MACHINE AND METHODS FOR ATTACHING A TRAY BLANK TO A COVER BLANK

• US 20190308381A1
• Filed: 04/10/2018
• Published: 10/10/2019
• Est. Priority Date: 04/10/2018
• 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, Gulik, Greg
• Granted Patent: US 11,400,679 B2
• Time in Patent Office: Days
• CPC Class Codes: B31B 2105/0022 Making boxes from tubular webs or blanks, e.g. with separate bottoms, including tube or bottom forming operations
• CPC Class Codes: B31B 2110/35 rectangular, e.g. square
• CPC Class Codes: B31B 2120/10 provided with covers, e.g. lids
• CPC Class Codes: B31B 2120/302 collapsible into a flat condition
• CPC Class Codes: B31B 50/042 using rolls, belts or chains
• CPC Class Codes: B31B 50/044 involving aligning
• CPC Class Codes: B31B 50/06 from stacks
• CPC Class Codes: B31B 50/07 by air pressure or suction
• CPC Class Codes: B31B 50/624 Applying glue on blanks

Abstract

A machine including a first deck, a second deck, a first blank transfer assembly, and a second blank transfer assembly is provided. The first and second decks are coupled to a frame. The first blank transfer assembly extends from a first end to a second end and includes a first pick-up assembly moveable between the first end, proximate the second deck, and the second end, proximate the first deck. The second blank transfer assembly extends from a third end to a fourth end and includes a second pick-up assembly moveable between the third end, proximate the second deck, and the fourth end, proximate the first deck. The first blank transfer assembly and the second blank transfer assembly are operationally offset when moving between the first and second ends and the third and fourth ends, respectively.

Claims

1. A machine comprising:

a first deck coupled to a frame;

a second deck coupled to the frame;

a first blank transfer assembly extending from a first end to a second end, said first blank transfer assembly comprising a first pick-up assembly moveable between said first end proximate said second deck and said second end proximate said first deck; and

a second blank transfer assembly extending from a third end to a fourth end, said second blank transfer assembly comprising a second pick-up assembly moveable between said third end proximate said second deck and said fourth end proximate said first deck,

wherein said first blank transfer assembly and said second blank transfer assembly are operationally offset when moving between said first and second ends and said third and fourth ends, respectively.

2. The machine in accordance with claim 1, wherein said first blank transfer assembly and said second blank transfer assembly are operationally offset such that said first blank transfer assembly is proximate said first end when said second blank transfer assembly is proximate said fourth end.

3. The machine in accordance with claim 1, wherein said first pick-up assembly is configured to move from proximate said first end of said first blank transfer assembly to proximate said second end of said first blank transfer assembly, and said second pick-up assembly is configured to move from proximate said third end of said second blank transfer assembly to proximate said fourth end of said second blank transfer assembly in a lateral direction that is generally perpendicular to the first and second decks.

4. The machine in accordance with claim 3, further comprising:

a first adhesive applicator configured to activate to apply adhesive as said first blank transfer assembly moves from said first end to said second end of said first blank transfer assembly; and

a second adhesive applicator configured to activate to apply adhesive as said second blank transfer assembly moves from said third end to said fourth end of said second blank transfer assembly.

5. A method for forming a plurality of blank assemblies using a machine, the plurality of blank assemblies including a first blank assembly including a first cover blank and a first tray blank coupled to the first cover blank and a second blank assembly including a second cover blank and a second tray blank coupled to the second cover blank, said method comprising:

positioning the first and second cover blanks on a first deck coupled to a frame of the machine;

advancing the first cover blank to a first position on the first deck and the second cover blank to a second position on the first deck;

positioning the first and second tray blanks on a second deck coupled to a frame of the machine

advancing the first tray blank to a first position on the second deck and the second tray blank to a second position on the second deck;

transferring the first tray blank from proximate a first end of a first blank transfer assembly to proximate a second end of the first blank transfer assembly using a first pick-up assembly of the machine;

depositing the first tray blank proximate the second end of the first blank transfer assembly in an at least partially overlying relationship with the first cover blank positioned on the first deck;

transferring the second tray blank from proximate a third end of a second blank transfer assembly to proximate a fourth end of the second blank transfer assembly using a second pick-up assembly of the machine, operationally offset from said transferring the first tray blank; and

depositing the second tray blank proximate the fourth end of the second blank transfer assembly in an at least partially overlying relationship with the second cover blank positioned on the first deck.

6. The method in accordance in claim 5, wherein said transferring the second tray blank comprises transferring the second tray blank from proximate the third end of the second blank transfer assembly to proximate the fourth end of the second blank transfer assembly simultaneously with said depositing the first tray blank.

7. The method in accordance with claim 5, wherein positioning the first and second cover blanks on the first deck and the first and second tray blanks on the second deck comprises moving the first and second cover blanks and the first and second tray blanks in a blank setup direction, and said transferring the first and second tray blanks comprises transferring the first and second tray blanks in a blank transfer direction that is generally perpendicular to the blank setup direction.

8. The method in accordance with claim 7, wherein advancing the first and second cover blanks to the respective first and second position on the first deck and the first and second tray blanks to the respective first and second position on the second deck further comprises forwarding the first and second cover blanks and the first and second tray blanks into respective positions such that the first and second cover blanks and the first and second tray blanks are precisely aligned with respect to the first and second blank transfer assemblies, such that respective first and second tray blanks are precisely coupled to respective first and second cover blanks.

9. The method in accordance with claim 8, wherein advancing the first and second cover blanks to the respective first and second position on the first deck further comprises:

activating a first plurality of stoppers configured to precisely align the first cover blank in a first position in the blank setup direction;

activating a second plurality of stoppers configured to precisely align the second cover blank in a second position in the blank setup direction;

advancing the first cover blank to engage a leading edge of the first cover blank with the first plurality of stoppers; and

advancing the second cover blank to engage a leading edge of the second cover blank with the second plurality of stoppers.

