US3383990A

US3383990A - Box forming apparatus

Info

Publication number: US3383990A
Application number: US521207A
Authority: US
Inventors: Lo-Roy K Cheu; King Clarence Van Houden
Original assignee: Boise Cascade Corp
Current assignee: Officemax Inc
Priority date: 1966-01-17
Filing date: 1966-01-17
Publication date: 1968-05-21
Anticipated expiration: 1985-05-21

Description

May 21, 1968 LO-ROY K. CHEU E AL 3,383,990

BOX FORMING APPARATUS Filed Jan. 17, 1966 5 Sheets-Shet 1 LO-ROY K. CHEU c. VANHOUDEN KING Q INVENTORS. I

lownsend lownsend May 21, 1968 LO-ROY K. CHEU ET AL 3,383,990

BOX FORMING APPARATUS 5 Sheets-Sheet 2 Filed Jan. 17, 1966 OY K. CHEU LO-R c. VAN HOUDEN KING INVENTORS.

lownsend o 'Iownsend y 1968 LO-ROY K. CHEU ET 3,383,990

BOX FORMING APPARATUS Filed Jan. 17, 1966 5Sheets-Sheet s LO-R K. CHEU c. v HOUQEN KING NVENTORS.

BY Ioumsend "wlownsend May 1968 LO-ROY K. CHEU ET 3,383,990

BOX FORMING APPARATUS 5 Sheets-Sheet 4 Filed Jan. 17, 1966 LO-ROY K. CHEU C. VAN HOUDEN KING INVENTORS.

BY 'lownsend ba'lownsend May 1968 LO-ROY K. CHEU ET AL 3,383,990

BOX FORMING APPARATUS Filed Jan. 17,. 1966 5 Sheets-Sheet 5 LO-ROY K. CHEU C. VANHOUDEN KING INVENTORS.

lownsend v Iownsend United States Patent Filed Jan. 17, 1966, Ser. No. 521,207 6 Claims. (Cl. 93-49) This invention relates to a machine for folding paperboard boxes in a fiat configuration and for completing the bottom closure of such box while retaining the remainder of the box in such flattened condition.

A box blank of the type that the present invention is particularly suitable for folding is described in commonly assigned copending application, Ser. No. 454,423, filed May 10, 1965, now abandoned. Such box is formed so that the bottom closure flaps of the box can be adhesively or otherwise joined to one another, and the box folded flat without interfering with the integrity of such bottom closure. Consequently, the box can be conveniently shipped flat in an empty condition and can be quickly set up for filling when such is desired. The present invention includes apparatus for automatically forming such box from a box blank and for delivering the box in a flattened condition with the bottom closure completely and permanently formed.

The apparatus exemplifying the invention that is described in detail hereinafter includes a folding section and a bottom closure forming section. The folding section is arranged so that forward movement of the box blank is imparted by engagement of the bottom flaps of the box blank, thereby permitting performance of folding operations on the upper panels of the box blank. The bottom closure forming section includes means for advancing the box by engagement with only the side panels of the folded box blank so that the bottom closure flaps can be manipulated and glued without interference with the forward movement of the box. Consequently, the apparatus is capable of high speed operation because the folding and gluing operations are performed while the box is moving.

The apparatus of the present invention is completely adjustable so that boxes of different dimensions can be handled by only minor adjustments of components of the device. Therefore, the apparatus is extremely versatile.

The present invention has for another object provision of a method by which box blanks can be formed with bottom closures and folded fiat in an efficient and rapid sequence of steps.

Other objects, features and advantages of the present invention will be more apparent on referring to the following specification and accompanying drawings in which:

FIG. 1 is a perspective view of the apparatus of the present invention;

FIG. 2 is a perspective view at enlarged scale of an input station of the folding section of the apparatus;

FIG. 3 is a perspective view similar to FIG. 2 showing a box blank in place in the folding section;

FIG. 4 is a perspective view of the folding and compressing section of the folding section;

FIG. 5 is a perspective view of the output end of the folding section and the input end of the bottom closure forming section showing transfer of a box blank from the former to the latter;

FIG. 6 is a perspective view of the portion of the bottom closure forming section showing mechanism for manipulating the lower flaps of the box blank;

FIG. 6A is a detail view of a fragment of FIG. 6;

FIG. 7 is a perspective view of a central portion of the bottom closure forming section of the apparatus; and

FIG. 8 is a perspective view of the output end of the gluing station.

