WO1999065668A1

WO1999065668A1 - Manufacture of boxes

Info

Publication number: WO1999065668A1
Application number: PCT/IL1999/000328
Authority: WO
Inventors: Avi Marom
Original assignee: Ima Engineering Ltd
Current assignee: Ima Engineering Ltd
Priority date: 1998-06-15
Filing date: 1999-06-15
Publication date: 1999-12-23
Anticipated expiration: 2000-12-15
Also published as: IL124920A0; AU4288399A

Abstract

A method of assembling into a four-sided, generally tubular article for erection into a container, first (10a) and second planar blanks (10b), each having first (12) and second rectangular panels (14) mutually connected along a primary fold line, the first panel having a first edge portion extending parallel to the primary fold line and having a connection tab (20b) extending therealong, the second panel having a second edge portion formed distally of the first edge portion and being formed parallel thereto; wherein each panel has one or more transverse end flaps, foldable about a secondary fold line, transverse to the primary fold line, so as to cooperate with the one or more end flaps of the other panel so as to form a box panel therewith once assembled.

Description

MANUFACTURE OF BOXES

FIELD OF THE INVENTION The present invention relates generally to the manufacture of corrugated cardboard boxes and, in particular, to outsized corrugated cardboard boxes.

BACKGROUND OF THE INVENTION Prism-shaped corrugated cardboard boxes have been known for many years, and are widely used for storage and transportation of many different types of goods in many different fields. This type of cardboard box, known also as a 'slotted carton', is shown fully assembled in Fig. 10, and is manufactured from a blank having four rectangular panels, shown as a, b, c and d, in Fig. 11. The four rectangular panels are connected along parallel fold lines, e, f and g, which, upon assembly, become three of the four corner edges e', f and g' of the box, as seen in Fig. 10. The fourth corner is formed by a connection between an additional side tab p of panel a, and free edge q of panel d. Upon fastening side tab p, such as by gluing, to edge portion q of panel d, as an initial step in assembly of the box, the blank takes on a generally flattened, tubular form, as seen in Fig. 12. Each panel typically has a pair of transverse end flaps, denoted j and k, which are foldable about transverse fold lines m and n, respectively, so as to cooperate with the remaining j and k flaps, respectively, so as to form the top and bottom panels of the box, once assembled.

These boxes are conveniently manufactured, as described, from a single portion of die cut corrugated cardboard, and are assembled by use of a so-called folder-gluer machine, which are well known, per se, in the art. Known folder-gluers are constructed to accept a width-wise feed of a box blank, and fold the side panels of the box laterally inward, along fold lines which are parallel to the direction of feed. This type of "lateral-feed" machine is satisfactory for producing many of the standard sizes of slotted cartons.

Referring now to Figs. 13 and 14, however, it is seen that, if it is sought to increase the size of the carton to, for example, a carton which is double the size, the overall width of the blank increases accordingly. It will thus be appreciated that construction of a lateral-feed folder gluer for large size boxes may become very expensive and uneconomical.

US Patent No. 4,650,448, entitled "Machine For Forming Full Overlap Shipping Container," describes a machine for forming a full overlap-type shipping container from two similar blanks. This container has double thickness in both the end flaps and the laminated side walls. The machine has a pair of conveyors arranged at right angles to each other. A first blank is transported on a main conveyor to a retractable stop located at a first combining section. Adhesive is applied to one of the side panels during transport. A second blank is then transported on a cross-conveyor to a second stop, and one side panel of this blank is positioned over the adhesive covered panel of the first blank, after which pressure is applied. Assembly can then be completed, in which case the combined blanks are transported to a second combining station. During transport, adhesive is appropriately applied to a second side panel. A retractable stop holds the panel in place while folder arms are activated so as to complete the assembly.

The above-described system is based on a pair of conveyers, combining stations and gluing stations, and is thus very bulky and expensive.

SUMMARY OF THE INVENTION The present invention seeks to provide an improved method and system for manufacturing outsized corrugated cartons, particularly slotted cartons, which is simpler, less expensive, and less bulky than known in the art.

