METHODS AND A MACHINE FOR FORMING MULTIPLE TYPES OF CONTAINERS

• US 20120100976A1
• Filed: 10/04/2011
• Published: 04/26/2012
• Est. Priority Date: 10/26/2010
• Status: Active Grant

• Current Assignee: WestRock Shared Services, LLC (WestRock Company)
• Original Assignee: WestRock Shared Services, LLC (WestRock Company)
• Inventors: Graham, Thomas Dean, Aganovic, Amer, D'Alesio, Claudio, Spurlock, Paul Andrew
• Granted Patent: US 9,409,367 B2
• Time in Patent Office: Days
• US Class Current: 493/52
• CPC Class Codes: B31B 2100/00 Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
• CPC Class Codes: B31B 2110/35 rectangular, e.g. square
• CPC Class Codes: B31B 50/00 Making rigid or semi-rigid containers, e.g. boxes or cartons
• CPC Class Codes: B31B 50/005 involving a particular layout of the machinery or relative arrangement of its subunits
• CPC Class Codes: B31B 50/006 Controlling; Regulating; Measuring; Improving safety
• CPC Class Codes: B31B 50/066 from above a magazine

Abstract

A blank delivery system for use in a machine for forming a container from a blank sheet of material is described herein. The blank delivery system includes a blank loading assembly that includes a plurality of blank hoppers. Each blank hopper is configured to hold a plurality of blanks for forming a different type of container. A blank transfer assembly is coupled to each blank hopper of the plurality of blank hoppers. The blank transfer assembly is configured to convey the blanks from each blank hopper to a container forming system of the machine.

Claims

1. A blank delivery system for use in a machine for forming a container from a blank sheet of material, said blank delivery system comprising:

a blank loading assembly comprising a plurality of blank hoppers, each blank hopper configured to hold a plurality of blanks for forming a different type of container; and

a blank transfer assembly coupled to each blank hopper of said plurality of blank hoppers, said blank transfer assembly configured to convey the blanks from each blank hopper to a container forming system of the machine.

2. A blank delivery system in accordance with claim 1, wherein each blank hopper of said plurality of blank hoppers is modular such that an additional blank hopper can be coupled within an existing set of blank hoppers to increase the number of blank hoppers included within the blank loading assembly, each blank hopper is configurable to receive blanks having different blank depths, different lid configurations, and different printing.

3. A blank delivery system in accordance with claim 1, wherein each blank hopper of said plurality of blank hoppers comprises:

a hopper assembly configured to support a plurality of blanks having a predefined number of sides and a predefined length, said hopper assembly comprising opposing sidewalls that are oriented such that the plurality of blanks are arranged in a stack within said hopper assembly; and

a vacuum puller assembly positioned below the stack of blanks, said vacuum puller assembly configured to transfer each blank from said hopper assembly to said blank transfer assembly.

4. A blank delivery system in accordance with claim 3, wherein said vacuum puller assembly comprises at least one vacuum assembly that is coupled to a support assembly, said support assembly configured to position said vacuum assembly between a first position wherein said vacuum assembly contacts a blank within said hopper assembly, and a second position wherein the blank is positioned onto said blank transfer assembly.

5. A blank delivery system in accordance with claim 4, wherein said vacuum assembly comprises a suction cup assembly configured to selectively form a suction seal with an outer surface of the blank to facilitate removing the blank from said hopper assembly.

6. A blank delivery system in accordance with claim 1, wherein said blank transfer assembly comprises a pair of lug assemblies for conveying the blanks from each of said blank hopper to the container forming system, each of said lug assembly comprising:

a lug chain extending between a tail sprocket and a drive sprocket, said lug chain extends through said blank loading assembly to define a loading path from said blank loading assembly to the container forming system; and

a plurality of lugs pivotably coupled to said lug chain, each lug of said plurality of lugs is aligned with a corresponding lug coupled to an adjacent lug chain to form a pair of pushing lugs.

7. A blank delivery system in accordance with claim 6, further comprising a pusher assembly oriented between said pair of lug assemblies, said pusher assembly configured to move between a pick-up position and a transfer position to convey a blank from said blank transfer assembly to the container forming system.

8. A blank delivery system in accordance with claim 7, wherein said pusher assembly comprises a pusher bar, a pair of pusher rods extending outwardly from said pusher bar, and a plurality of pusher feet, wherein each pusher foot of said plurality of pusher feet is pivotably coupled to a corresponding pusher rod such that said pusher foot is below the blank as said pusher assembly moves to the pick-up position, and contacts the blank as said pusher assembly moves from the pick-up position to the transfer position.

9. A blank delivery system in accordance with claim 1, further comprising a control system coupled to said blank loading assembly and to said blank transfer assembly to selectively convey the different types of blanks from said blank loading assembly to the container forming system to form different types of containers.

10. A machine for forming a container from a blank of sheet material, said machine comprising:

a mandrel assembly configured to form a container from a blank sheet of material; and

a container delivery system configured to selectively convey the container from said mandrel assembly to a plurality of product loading areas, said container delivery system comprising;

a conveyor belt assembly positioned downstream of said mandrel assembly, said conveyor belt assembly comprising a first conveyor section and at least a second conveyor section, wherein said first conveyor section is coupled to a first product loading area, said second conveyor section is coupled to a second product loading area that is different than the first product loading area; and

a container loading assembly coupled to said mandrel assembly, said container loading assembly positionable between a first position to convey a container from the container forming section to said first conveyor section, and a second position to convey the container from the container forming system to said second conveyor section.