3,383,990 Patented May 21, 1968 Referring more particularly to the drawing and specifically to FIG. 1, the apparatus includes a folding section 12 and a bottom closure forming section 14 for automatically folding and gluing bottom flaps of the box blank into a completed bottom closure. Folding section 12 has an input station 16 (see FIG. 2) which includes a projecting lower input bar 18 on which box blank B is initially received from conventional conveying apparatus, not shown, or by manual placement thereon by a human operator. A frame 20 is provided for supporting folding section 12, and input bar 18 is mounted to and spaced above the frame by an amount sufficient to permit lower side flaps 22 of box blank B to depend in coplanar relationship with side panel 24 of the box blank. The input bar is adapted to bend forward lower end flap 26 and rear lower end flap 28 upwardly and rearwardly into a horizontal position on the bar. Input station 16 also includes side bars 30 for affording lateral support to box blank B by engagement with side panels 24 thereof. Side bars 30 are carried in frame members 32 which afford lateral adjustment of the bars so as to accommodate box blanks of different sizes. Supported above the side bars is a top bar 34 which is carried in a frame member 36 so as to afford vertical adjustment of the top bar. As shown more clearly in FIG. 2, top bar 34 is positioned to bend upper forward flap 36 and upper rear flap 38 of box B into a rearwardly extending horizontal position.

Spaced along the path of travel of the box blank and at the same horizontal level and coplanar with bar 18 is a plate 49 defining smooth upper and lower surfaces and here shown as being formed by two laterally spaced-

apart plate segments

40a and 40b for weight reduction. Beneath plate 40 are lower side flap plow members 41 which converge in the direction of forward movement so that lower side flaps 22 of box B are folded upwardly into contact with the lower surface of plate 40. The motive power for moving box B into the position shown in FIG. 3 is provided either manually or from automatic feeding apparatus not shown.

,Spaced along the path of travel from input station 16 is an endless belt 42 having an upper reach 42a parallel to and in close proximity beneath plate 40. Conveyor 42 is so driven (by conventional means not shown) that upper reach 42a moves forwardly. Therefore, the lower surface of side flaps 22 is frictionally engaged by conveyor reach 42a and box B is thereby moved forwardly with the upper portion thereof in an unrestricted or unimpeded condition to enable subsequent folding operations to be performed on the upper portion of the box. During such forward movement the box is stabilized by support thereof on plate 40.

Spaced along the path of box travel (see FIG. 4) is a side panel folding station 50 which is supported above the path of box travel by a rear frame structure 52 and a forward frame structure 54. Iournalled in the frame are

shafts

56 and 58 which are disposed on axes parallel with the direction of box travel and laterally of and above the center of the path of box travel. Shafts 56 and 58 carry at their

forward ends cranks

60 and 62, respectively for rotatively driving the shafts. An arm 64 extends between cranks 69 and 62 so that on pivotal driving movement of the latter crank, the former will experience an equal amount of pivotal or rotative movement. A conventional pneumatic actuator 66 is mounted on frame 54 and has a rod 68 operatively connected to crank 62. Pneumatic cylinder 66 is controllably supplied with air from any conventional source, not shown. A side panel folding arm 72 is mounted on each

shaft

56, 58 which arm moves in response to pivotal movement of the respective shaft from a horizontal position above the path of travel of the box into a depending vertical position.

Shafts

56, 58 are spaced from one another by an amount greater than the width of the box so that when arms 72 are in a vertical position the side panels and top side flaps of the box are bent or folded outwardly, as more clearly shown in FIG. 4. A pair of levers, one of which is exemplified at 74 in FIG. 4, supports a crossbar 76 within the path of box travel and is contacted by a passing box. The upper end of lever 74 is operatively associated with a microswitch 78, or like electrical control element, which actuates, through conventional electromechanical control apparatus 80 the pneumatic actuator 66 so that when the box encounters the crossbar, arms 72 pivot from the horizontal position to the vertical position and fold the side panels of the box outwardly. Such lateral folding movement of the sides of the box cause the leading panel of the box to slope rearwardly as more clearly shown in the figure.