10. The method in accordance with claim 9, wherein advancing the first and second cover blanks to the respective first and second positions on the first deck further comprises:

deactivating the first plurality of stoppers before the first blank transfer assembly couples the first tray blank to the first cover blank; and

deactivating the second plurality of stoppers before the second blank transfer assembly couples the second tray blank to the second cover blank.

11. The method in accordance with claim 8, wherein advancing the first and second tray blanks to the respective first and second positions on the second deck further comprises:

activating a third plurality of stoppers configured to precisely align the first tray blank in a first position in the blank setup direction;

activating a fourth plurality of stoppers configured to precisely align the second tray blank in a second position in the blank setup direction;

advancing the first tray blank to engage a leading edge of the first tray blank with the third plurality of stoppers; and

advancing the second tray blank to engage a leading edge of the second tray blank with the fourth plurality of stoppers.

12. The method in accordance with claim 8, wherein transferring the first and second tray blanks comprises translating a first gantry between the first end and the second end of the first blank transfer assembly in the blank transfer direction, and translating a second gantry between the third end and the fourth end of the second blank transfer assembly in the blank transfer direction.

13. The method in accordance with claim 12, wherein a first servomechanism is coupled to the first blank transfer assembly and a first belt, the first servomechanism and the first belt configured to translate the first gantry between the first end and the second end of the first blank transfer assembly, and wherein a second servomechanism is coupled to the second blank transfer assembly and a second belt, the second servomechanism and the second belt configured to translate the second gantry between the third end and the fourth end of the second blank transfer assembly.

14. The method in accordance with claim 12 further comprising:

applying adhesive to the first tray blank with a first adhesive applicator as the first blank transfer assembly moves the first tray blank from the first end to the second end of the first blank transfer assembly; and

applying adhesive to the second tray blank with a second adhesive applicator as the second blank transfer assembly moves the second tray blank from the third end to the fourth end of the second blank transfer assembly.

15. A machine for forming a blank assembly including a first cover blank and a first tray blank coupled to the first cover blank and a second cover blank and a second tray blank coupled to the second cover blank, said machine comprising:

a first deck coupled to a frame, wherein the first and second cover blanks are positioned on the first deck;

a second deck coupled to the frame, wherein the first and second tray blanks are positioned on the second deck;

a first blank transfer assembly extending from a first end to a second end, said first blank transfer assembly comprising a first pick-up assembly moveable between said first end and said second end, said first pick-up assembly configured to pick up the first tray blank proximate said first end and deposit the first tray blank proximate said second end in an at least partially overlying relationship with the first cover blank positioned on said first deck; and

a second blank transfer assembly extending from a third end to a fourth end, said second blank transfer assembly comprising a second pick-up assembly moveable between said third end and said fourth end, said second pick-up assembly configured to pick up the second tray blank proximate said third end and deposit the second tray blank proximate said fourth end in an at least partially overlying relationship with the second cover blank positioned on said first deck,

wherein said first blank transfer assembly and said second blank transfer assembly are operationally offset when transferring the first tray blank and transferring the second tray blank.

16. The machine in accordance with claim 15, wherein said first blank transfer assembly and said second blank transfer assembly are operationally offset from one another such that said first blank transfer assembly deposits the first tray blank on the first cover blank as said second blank transfer assembly picks up the second tray blank.

17. The machine in accordance with claim 15, wherein said first deck extends from a first deck end to a second deck end and wherein said second deck extends from a third deck end to a fourth deck end.

18. The machine in accordance with claim 17, further comprising:

a first blank setup assembly configured to transfer the first and second cover blanks onto said first deck in series at said first deck end;

a first forwarding assembly configured to advance the first and second cover blanks in a blank setup direction;

a second blank setup assembly configured to transfer the first and second tray blanks onto said second deck in series at said third deck end; and

a second forwarding assembly configured to advance the first and second tray blanks in the blank setup direction.

19. The forwarding assembly in accordance with claim 18, further comprising:

a first plurality of stoppers downstream of a first position in the blank setup direction;

a second plurality of stoppers downstream of a second position in the blank setup direction; and

a plurality of lugs configured to advance the first cover blank to the first position wherein a leading edge of the first cover blank is engaged with said first plurality of stoppers and to advance the second cover blank to the second position wherein a leading edge of the second cover blank is engaged with said second plurality of stoppers.

20. The machine in accordance with claim 15, wherein said first deck comprises a first assembly zone located at said first deck end, a second assembly zone located at said second deck end, and an idle indexing zone located between said first assembly zone and said second assembly zone.

21. The machine in accordance with claim 20, wherein said first blank transfer assembly deposits the first tray blank in the at least partially overlying relationship with the first cover blank proximate said first assembly zone, and wherein said second blank transfer assembly deposits the second tray blank in the at least partially overlying relationship with the second cover blank proximate the second assembly zone.

22. The machine in accordance with claim 15, wherein said first blank transfer assembly has a first sensor coupled to said first blank transfer assembly configured to monitor placement of said first tray blank relative to said first blank transfer assembly, and wherein said second blank transfer assembly has a second sensor coupled to said second blank transfer assembly configured to monitor placement of said second tray blank relative to said second blank transfer assembly.

23. A machine comprising:

a first deck coupled to a frame;

a second deck coupled to the frame;

a first gantry configured to move between said first deck and said second deck; and

a second gantry configured to move between said first deck and said second deck in an operationally offset manner from said first gantry.

24. The machine in accordance with claim 23, wherein the first gantry moves away from said first deck as the second gantry moves toward said first deck, and wherein the first gantry moves away from said second deck as the second gantry moves toward said second deck.