There is thus provided, in accordance with a preferred embodiment of the invention, a method of assembling into a four-sided, generally tubular article for erection into a container, first and second planar blanks, each having first and second rectangular panels mutually connected along a primary fold line, the first panel having a first edge portion extending parallel to the primary fold line and having a connection tab extending therealong, the second panel having a second edge portion formed distally of the first edge portion and being formed parallel thereto; wherein each panel has one or more transverse end flaps, foldable about a secondary fold line, transverse to the primary fold line, so as to cooperate with the one or more end flaps of the other panel so as to form a box panel therewith once assembled, wherein the method includes the following steps: a) arranging the first and second blanks along a conveying axis so that the primary fold lines are generally perpendicular thereto, and so that, with respect to a direction of travel, the first edge portion of each blank is a leading edge portion, and the second edge portion of each blank is a trailing edge portion; b) conveying the first blank longitudinally along the conveying axis so as to bring the trailing edge portion thereof into alignment with an adhesive applying station; c) applying adhesive to an upward facing surface of the trailing edge portion of the first blank; d) conveying the second blank longitudinally along the conveying axis so as to bring the connection tab thereof into mutually adhering contact with the upward facing surface of the trailing edge portion of the first blank, thereby to form a composite blank; e) folding the first panel of the first blank about the primary fold line thereof, thereby to fold the first panel of the first blank over the second panel thereof; f) applying adhesive to an upward facing surface of the connection tab of the first blank; and g) folding the second panel of the second blank about the primary fold line thereof, thereby to fold the second panel of the second blank down onto the adhesive bearing connection tab of the first blank, thereby to form a four-sided, generally tubular article.

Additionally in accordance with the preferred embodiment of the present invention, in steps c) and f), the steps of applying adhesive include application of adhesive along a predetermined adhesive application path, transverse to the conveying axis.

Further in accordance with a preferred embodiment of the present invention, the method also includes, prior to step e) of folding, conveying the composite blank longitudinally along the conveying axis into a position which is predetermined such that step e) of folding brings the connection tab of the first blank into alignment with the adhesive application path. Additionally in accordance with a preferred embodiment of the present invention, in each of steps d) and g), there is included the sub-step of applying pressure to the portions of the first and second blanks to be adhered to each other.

Further in accordance with a preferred embodiment of the present invention, the method also includes, prior to steps c) and f) of applying adhesive, straightening the blank bearing the surface to which adhesive is to be applied, so as to be parallel with the adhesive application path.

Additionally in accordance with a preferred embodiment of the present invention, the method also includes after step g), the following additional steps: h) conveying the four-sided article longitudinally along the conveying axis to an adjustable support platform arranged adjacent to an exit conveyor, and elevated thereabove; i) arranging the four-sided articles in vertical registration with other similar four-sided articles, so as to form a stack thereof, j) lowering the adjustable support platform in accordance with the height of the stack, until the adjustable support platform is level with the height of the exit conveyor; and k) conveying the stack away.

There is also provided in accordance with an additional preferred embodiment of the invention, an article formed in accordance with the above method.

There is also provided in accordance with a further preferred embodiment of the invention, apparatus for assembling into a four-sided, generally tubular article for erection into a container, first and second planar blanks, each having first and second rectangular panels mutually connected along a primary fold line, the first panel having a first edge portion extending parallel to the primary fold line and having a connection tab extending therealong, the second panel having a second edge portion formed distally of the first edge portion and being formed parallel thereto; wherein each panel has one or more transverse end flaps, foldable about a secondary fold line, transverse to the primary fold line, so as to cooperate with the one or more end flaps of the other panel so as to form a box panel therewith once assembled, wherein the apparatus includes: a) a longitudinal folder gluer having a conveyor for conveying the first and second blanks between a feed end and a discharge end, and defining a conveying axis which extends therebetween, so that the primary fold lines are generally perpendicular thereto, and so that, with respect to a direction of travel, the first edge portion of each blank is a leading edge portion, and the second edge portion of each blank is a trailing edge portion; b) adhesive applying apparatus located between the feed and discharge ends for applying adhesive to a preselected upward facing surface of each blank; and c) folding apparatus located between the feed and discharge ends for folding a preselected panel of each blank in a predetermined direction about the primary fold line thereof, thereby to facilitate formation of a joint between preselected edges of preselected blanks, and thereby to facilitate assembly of a four-sided, generally tubular article, configured for erection into a box.

Further in accordance with the further preferred embodiment of the present invention, the adhesive applying apparatus includes apparatus for applying adhesive along a predetermined adhesive application path, transverse to the conveying axis.

Additionally in accordance with the further preferred embodiment of the present invention, there is also included a pressure element for applying adhesion pressure to a pair of overlapping adhesive-bearing portions of the first and second blanks, thereby to form a joint therebetween.

Further in accordance with the further preferred embodiment of the present invention, there is also included: apparatus, arranged at the feed end of the folder gluer, for feeding the blanks into the folder gluer; and apparatus, arranged at the discharge end of the folder gluer, for discharging the assembled tubular articles from the folder gluer.