Along the path of travel from the location of arms 72 is a roller 82 for supporiing one end of an endess belt 84, the other end of which is supported on a roller 86.

Roller 82 is carried in a pair of blocks, one being shown at 88, which are supported on a vertically adjustable mounting structure 90. Roller 82 is established at a height such that lower reach 84a of conveyor belt 84 converges forwardly and downwardly toward plate 48, as a consequence of which front panel 91 and top forward end flap 37 of the box are compressed and folding of the box is completed on passage of the box beneath conveyor 84.

From FIG. 4 it will be observed that box blank B is conveyed forwardly in the folding station 58 (rightwardly in the drawing) by frictional engagement between conveyor belt 42 and lower side flaps 22 of the box blank. Plate segments a and 40b constrain the box blank in the path of travel so that the upper portions of the box blank contact rod 76 and initiate the downward pivotal movement of panel-folding arms 72. The lateral folding or bending of side panels 24 causes front panel 91 to be folded to a rearwardly-sloping position prior to transport of the box blank to conveyor 84. When the box blank has completed traverse of conveyor 84 it is in a flattened condition because output roller 86 of the conveyor is spaced closely adjacent to plate segments 411a and 40b.

As the folded box exits from the folding section 12, the side panels and upper side flaps, in a substantially flat tened condition, project laterally from the remainder of the box blank including the bottom flaps. Spaced on opposite sides of the path of box travel for engaging such laterally extended portions of the box are upper endless belts 92 and lower endless belts 94. See FIG. 5.

The forward moving reaches of

belts

92 and 94 are spaced sufiiciently close to one another to compress and frictionally engage the laterally-extending portions of the box blank so that forward movement of the box blank is continued. Along the path of travel from the inlet side of bottom closure forming section 14,

plate segments

40a and 40b are formed to unfold bottom side flaps 22 into a generally vertical position. To accomplish such unfolding each segment is twisted 90 in a gradual and continuous fashion. Such unfolding operation occurs without affecting the forward movement of the box blank because such forward movement is imparted solely by engagement of the folded "and laterally extending side panel between

belts

92 and 94, and without restriction to movement of the lower flaps.

Forward lower flap 26 and rear lower flap 28 are both in a trailing or rearwardly extending position; as the first step in completing the bottom closure it is necessary to fold rear flap 28 forwardly. For this purpose a flap folding station 100 is provided along the path of box travel. See FIG. 6. A frame 102 for pivotally supporting a shaft 104 over the path of travel is provided. Mounted on shaft 104 is a lever 166 to the outer end of which is secured the rod of a pneumatic or hydraulic actuator 188. The cylinder of the actuator is secured to frame 102 by a bracket 110 so that actuator 108 pivotally drives shaft 184. Beneath the path of box travel is mounted a microswitch 112 for sensing the arrival of the box blank beneath shaft 104. A conventional electromechanical transducer 114 is provided for linking microswitch 112 to actuator 108 to the end that closure of the microswitch by laterally extending flaps 24 will cause actuator 103 to pivotally drive shaft 104.

Secured to shaft 184 for pivotal movement therewith is a flap folding arm 116 which includes arcua'te fingers 118 and a crossbar 120 spanning the outer ends of the fingers.

Referring now to FIGURE 6A, arm 116 normally resides in a generally horizontal position spaced above the path of travel of the flattened box. In response to arrival of the box as sensed by microswitch 112, arm 116 is driven downwardly (counter-clockwise as viewed in the figure) to fold lower flap 28 through a 180 arc and into a position underlying the box blank. Side flaps 22 do not interfere with such action because they are retained in a vertical position by

plate segments

40a and 40b. Spaced along the path of travel from the flap-folding station is a lower skid 112, which retains the rear flap 28 into the forwardly extending position established by arm 116. The rear extremity of skid 122 is formed with an upwardly, forwardly sloping portion 124 to assure a smooth transition of the box blank from folding station 102 to the gluing station of the apparatus.

