin0n00eie mtril t h p(b)ialyng cte an h adhesive material h including a hot melt adhesive and a cold melt adhesive; COMS ID No: SBMI-00905975 Received by IP Australia: Time 13:13 Date 2004-09-09 00/09 '04 THU 13:03 FAX 61 3 9243 8333 GRIFFITH HACK 16]007 -3outwardly and downwardly folding the side flaps against the side walls or outwardly and downwardly folding the end flaps against the end walls at a flap folding station of the apparatus while the partially erected box is stationary at the station ao that the gusset corners are sandwiched between the folded down side flaps and the side walls or between the folded down end flaps and the end walls; holding the side flaps and/or the end flaps against the side walls or the end walls until the hot glue establishes a tack weld while the partially erected box is stationary at the station; and discharging the tack welded box from the apparatus.

Each gusset corner may be formed from any 0: suitable number of adjacent panels.

0*25 Preferably each gusset corner is formed from two adjacent panels.

0 0 Step may be carried out with any suitable means.

The adhesive material may be any suitable adhesive material.

Preferably step includes outwardly folding :35 the side and/or end flaps by contacting the side and/or end flaps with flap folding members and swinging the members outwardly in a flicking motion and contacting and folding COMS ID No: SBMI-00905975 Received by IP Australia: lime 13:13 Date 2004-09-09 10/09 2004 09:28 FAX 61 3 92438333 GRIFFITH HACK 4, IPAUSTRALIA Q0044 4 outwardly the side and/or end flaps.

Preferably step further includes 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 folding the side and/or end flaps downwardly against the side and/or end walls.

Preferably step includes swinging the flap folding members inwardly and forcing the side and/or end flaps inwardly against the side and/or end walls.

15 According to the present invention there is also provided a method of producing a food product which includes the steps of: forming a box as described above; placing a food product mix in the box; and baking the food product in the box in an oven.

According to the present invention there is also provided an apparatus for forming a box from a blank which includes a series of panels separated by fold lines, which apparatus includes: 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, the box forming COMS ID No: SBMI-00907620 Received by IP Australia: Time 09:33 Date 2004-09-10 09/09 '04 THUI 13:04_FAX_61 3 9243 8333 GRIFFITH RACK 0~009 station including a forming chamber and a means for forcing the blank into the Chamber and thereby causing the blank to fold about the fold lines and form the partiallierected box; an adhesive material application station for applying an adhesive material to the partially-erected box, the adhesive material including a hot melt adhesive and a cold melt adhesive; and a flap folding station for outwardly and downwardly folding and holding the side flaps against the side walls or for outwardly and downwardly folding and holding the end flaps against the end walls while the partially-erected box is stationary at the flap folding station so that: Mi the gusset corners are sandwiched between the folded down side flaps and the aide walls or between the folded down end flaps and the end walls; and the hot melt glue establishes a tack weld that is sufficient to hold folded down side flaps to the side walls or the folded down end flaps to the end walls.

It is preferred that the apparatus includes 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 stations.

COMS ID No: SBM[00)905975 Received by IP Australia: rime (ltm) 13:13 Date 20D44)9-09 09/09 '04 THU 13:04_FAX 61 3 9243 8333 GRIFFITH HACK Z010i SA It is preferred that the flap forming station includes an assembly for folding each flap.

it is preferred that each assembly includes 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; the members downwardly towards and upwardly away f rom the box at the station; and 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: initially moves downwardly to a position at which the outer member is located inwardly of one of the side flaps or the end flaps; COMS ID No: SBMI-00905975 Received by IP Australia: Time 13:13 Date 2004409-09 31/08 2004 15:05 FAX 51 3 92438333 GRIFFITH HACK T PAUSTRALIA aj013 6the outer member then swings outwardly in a flicking motion and contacts and folds the side flap or the end flap outwardly; simultaneously with step 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 membe; and 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.

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 apparatus of the present invention; 25 eetd Figure 2 is a perspective view of a partiallyeretedbox 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 shown in Figure I includes a series of panels separated by fold lines.

COMS ID No: SBMI-00893021 Received by IP'Autstialia: Time 15:13 Date 2004-08-31 WO 00/53505 PCT/AU00/00178 -7- 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 the panels 7 form the end walls the pairs of adjacent panels 9 form the outwardly facing gusset corners the panels 11 form the outwardly and downwardly facing side flaps 11', and the panels 15 form the outwardly and downwardly facing end flaps 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 It can readily be appreciated that an alternative arrangement is one in which the outwardly facing gusset corners are sandwiched 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 1800 to contact the panels 7 and to glue together the panels 7, In effect, this step pre-forms what will become the outwardly and downwardly facing end flaps 15' of the WO 00/53505 PCT/AU00/00178 -8finished box.

The blank is then folded and glued by a box forming apparatus and thereby formed into the box shown in Figure 3. The apparatus includes 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 apparatus 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 the end walls and the gusset corner 9' folded against the side walls In this partially erected state the side flaps 11' extend upwardly from the side walls 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 includes 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 walls 5' and sandwiches the corner gussets 9' between the side flaps 11' and the side walls Whilst at the side flap folding station the hot melt glue WO 00/53505 PCT/AUOO/00178 9 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 apparatus.

The above-described box forming apparatus also includes an indexing means which controls movement of blanks through the apparatus.