Additionally in accordance with the further preferred embodiment of the present invention, there is also included straightening apparatus associated with the folder-gluer, for straightening blanks conveyed therealong, thereby to maintain parallel alignment between a preselected axis of symmetry of the blanks and the conveying axis. Preferably in accordance with the further preferred embodiment of the present invention, there is also included: an adjustable height support platform arranged adjacent to the feed end of the folder gluer, operative to support a stack of the blanks thereon; and a gripper and feeder, associated with the folder gluer, for gripping the top one of the stack of blanks and for feeding it onto the conveyor.

Preferably in accordance with the further preferred embodiment of the present invention, there is also included: an adjustable height support platform arranged between the discharge end of the folder gluer and a discharge conveyor, operative to receive assembled tubular articles discharged from the discharge end of the folder gluer and to facilitate selectable transfer of the articles to the discharge conveyor; and apparatus for forming a vertical stack of the discharged articles.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:

Figs. 1A and IB are respective plan and end views of a carton blank used for manufacturing a four-sided, generally tubular article for erection into a container, in accordance with a preferred embodiment of the present invention;

Figs. 2 A and 2B are respective plan and end views of first and second carton blanks, such as those seen in Figs. 1A and IB, prior to assembly;

Figs. 3 A and 3B are respective plan and end views of the pair of carton blanks seen in Figs. 2 A and 2B, during application of an adhesive to a trailing edge of the first carton blank, and immediately prior to placement of a connection tab of the second carton blank in adhesive contact with the trailing edge of the first carton blank;

Figs. 4A and 4B are respective plan and end views of the carton blanks seen in Figs. 3A and 3B, immediately after assembly thereof, and during application of pressure along a join therebetween, thereby to assemble the blanks into an integral, composite blank; Figs. 5 A and 5B are respective plan and end views of the composite blank seen in Figs. 4A and 4B, showing rearward folding of the front panel of the first blank, and application of adhesive to the connection tab thereof;

Figs. 6A and 6B are respective plan and end views of the composite blank seen in Figs. 5 A and 5B, showing forward folding of the rear panel of the second blank into engagement with the adhesive-coated connection tab of the first blank, and application of pressure along the join therebetween, thereby to form a four-sided, generally tubular article for erection into a box, in accordance with a preferred embodiment of the present invention, seen in a flattened position in the drawings; Figs. 7A and 7B are a front elevation of apparatus for assembling the flattened tubular article of Figs. 6A and 6B, during use thereof, in accordance with a preferred embodiment of the invention;

Figs. 7C, 7D, 7E, 7F, and 7G are respective enlarged views of portions of details C, D, E, F, and G in Figs 7A and 7B; Fig. 7H is an enlarged perspective view of a portion referenced H, of the apparatus in Fig. 7B;

Figs. 8 A and 8B are plan views of the apparatus of Figs. 7 A and 7B;

Figs. 8C, 8D, and 8E are respective enlarged views of portions of details C, D, and E in Figs. 8 A and 8B; Fig. 9 is a cross-sectional view taken along the line X — X of FIG. 7 A; and

Figs. 9A and 9B are respective enlarged views of portions of details A and B in Fig. 9.

Fig. 10 is an isometric view of a slotted carton as known in the PRIOR ART;

Fig. 11 is a plan view of a one-piece carton blank as known in the PRIOR ART, for forming the carton of Fig. 10;

Fig. 12 is an isometric view of a four-sided, generally tubular article formed from the blank of Fig. 11, for erection into the carton of Fig. 10;

Fig. 13 is an isometric view of an outsize slotted carton as known in the PRIOR ART; Fig. 14 is a plan view of a one-piece carton blank as known in the PRIOR

ART, for forming the outsize carton of Fig. 13; DETAILED DESCRIPTION OF THE PRESENT INVENTION Referring now to Figs. 1A and IB, there is seen a planar blank, referenced generally 10, for manufacturing a four-sided, generally tubular article for erection into a container, such as seen in Fig. 13, in accordance with a preferred embodiment of the present invention. Blank 10 is preferably formed of a strong, environment-friendly material, such as, corrugated cardboard, but, alternatively may be formed of any other suitable paper or plastic sheet material.

Blank 10 has first and second rectangular panels, respectively referenced 12 and 14, which are joined to each other along a primary fold line 16. As will be understood from the description of the method of the invention hereinbelow in conjunction with Figs. 7-9, blank 10 is fed into a folder-gluer 100, such that primary fold line 16 is perpendicular to a direction of feed along a conveying axis 110 defined by the folder-gluer 100. Accordingly, various portions of blank 10 are described herein as being front, forward, rear, trailing, it being understood that these are with respect to the feed direction into and through the folder-gluer.