Spaced along the path of box travel from rear fiapfolding section 100 is a bottom flap-gluing station 130, which includes a pair of conventional adhesive-spreading rollers 132 mounted on opposite sides of skid 122 below the path of travel. Liquid adhesive under pressure is controllably supplied to rollers 132 by a conventional mechanism not shown. Such mechanism typically includes an electrically-controlled valve for permitting and arresting adhesive or glue How to the rollers.

As box blank B approaches gluing station the lower front and rear end flaps 26 and 28 retained by skid 122 in a position underlying box blank B and lower side flaps 22 are retained in a generally vertical position by

plate segments

40a and 40b. Forward movement of the box blank is caused by engagement of the laterally-extending side flaps between

conveyor belts

92 and 94. A first glue control microswitch 134 is mounted in the path of the laterally-extending side flaps and is operatively connected to glue rollers 132 so that closure of the microswitch on arrival of the boxblank causes the glue rollers to begin applying glue to the bottom surface of front lower flap 26. Microswitch 134 is mounted in a slot 136 so that the microswitch can be positioned to initiate glue application at the correct location on flap 26. Spaced along the path of travel is a second glue control microswitch 138, actuation of which interrupts glue delivery by rollers 132. Microswitch 138 is positioned so that glue delivery is interrupted at or before the passage of the trailing edge of flap 26. A third glue control microswitch 140 is provided along the path of travel and is adapted to start glue delivery from rollers 132 when the leading edge of flap 28 is in contact with the rollers. A fourth glue control microswitch 142 is spaced along the path of travel from microswitch 140 and is adapted to interrupt glue delivery at or before the trailing edge of flap 28. Because the microswitches are mounted in slot 136, the apparatus is adjustable to permit formation of boxes of various sizes. Thus, it will be seen that after the box blank passes through gluing station 130, front and rear

lower flaps

26 and 28 will have glue lines thereon for securing the lower side flaps 22 thereto for completing the bottom closure of the box.

A lower side flap folding station 144 is spaced along the path of travel from the gluing station. In the inlet end of folding station 144 and below the path of box travel is a pair of vertically-mounted rollers 146, and at the outlet end of the folding station is a pair of horizontally extending rollers 148. Endless belts are carried between

rollers

146 and 148 so that side flaps 22 of the box blank are folded up into contact with

end flaps

26 and 28 during traverse of folding station 144. Consequently as the box blank exits from folding station 144 the bottom closure consisting of end flaps 26 and 28 and side flaps 22 is completed.

The box blank is delivered to a compression section fragmentarily shown in FIG. 1 at 152 which acts to compress the box blank in a folded condition until the glue or like adhesive has cured or set. The determination of the length of compression section 152 depends on the time required for the adhesive to cure and is well within the knowledge of one skilled in the art.

The completed and flattened boxes are then transported, stored and shipped in accordance with conventional practices and are readily available for setting up at the place of use. Because compression belt firmly retains the bottom closure flaps in contact during the curing period of the adhesive, the bottom closure is permanently formed and will not be destroyed or weakened during shipment or subsequent unfolding for use.

Thus, it will be seen that the present invention provides apparatus for folding a box blank into a flattened condition and for permanently forming the bottom closure of such box. Because both the folding and the gluing operations are performed while the box is moving, extremely high speed of operation is obtained. Moreover, because of the particular arrangement of the components of the apparatus, it is adjustable to accommodate boxes and/or box blanks of widely varying sizes.

Although one embodiment of the invention has been shown and described, it will be obvious that other adaptations and modifications can be made without departing from the true spirit and scope of the invention.

What is claimed is:

1. Apparatus for folding a box blank into a flattened condition and for forming the bottom closure of the box blank comprising a first conveyor for engaging the lower flaps of the box blank and propelling the box blank along a path of travel, means adjacent the path of box travel along said first conveyor for folding the side flaps of the box laterally outwardly of the path of travel, a second conveyor in box blank receiving relationship to said first conveyor, said second conveyor engaging only the laterally extending side fiaps of the box blank, and means adjacent the path of travel of the box blank on said second conveyor for folding and gluing the bottom flaps of said box blank to form a bottom closure panel therefor.