With reference to Figure 4, the assembly (shown in very diagrammatic form) on each side of the box includes 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' and 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 reaction surface against which the side flap 11' is folded.

WO 00/53505 PCT/AU00/00178 10 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.

Claims (12)

1. A method of forming a box f rom a blank using aL box forming apparatus, the blank having a series of panels separated by fold lines, which method includes the Steps of: forcing the blank into a forming chamber at a box forming station of the apparatus and thereby causing the blank to fold about the fold lines and form 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 aide walls and/or end flaps that extend upwardly from end walls; applying an adhesive material to the partially-erected box, the adhesive material including a hot melt adhesive and a cold melt adhesive; outwardly and downwardly folding the Bide flaps against the side walls or outwardly *and downwardly folding the end flaps against the end walls at a flap folding station of the apparatus while the partially erected box is stationary at the station so that the gusset corners are sandwiched between the folded down side flaps and the side walls or between the folded down end flaps and the walls; holding the side flaps and/or the end flaps r:against the side walls or the end walls until the hot glue establishes a tack weld COMS ID No: SBMI-00905975 Received by IP Australia: Time 13:13 Date 2004-09-09 10/09 2004 09:28 FAX 61 3 92438333 GRIFFITH HACK IPAUSTRALIA [A005 -12 while the partially erected box is stationary at the station, and discharging the tack welded box from apparatus.

2. The method defined in claim 2 includes forming each gusset corner from two adjacent panels.

3. The method defined claim 1 or claim 2 in any one of the preceding claims wherein step includes outwardly :folding the side and/or the end flaps by contacting the Bide and/or end flaps with flap folding members and swinging the members outwardly in a flicking motion and contacting and folding outwardly the side and/or end flaps.

4. The method defined in claim 3 further includes 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 folding the side and/or end flaps downwardly against the side and/or *V end walls.

5. The method defined in claim 4 wherein step (d) includes swinging the flap folding members inwardly and forcing the side and/or end flaps inwardly against the side and/or end walls.

6. A method of producing a food product which includes the steps of: forming a box in accordance with the method defined in any one of the preceding claims, placing a food product mix in the box; and COMS ID No: SBMI-00907620 Received by IP Australia: Time 09:33 Date 2004-09-10 009/09 '04 THU 13.:05 FAX 81 3 9243 8333 GRIFFITH RACK [Z6013 -13 baking the food product in the box in an oven. s

7. An apparatus for forming a box from a blank which includes a series of panels separated by fold lines, which apparatus includes: 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, the box forming station including a forming chamber and a means for forcing the blank into the chamber and thereby causing the blank to fold about the fold lines and form the partially- erected box; an adhesive material application station for applying an adhesive material to the 9***25 partially-erected box, the adhesive material including a hot melt adhesive and a cold melt adhesive; and a flap folding station for outwardly and downwardly folding and holding the side flaps against the side walls or for outwardly and downwardly folding and holding the end flaps against the end walls while the partially-erected box is stationary at the flap folding station so that: COMS ID No: SBMI-00905975 Received by IP Australia: lime 13:13 Date 2004-09-09 09/09 '04 THU 13:05 FAX 61 3 9243 8333 GRIFFITH HACK 0~014 -14 the gusset corners are sandwiched between the folded down side flaps and the side walls or between the folded down end flaps and the end walls; and (ii) the hot glue establishes a tack weld that is sufficient to hold folded down aide flap. to the side walls or the folded down end flaps to the end walls.

8. The apparatus defined in claim 7 includes 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 stations.

9. The apparatus defined in claim 7 or claim 8 wherein the flap forming station includes an assembly for folding each flap.

The apparatus defined in claim 9 wherein each assembly includes an inner downwardly extending member, an 25 outer downwardly extending member, a means which couples together upper sections of the members so that the outer member can swing tbout the coupling outwardly and inwardly relative to the inner member, and a means: for moving the members downwardly towards and upwardly away from the box at the station; and for moving the outer member outwardly and inwardly relative to the inner member; COMS ID No: SBMI-00905975 Received by IP3 Australia: ime 13:13 Date 2004-09-09 09/09 '04 THU 13:05 FAX 61 3 9243 8333 GRIFFITH HACK 1015 whereby in use of the assembly, when a partially-erected box with upwardly extending side or end flaps is at the flap-forming station, each assembly: initially moves downwardly to a position at which the outer member is located inwardly of one of the side flaps or the end flaps; the outer member then swings outwardly in a flicking motion and contacts and folds the side flap or the end flap outwardly; simultaneously with step 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 as the assembly continues to move downwardly, the outer member swings inwardly and forces the side flap or the end flap one of the side walls or the end 25 walls.

11. A method of forming a box from a blank substantially as hereinbefore described with reference to the accompanying drawings. *o eo •cede go *oo COMS ID No: SBMI-00905975 Received by IP Australia: Time 13:13 Date 2004-09-09 09/09 '04 THU 13:06 FAX 61 3 9243 8333 GRIFFITH HACK 016 16

12. An apparatus for forming a box from a blank substantially as hereinbefore described with reference to the accompanying drawings. Dated this 9th day of September 2004 AMCOR LIMITED By their Patent Attorneys GRIFFITH HACK Fellows Institute of Patent and Trade Mark Attorneys of 0* 4* S* 0 S 0 0 0 0 S **Sf S SO S o* ooop COMS ID No: SBMI-00905975 Received by IP Australia: Time 13:13 Date 2004-09-09