The first panel 12 has a first edge portion 18 which extends parallel to the primary fold line 16, and has formed therealong a connection tab 20. The second panel 14 has a second edge portion 22 which is parallel to the first edge portion 18, and is located distally thereof. Both panels 12 and 14 have at least one, but preferably two transverse end flaps 24, which are foldable about secondary fold lines 26, transverse to the primary fold line 16, so as to cooperate with other end flaps 24 so as to form therewith top and/or bottom box panels, once assembled.

Referring now to Figs. 2A-6B, assembly of a flattened tubular article from which a box is intended to be erected, is now described. As seen in Figs. 2A and 2B, a pair of blanks 10 are depicted herein as first blank 10a and second blank 10b. The various folds and portions of blanks 10a and 10b, described above in conjunction with blank 10 of Figs. 1A and IB, are depicted in Figs. 2A-6B with similar reference numerals, but with the addition of an appropriate a or b suffix. First blank 10a and second blank 10b are arranged along conveying axis 110, so that primary fold lines 16a and 16b are generally perpendicular thereto, and so that, with respect to the direction of travel, indicated by arrow 28 (Fig. 2A), first edge portions 18a and 18b of blanks are leading edge portions, and second edge portions 22a and 22b of blanks 10a and 10b are trailing edge portions.

As shown schematically in Figs. 3 A and 3B, the first blank 10a is fed longitudinally along conveying axis 110 so as to bring the trailing edge portion thereof, referenced 22a, into alignment with an adhesive applying station 112. At station 112, a strip 30 (Fig. 3 A) of an adhesive, preferably a hot melt adhesive, is applied, preferably by spraying, onto an upward-facing surface of trailing edge portion 22a, after which, as indicated by arrow 32, second blank 10b is conveyed along conveying axis 110 so as to bring the connection tab 20b thereof into mutually adhering contact with the upward facing surface of the adhesive-bearing trailing edge portion 22a of first blank 10a.

As seen in Figs. 4A and 4B, pressure, indicated by a downward-pointing arrow 36, is applied along the joint 34 between the first and second blanks 10a and 10b, thereby to form a composite blank, denoted generally by the reference numeral 10'.

Referring now to Figs. 5A-6B, in order to complete the closed, tubular shape depicted in Fig. C, the first panel 12a of first blank 10a and the second panel 14b of second blank 10b, are folded onto each other and joined.

In more detail, and referring first to Figs. 5 A and 5B, the first panel 12a of first blank 10a is folded rearwardly about primary fold line 16a, as indicated by arrows 36 and 38, so as to lay flat on second panel 14a of first blank 10a, and on a forward portion of first panel 12b of second blank 10b, such that connection tab 20a is brought into vertical registration with adhesive applying station 112. Thereafter, a strip 40 (Fig. 5 A) of an adhesive, preferably a hot melt adhesive, is applied, preferably by spraying, onto an upward-facing surface of connection tab 20a.

Referring now to Figs. 6 A and 6B, the second panel 14b of second blank 10b is folded forwardly about primary fold line 16b, as indicated by arrows 42 and 44, such that a trailing edge portion thereof, referenced 22b, is brought into adhesive engagement with the adhesive bearing upward-facing surface of connection tab 20a (Fig. 5A), so as to form a second joint 46. Subsequently, as indicated by a downward-pointing arrow 48, pressure is applied along the second joint 46, thereby to form the closed, tubular shape depicted in Fig. C, which may then be conveyed away by any suitable means, for erection as a box. Referring now to Figs. 7-9, there is now described apparatus, referenced generally 60, for manufacturing the flattened tubular article of Figs. 6A and 6B, in accordance with the method shown and described above in conjunction with Figs. 2A-6B. Apparatus 60 is characterized by the provision of longitudinal feed folder-gluer

100, constructed in accordance with a preferred embodiment of the present invention, which has a feed end, referenced generally 62, and a discharge end 64 (Figs. 7 and 8). A pair of individual blanks 10 (Figs. 1A and IB) are fed into feed end 62, they are folded and glued as described above in conjunction with Figs. 2A-6B, and the flattened, tubular composite forms that are assembled in the folder-gluer, are discharged from discharge end 64 for shipping.

Adjacent to feed end 62 of folder-gluer 100 is an adjustable height feed platform, referenced 66, which receives a stack 101 of blanks 10 from a feed conveyor 68 (Fig. 8B). Feed platform 66 incorporates a roller conveyor 180, which operates by means of rollers 181 driven by a motor 70. In use, feed platform 66 is adjusted preferably automatically by means of a suitable lift table 69 (Fig. 7B), which is operative to incrementally raise the height of feed platform 66 after each blank is removed therefrom and fed into the folder gluer 100. An example of a suitable lift table which may be incorporated into feed platform 66, is the MarcoLift table, produced by Marco AB, Box 1080, S-262 01 Angelholm, Sweden, which employs a scissor unit for height adjustment.