2. Apparatus for forming into a box, a box blank that has four side panels each of which includes an upper fold line for defining a top closure flap and a lower fold line for defining a lower closure flap, said folding apparatus comprising an input station for receiving said box blank with the panels in a generally rectangular configuration with the lower forward and rear flaps folded rearwardly, first and second arms pivotally mounted adjacent said receiving station, and laterally thereof means for pivotally driving said arms downwardly and outwardly into contact with the interior surface of the side panels of said box blank, a converging endless conveyor for flattening the forward panel of said box against the rear panel thereof, and means at the outlet end of said converging conveyor for adhesively joining the bottom flaps of said box blank to form a bottom closure therefor.

3. Apparatus for forming into a box a box blank that has four side panels each of which includes an upper fold line for defining a top closure flap and a lower fold line for defining a lower closure flap, said folding apparatus comprising an input station for receiving said box blank with the panels in a generally rectangular configuration and the lower forward and rear flaps folded rearwardly; means disposed in box receiving relation to said input station to define a planar surface for supporting said lower forward and rear flaps siidably thereover; plow means mounted below said planar surface for folding the side lower flaps upwardly into substantial contact with the lower face of said planar surface; conveying means for contacting the lower surface of the folded side flaps and propelling said box blank forwardly so that portions of the box blank above the lower flaps are moved forwardly in unobstructed condition along a path; means in the path for folding the side panels of the box outwardly, said side panel folding means including first and second arms mounted for pivotal movement with respect to axes spaced on opposite sides of the path, means for pivotally driving said arms from a generally horizontal position above the path to a downwardly depending position in engagement interiorly of the side panels, and means responsive to arrival of a box blank at said side panel folding means for actuating said arm driving means whereby the front and rear panels of said box blank will be folded into an upwardly converging position; means spaced along the path from said side panel folding means for compressing the convergent front and rear panels into .a substantially flattened condition; means at the output of said compressing means for engaging the laterally extending side panels and for conveying the flattened box blank forwardly; and means beneath the path of travel of last said means for adhesively joining the bottom flaps to form a bottom closure for said box.

4. Apparatus for forming a box from a box blank having upper and lower front flaps, upper and lower rear flaps, and upper and lower side flaps foldably joined to a body composed for four side panels, said apparatus comprising an input station having a center bar for folding said lower front and rear flaps in trailing horizontal relation, endless conveyor means having a top reach movable away from said input station, said input station including guide means for folding said lower side flaps upwardly beneath said top conveyor reach, means for retaining said lower side flaps in frictional contact with said top conveyor reach so that said box is moved forwardly by said conveyor, a folding station spaced from said input station along said conveyor for folding the side panels of said box blank outwardly, said folding station including a pair of arms mounted for pivotal movement about axes aligned longitudinal of said conveyor and on opposite sides thereof, means for moving said arms to a generally horizontal position above a box in said conveyor to a generally vertical position within the box and in engagernent with the side panels thereof, means for sensing arrival of a box at said folding station and for activating said arm moving means toward the vertical position, a second endless conveyor spaced along the path of box travel from the folding station said conveyor having a forward moving reach disposed in overlying opposed relation to said first conveyor and converging in the direction of movement of said conveyor, so that a box is conveyed and compressed thereby, said guide means having diverging portions spaced from said second belt along the path of travel of said first conveyor for unfolding the side bottom flaps into generally vertically depending relation, means spaced along the path of travel from said diverging portions for folding the rear lower flap for- 'wardly and upwardly of said box into approximately horizontal relationship, means for applying glue to the bottom surface of said forward and rear lower flaps, guide means having a converging portion spaced from said glue applying means along the path of travel of said box for folding said lower side flaps upwardly into contact with glue on the forward and rear lower flaps, and means for compressing said box for a time sufficient for the glue to set.