11. A machine in accordance with claim 10, wherein said container loading assembly comprises a loading rail assembly extending outwardly from the container forming system, said loading rail assembly comprises an outer surface that is oriented to enable the container to slide across said outer surface from the container forming system to said conveyor belt assembly.

12. A machine in accordance with claim 11, wherein said loading rail assembly extends across said first conveyor section towards said second conveyor section in the second position to prevent the container from being conveyed to said first conveyor section.

13. A machine in accordance with claim 11, wherein said container loading assembly further comprises:

a frame; and

a diverter plate that is pivotably coupled to said frame, said diverter plate is spaced a distance from said loading rail assembly, and is oriented to channel the container towards one of the first conveyor section and the second conveyor section.

14. A machine for forming a container from a blank of sheet material, said machine comprising:

a mandrel assembly comprising a mandrel having an external shape complimentary to an internal shape of at least a portion of a container, and at least one lifting mechanism configured to wrap at least a portion of the blank about said mandrel to facilitate forming the container; and

a blank delivery system coupled to said mandrel assembly, said blank delivery system configured to selectively deliver a plurality of blanks to said mandrel assembly for forming a plurality of different types of containers, said blank delivery system comprising;

a blank loading assembly comprising a plurality of blank hoppers, each blank hopper configured to hold a plurality of blanks; and

a blank transfer assembly coupled to each blank hopper of said plurality of blank hoppers, said blank transfer assembly configured to convey the blanks from each blank hopper to said mandrel assembly.

15. A machine in accordance with claim 14, wherein each blank hopper of said plurality of blank hoppers is modular such that an additional blank hopper can be coupled within an existing set of blank hoppers to increase the number of blank hoppers included within the blank loading assembly, each blank hopper is configurable to receive blanks having different blank depths, different lid configurations, and different printing.

16. A machine in accordance with claim 14, wherein each blank hopper of said plurality of blank hoppers comprises:

a hopper assembly configured to support a plurality of blanks having a predefined number of sides and a predefined length, said hopper assembly comprising opposing sidewalls that are oriented such that the plurality of blanks are arranged in a stack within said hopper assembly; and

a vacuum puller assembly positioned below the stack of blanks, said vacuum puller assembly configured to transfer each blank from said hopper assembly to said blank transfer assembly.

17. A machine in accordance with claim 16, wherein said vacuum puller assembly comprises at least one vacuum assembly that is coupled to a support assembly, said support assembly configured to position said vacuum assembly between a first position wherein said vacuum assembly contacts a blank within said hopper assembly, and a second position wherein the bank is positioned onto said blank transfer assembly.

18. A machine in accordance with claim 17, wherein said vacuum assembly comprises a suction cup assembly configured to selectively form a suction seal with an outer surface of the blank to facilitate removing the blank from said hopper assembly.

19. A machine in accordance with claim 14, wherein said blank transfer assembly comprises a pair of lug assemblies for conveying the blanks from each of said blank hopper to said mandrel assembly, each of said lug assembly comprising:

a lug chain extending between a tail sprocket and a drive sprocket, said lug chain extends through said blank loading assembly to define a loading path from said blank loading assembly to said mandrel assembly; and

a plurality of lugs pivotably coupled to said lug chain, each lug of said plurality of lugs is aligned with a corresponding lug coupled to an adjacent lug chain to form a pair of transfer lugs.

20. A machine in accordance with claim 19, further comprising a pusher assembly oriented between said pair of lug assemblies, said pusher assembly configured to move between a pick-up position and a transfer position to convey a blank from said blank transfer assembly to said mandrel assembly.

21. A machine in accordance with claim 20, wherein said pusher assembly comprises a pusher bar, a pair of pusher rods extending outwardly from said pusher bar, and a plurality of pusher feet, wherein each pusher foot of said plurality of pusher feet is pivotably coupled to a corresponding pusher rod such that said pusher foot is below the blank as said pusher assembly moves to the pick-up position, and contacts the blank as said pusher assembly moves from the pick-up position to the transfer position.

22. A machine in accordance with claim 14, further comprising a container delivery system positioned downstream of said mandrel section, said container delivery system comprising:

a conveyor belt assembly comprising a first conveyor section and at least a second conveyor section, wherein said first conveyor section is coupled to a first product loading area, said second conveyor section is coupled to a second product loading area that is different than the first product loading area; and

a container loading assembly coupled to said mandrel assembly for conveying the container from said mandrel assembly to said conveyor belt assembly, said container loading assembly positionable between a first position to convey the container from said mandrel assembly to said first conveyor section, and a second position to convey the container from said mandrel assembly to said second conveyor section.

23. A machine in accordance with claim 22, wherein said container loading assembly comprises a loading rail assembly extending outwardly from said mandrel assembly, said loading rail assembly comprises an outer surface that is oriented to enable the container to slide across said outer surface from said mandrel assembly to said conveyor belt assembly.

24. A machine in accordance with claim 23, wherein said loading rail assembly extends across said first conveyor section to said second conveyor section in the second position to prevent the container from being conveyed to said first conveyor section.

25. A machine in accordance with claim 14, further comprising a control system coupled to said blank loading assembly and to said blank transfer assembly to selectively convey the different types of blanks from said blank loading assembly to the mandrel assembly to form different types of containers.