Adjacent to discharge end 64 of folder gluer 100 is an adjustable height discharge platform 72, which is typically similar to feed platform 66, and which is operative to receive an accumulated stack 166 of flattened composite forms thereon, as these are discharged, one by one, from folder gluer 100 (Figs. 7 and 8). There is also provided suitable apparatus, which may be a plurality of vertically suspended mechanical pushers 76, for straightening the forms as they are discharged from folder gluer 100. A discharge conveyor 74 is located adjacent to discharge platform 72 (Fig. 8 A). As the stack 166 of composite forms on the discharge platform 72 increases, the platform is lowered incrementally by means of an incorporated lift table 73 (Fig. 7A) similar to the lift table described above in conjunction with feed platform 66. Once the height of the platform 72 reaches the height of the discharge conveyor 74, the stack 166 of composite forms is transferred thereto for packing and shipping.

Folder gluer 100 typically includes a chain conveyor 106 (Figs. 7 and 8) which is operative to selectably convey blanks 10 longitudinally along conveying axis 110 for the various gluing and folding operations described above in conjunction with Figs. 2A-6B. Chain conveyor 106 includes a pair of chains 106a and 106b (Figs. 8A and 8B), which are mounted onto a frame support 108 via a suitable pair of drive wheels 109 (Figs. 7C and 8C) and a pair of idler wheels 111 (Fig. 8D). A laterally positioned rotatable axle 107 (Fig. 8 A), driven by a motor 107a, connects drive wheels 109, which, together with idler wheels 111, are operative to drive conveyor chains 106a and 106b.

Frame support 108 includes a first, upper pair of longitudinally extending support members 113, between which extend a plurality of transverse bracing members 114 (Figs. 8A and 8B). Frame support 108 also includes a second, lower, pair of longitudinally extending support members 115 upon which wheels 109 and 111 are mounted, as well as a plurality of vertically extending stand elements 116 (Figs. 7 A and 7B) for supporting frame 108 when placed on a suitable horizontal surface.

A vacuum gripper and feeder 117, which includes a driving mechanism 118 driven by a motor 119, is mounted via transverse bracing members 114 to a rear end 120 of frame support 108 (Figs. 7B and 8B). A reciprocally movable linear support member 121, is drivingly engaged by driving mechanism 118 at one end, and supports a transverse elongate member 122 (Figs. 7H and 8B) at the other end. Preferably, elongate member 122 is suspended from support member 121 by means of a pneumatic piston 121a so as to allow for relative movement therebetween (Fig. 7H). Attached to elongate member 122 are at least a pair of selectably pressurizable suction cups 123 which are resiliently mounted upon end portions 122a and 122b of elongate member 122, via rods 125a and 125b (Fig. 7H). As is described hereinbelow, suction cups 123 cooperate with adjustable feed platform 66, so as to engage and grip the uppermost of a stack 101 of blanks thereon, and to feed it between a pair of feed rollers, respectively referenced 124 and 126 (Fig. 7D).

Typically, the connector tab 20 of a blank 10 is fed between rollers 124 and 126, whereupon upper roller 124 is lowered onto blank 10, typically by means of suitable actuators 167 (Fig. 7D), such as pneumatic actuators. As upper roller 124 is lowered, the connection tab 20 of blank 10 is pinched lightly between the two rollers, and lower, drive roller 126 is rotated by means of a suitable motor 128 (Fig. 7B) so as to feed blank 10 between rollers 124 and 126 and onto chain conveyor 106. Located at the adhesive applying station 112 (Fig. 8 A) is a hot melt glue spraying unit 130 (Figs. 7-9) which is associated with a glue reservoir 131 (Figs. 7A and 8A). Glue spraying unit 130 includes a nozzle 132 (Fig. 9) supported by a lateral support arm 133 (Figs. 8 A and 9), which is drivingly engaged by a driving mechanism 134 (Figs. 8 A and 9) actuated by a suitable motor 135. In a preferred embodiment of the invention, nozzle 132 projects beneath support arm 133 (Fig. 9), and is used for applying adhesive strips 30 (Fig. 3A) and 40 (Fig. 5A), in registration with a predetermined adhesive application path, generally parallel to support arm 133.

A pressure element 136 (Figs. 7-9), formed typically as a roller and actuated by motor 137, is mounted for selectable pivoting about a laterally positioned axle 138, so as to apply the above-described pressing force along joints 34 and 46 (Figs. 4B and 6B).