5. A box forming and folding machine comprising a first endless conveyor having an upper reach for transporting a box along a path; an input structure for said conveyor, said input structure including a longitudinally extending bar ahead of said conveyor and generally coplanar with said upper conveyor reach to afford a support for the lower front and rear flaps of the box, transversely spaced side supports for affording lateral support to a box intermediate said bar and said conveyor, means defining a relatively smooth bearing surface overlying said upper reach in confronting relation thereto and spaced therefrom by an amount sufficient to urge a box flap therebetween into contact with said upper conveyor reach, means intermediate said longitudinally extending bar and said conveyor for folding the lower side flaps against said bearing surface so that the lower side flaps are disposed between said bearing surface and said conveyor for transport thereby; a folding structure spaced from said input structure along the path, said folding structure including a frame mounted above the path, first and second arms pivotally mounted on said frame along axes generally parallel to the path, said arms being pivotally movable between an upper position above a box in the path to a lower position at which the arms contact the inner surface of the top side flaps of said box to bendably deform the flaps outwardly, the front panel and upper front fiap being folded rearwardly in response to outward folding of the upper side flaps, a second end less conveyor having a lower reach said above said first conveyor in confronting relation thereto, said second conveyor converging toward said first conveyor along the path and having an input end in box receiving relation to said pivotally mounted arms so that a box between said first and second conveyors is folded fiat on transport between said conveyors; a lower flap gluing station spaced from said folding structure along the path, said gluing station including upper and lower endless conveyors at the output of said first and second conveyors, said upper and lower conveyors each including laterally spaced belts for engaging only the laterally extending side flaps of the box, a lower side flap guide mounted between said laterally spaced belts for folding the side flaps downwardly in generally vertical depending relation, a frame overlying said laterally spaced belts, a rear flap pusher mounted on said frame for pivotal movement about an axis generally transverse of the path, means responsive to the arrival of a box beneath said pusher for pivotally actuating said pusher to move the lower rear flap of said box forwardly and beneath the box into a horizontal position, means for applying glue to the lower surfaces of said front and rear lower flaps, means for folding the side lower flaps into contact with the lower glued surface of said front and rear flaps; and conveyor means for compressing said box for a duration sufficient to permit the glue to set.

6. A method for forming and folding a box comprising the steps of transporting the box along a path, folding the front and rear lower flaps in trailing relation to the box, folding the lower side flaps into substantially coplanar relationship With the trailing flaps, pulling the lateral panels outwardly and downwardly of the box, compressing the outwardly folded panels to flatten the box, unfolding the bottom side panels, folding the rear bottom flap forwardly, applying adhesive to the bottom surface of the front and rear flaps, folding the side flaps into contacting relation with the adhesive on the front and rear flaps, and retaining the box in a compressed condition for a duration suflicient to cure the adhesive.

References Cited UNITED STATES PATENTS BERNARD STICKNEY, Primary Examiner.

Claims

1. APPARATUS FOR FOLDING A BOX BLANK INTO A FLATTENED CONDITION AND FOR FORMING THE BOTTOM CLOSURE OF THE BOX BLANK COMPRISING A FIRST CONVEYOR FOR ENGAGING THE LOWER FLAPS OF THE BOX BLANK AND PROPELLING THE BOX BLANK ALONG A PATH OF TRAVEL, MEANS ADJACENT THE PATH OF BOX TRAVEL ALONG SAID FIRST CONVEYOR FOR FOLDING THE SIDE FLAPS OF THE BOX LATERALLY OUTWARDLY OF THE PATH OF TRAVEL, A SECOND CONVEYOR IN BOX BLANK RECEIVING RELATIONSHIP TO SAID FIRST CONVEYOR, SAID SECOND CONVEYOR ENGAGING ONLY THE LATERALLY EXTENDING SIDE FLAPS OF THE BOX BLANK, AND MEANS ADJACENT THE PATH OF TRAVEL OF THE BOX BLANK ON SAID SECOND CONVEYOR FOR FOLDING AND GLUING THE BOTTOM FLAPS OF SAID BOX BLANK TO FORM A BOTTOM CLOSURE PANEL THEREFOR.