In order to perform the folding operations described above in conjunction with Figs. 5A and 5B, and Figs. 6A and 6B, respectively, there are provided a first, rearward folding member, referenced 140, and a second, forward folding member, referenced 142 (Figs. 7A and 8 A).

First folding member 140 has an elongate, lateral, panel engaging member 144, which is typically supported by a pair of arms 146, and mounted via a pivot element 147, for selectable pivoting about a first pivot axis 148 (Fig. 7A). Second folding member 142 has an elongate, lateral, panel engaging member 150, which is typically supported by a pair of arms 152, and mounted via pivot element 153, for selectable pivoting about a second pivot axis 154 (Fig.7A). Folding members 140 and 142 are selectably actuated via suitable motors 149 and 155.

Operation of apparatus 60 in performing the method of the invention, described above in conjunction with Figs. 2A-6B, is now described. Stack 101 of blanks 10 is placed, typically by use of a forklift (not shown), onto feed conveyor 68 (Fig. 8B), after having been cut and printed as desired. Stack 101 is moved along feed conveyor 68 and delivered onto feed platform 66 (Figs. 7B and 8B), whereupon conveyor 180 is operative to align the blanks 10 against a support wall 156 such that a longitudinal axis of symmetry 15 of each blank 10 coincides with conveying axis 110 (Fig. 8B).

At this point, an operator activates the folder-gluer 100 by use of an appropriate switch (not shown), so as to actuate it as follows:

The feed platform 66, driven by lift table 69, is initially elevated, whilst at the same time elongate member 122 supported by piston 121a (Fig. 7H) is lowered, so that a first blank, referenced 10a (also seen in Figs. 2A-6B), engages vacuum cups 123.

Once vacuum cups 123 grip blank 10a, they continue to rise together with feed platform 66, until an end segment 127 of rod 125b interrupts the line of sight / of an optical sensor 129, which may be mounted upon elongate member 122 as illustrated in Fig. 7H. The sensor then sends a command to a programmed controller (not shown) whereupon feed platform 66 is lowered by a pre-determined amount, and elongate member 122 is raised by piston 121a to an appropriate height, so as to enable placement of blank 10a upon lower entry roller 126, as linear support member 121 moves the vacuum cups closer towards feed end 62 of folder-gluer 100. Thereafter, upper entry roller 124 is lowered onto blank 10a by means of actuators 167 (Fig. 7D), such that the blank becomes lightly gripped between rollers 124 and 126. Lower roller 126 is then rotated for continued feeding of blank 10a into the folder gluer 100 along axis 110.

Blank 10a thus enters the folder gluer 100 and is guided therethrough with the aid of pushers 170 which are mounted onto conveyor chains 106a and 106b. A suitably positioned optical sensor (not shown), attached to a side of frame support 108, signals motor 107a to cease operation upon detection of leading edge 18a, so that the passage of blank 10a is brought to a halt with its trailing edge 22a coming to rest within adhesive applying station 112 (Fig. 8A). Thereafter, lateral straightening members 173 (Figs. 8E and 9A) - which typically take the form of a pair of reciprocating straightening plates running the length of frame 108, and driven by pneumatic pistons 174 (Figs. 8E and 9 A) - are operative to straighten the blank, so that its leading edge 18a is perpendicular to conveying axis 110. A set of pivotable grippers 178 (Figs. 7A, 8 A, 9B), operated by actuators 179 (Fig. 9B), then engage first blank 10a, so as to ensure that the blank remains in position. Once blank 10a has been suitably positioned and secured as described, a second blank 10b (also seen in Figs. 2A-6B) is fed in similar fashion between entry rollers 124 and 126. Second blank 10b is brought to a halt in the center portion of the machine by means of centrally positioned, vertically extending, stop members 182, which are operated by actuators 184 (Figs. 7E and 9). The glue spraying unit 130 is then actuated so as to travel along arm 133 (Figs. 8 A and 9), and to spray a strip 30 of adhesive onto rear portion 22a of first blank 10a, as described above in conjunction with Figs. 3 A and 3B.

Stop members 182 are then retracted and second blank 10b is pushed onto first blank 10a by means of a pivotable pusher 188 (Fig. 7F), operated by an actuator 190, such that connection tab 20b on the leading edge 18b of blank 10b, overlaps the adhesive bearing rear portion 22a of blank 10a. During this process, first blank 10a is held in position, by means of a second pivotable pusher 192, and associated actuator 194 (Fig. 7G). Lateral straightening members 173 then straighten second blank 10b which is subsequently also gripped by grippers 178. Thereafter, pressure element 136 is rotated downwardly, as shown by arrow 158 (Fig. 7 A), thereby pressing the two blanks 10a and 10b together so as to form composite blank 10', as shown and described above in conjunction with Figs. 4A and 4B. Following this process, pressure element 136 and grippers 178 release composite blank 10', which is thereafter conveyed along conveying axis 110 with the aid of pushers 170. A further suitably positioned optical tracking sensor (not shown), is used to determine the appropriate positioning of composite blank 10' for folding and further gluing as described below. Initially, the first folding mechanism 140 folds the larger, first panel 12a of first blank 10a about primary fold line 16a (Figs. 5 A and 5B), whereafter the partly folded composite blank 10' is straightened by lateral straightening members 173 and the blank is once again engaged by grippers 178. The glue spraying unit 130 is actuated for a second time, thereby spraying a further strip 40 of adhesive onto connector tab 20a, as shown and described above in conjunction with Figs. 5A and 5B.

The second shorter, folding mechanism 142 is then operative to fold the smaller, second panel 14b of second blank 10b about primary fold line 16b (Figs. 5 A and 5B), so as to enable the folding of trailing edge portion 22b thereof onto adhesive bearing connector tab 20a. The folded composite blank 10' is once again straightened by lateral straightening members 173 (Figs. 8E and 9A), and the pressure element 136 is once more rotated downwardly, as shown by arrow 158 (Fig. 7 A), thereby pressing edge portion 22b onto connector tab 20a so as to form joint 46. As shown and described above in conjunction with Figs. 6A and 6B, the above process completes the assembly of a flattened, four- sided tubular box blank, referenced 10" (Fig. 8 A).

Following assembly of the above-described tubular box blank 10", grippers 178 release the composite box blank 10" which is then conveyed away from folder gluer 100 by means of rotating exit rollers 162 and 164 (Fig. 7 A), which operate in a generally similar manner to that of entry rollers 124 and 126, and which are thus not described herein, in detail. Box blanks 10" exiting folder gluer 100 in this manner thereafter descend onto discharge platform 72 (Figs. 7 A and 8 A).

As described hereinabove, a plurality of box blanks 10" is allowed to accumulate on platform 72 in a stack 166, whereupon pushers 76 are operative to straighten the blanks as they are discharged from folder gluer 100. With the addition of each box blank 10" to the stack, the discharge platform 72 - aided by lift table 73 and a suitably positioned optical sensor (not shown) similar to those employed by feed platform 66 - descends so as to accommodate the next box blank 10". Once platform 72 has reached the height of discharge conveyer 74 (Fig. 8 A), the stack 166 is moved thereonto with the aid of a roller conveyor 195 (Figs. 7 A and 8 A). Thereafter, the stack 166 is conveyed away for tying and wrapping.

It will be appreciated, by persons skilled in the art that the scope of the present invention is not limited by what has been shown and described hereinabove, in conjunction with any of the embodiments. Rather, the scope of the invention is limited solely by the claims, which follow.

Claims

1. A method of assembling into a four-sided, generally tubular article for erection into a container, first and second planar blanks, each having first and second rectangular panels mutually connected along a primary fold line, the first panel having a first edge portion extending parallel to the primary fold line and having a connection tab extending therealong, the second panel having a second edge portion formed distally of the first edge portion and being formed parallel thereto; wherein each panel has at least one transverse end flap, foldable about a secondary fold line, transverse to the primary fold line, so as to cooperate with at least the at least one end flap of the other panel so as to form a box panel therewith once assembled, wherein said method includes the following steps: a) arranging the first and second blanks along a conveying axis so that the primary fold lines are generally perpendicular thereto, and so that, with respect to a direction of travel, the first edge portion of each blank is a leading edge portion, and the second edge portion of each blank is a trailing edge portion; b) conveying the first blank longitudinally along said conveying axis so as to bring the trailing edge portion thereof into alignment with an adhesive applying station; c) applying adhesive to an upward facing surface of the trailing edge portion of the first blank; d) conveying the second blank longitudinally along said conveying axis so as to bring the connection tab thereof into mutually adhering contact with the upward facing surface of the trailing edge portion of the first blank, thereby to form a composite blank; e) folding the first panel of the first blank about the primary fold line thereof, thereby to fold the first panel of the first blank over the second panel thereof; f) applying adhesive to an upward facing surface of the connection tab of the first blank; and g) folding the second panel of the second blank about the primary fold line thereof, thereby to fold the second panel of the second blank down onto the adhesive bearing connection tab of the first blank, thereby to form a four-sided, generally tubular article.

2. A method according to claim 1 wherein, in said steps c) and f), the steps of applying adhesive include application of adhesive along a predetermined adhesive application path, transverse to said conveying axis.

3. A method according to claim 2, wherein said method includes, prior to said step e) of folding, conveying the composite blank longitudinally along said conveying axis into a position which is predetermined such that said step e) of folding brings said connection tab of the first blank into alignment with said adhesive application path.

4. A method according to claim 1, wherein, in each of steps d) and g), there is included the sub-step of applying pressure to the portions of the first and second blanks to be adhered to each other.

5. A method according to claim 1, wherein said method includes, prior to said steps c) and f) of applying adhesive, straightening the blank bearing the surface to which adhesive is to be applied, so as to be parallel with said adhesive application path.

6. A method according to claim 1, wherein, said method includes after said step g), the following additional steps: h) conveying the four-sided article longitudinally along said conveying axis to an adjustable support platform arranged adjacent to an exit conveyor, and elevated thereabove; i) arranging the four-sided articles in vertical registration with other similar four-sided articles, so as to form a stack thereof; j) lowering the adjustable support platform in accordance with the height of the stack, until the adjustable support platform is level with the height of the exit conveyor; and k) conveying the stack away.

7. An article formed in accordance with the method of claim 1.

8. Apparatus for assembling into a four-sided, generally tubular article for erection into a container, first and second planar blanks, each having first and second rectangular panels mutually connected along a primary fold line, the first panel having a first edge portion extending parallel to the primary fold line and having a connection tab extending therealong, the second panel having a second edge portion formed distally of the first edge portion and being formed parallel thereto; wherein each panel has at least one transverse end flap, foldable about a secondary fold line, transverse to the primary fold line, so as to cooperate with at least the at least one end flap of the other panel so as to form a box panel therewith once assembled, wherein said apparatus includes: a) a longitudinal folder gluer having a conveyor for conveying the first and second blanks between a feed end and a discharge end, and defining a conveying axis which extends therebetween, so that the primary fold lines are generally perpendicular thereto, and so that, with respect to a direction of travel, the first edge portion of each blank is a leading edge portion, and the second edge portion of each blank is a trailing edge portion; b) adhesive applying apparatus located between said feed and discharge ends for applying adhesive to a preselected upward facing surface of each blank; and c) folding apparatus located between said feed and discharge ends for folding a preselected panel of each blank in a predetermined direction about the primary fold line thereof, thereby to facilitate formation of a joint between preselected edges of preselected blanks, and thereby to facilitate assembly of a four-sided, generally tubular article, configured for erection into a box.

9. Apparatus according to claim 8, wherein said adhesive applying apparatus includes apparatus for applying adhesive along a predetermined adhesive application path, transverse to said conveying axis.

10. Apparatus according to claim 8, also including a pressure element for applying adhesion pressure to a pair of overlapping adhesive-bearing portions of the first and second blanks, thereby to form a joint therebetween.

11. Apparatus according to claim 8, wherein said folding apparatus includes: first folding apparatus arranged, with respect to a direction of conveying, upstream of said discharge end, and operative to selectably fold the first panel of the first blank about its primary fold line, so as to bring the first panel of the first blank into touching contact with the second panel of the first blank; and second folding apparatus arranged, with respect to the direction of conveying, downstream of said feed end, and operative to selectably fold the second panel of the second blank about its primary fold line, so as to bring an edge portion of the second panel of the second blank into overlapping touching contact with an edge portion of the first panel of the first blank.

12. Apparatus according to claim 8, and also including: apparatus, arranged at said feed end of said folder gluer, for feeding the blanks into said folder gluer; and apparatus, arranged at said discharge end of said folder gluer, for discharging the assembled tubular articles from said folder gluer.

13. Apparatus according to claim 8, and including straightening apparatus associated with said folder-gluer, for straightening blanks conveyed therealong, thereby to maintain parallel alignment between a preselected axis of symmetry of the blanks and said conveying axis.

14. Apparatus according to claim 8, and also including: an adjustable height support platform arranged adjacent to said feed end of said folder gluer, operative to support a stack of the blanks thereon; and a gripper and feeder, associated with said folder gluer, for gripping the top one of the stack of blanks and for feeding it onto said conveyor.

15. Apparatus according to claim 8, and also including: an adjustable height support platform arranged between said discharge end of said folder gluer and a discharge conveyor, operative to receive assembled tubular articles discharged from said discharge end of said folder gluer and to facilitate selectable transfer of the articles to the discharge conveyor; and apparatus for forming a vertical stack of the discharged articles.