Apparatus and methods relating to corrugated materials, containers, and packaging

• US 8,343,024 B1
• Filed: 05/07/2012
• Issued: 01/01/2013
• Est. Priority Date: 03/14/2011
• Status: Active Grant

• Current Assignee: THATBox Design, LLC
• Original Assignee: THATBox Design, LLC
• Inventors: Costanzo, Donn J. Jr., Costanzo, Donn J.
• Primary Examiner(s): DESAI, HEMANT
• Application Number:
  US13/465,033
• Time in Patent Office: 239 Days
• Field of Search: 493/128, 493/162, 493/167, 493/175, 493/185, 493/311, 493/317
• US Class Current: 493/128
• CPC Class Codes: B31B 2100/00 Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
• CPC Class Codes: B31B 2100/0024 having all side walls attached to the bottom
• CPC Class Codes: B31B 2105/0027 Making boxes from blanks consisting of side wall panels integral with a bottom panel and additional side wall panels
• CPC Class Codes: B31B 2120/30 collapsible; temporarily collapsed during manufacturing
• CPC Class Codes: B31B 2120/302 collapsible into a flat condition
• CPC Class Codes: B31B 50/26 Folding sheets, blanks or webs
• CPC Class Codes: B31B 50/44 by plungers moving through folding dies
• CPC Class Codes: B31B 50/98 in stacks or bundles
• CPC Class Codes: B65D 25/205 Means for the attachment of labels, cards, coupons or the like; cards or coupons for the other types of rigid or semi-rigid containers B65D25/36 takes precedence
• CPC Class Codes: B65D 5/20 by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form B65D5/36 takes precedence
• CPC Class Codes: B65D 5/2047 trapezoidal, e.g. to form a body with diverging side walls B65D5/2033 takes precedence
• CPC Class Codes: B65D 5/241 and the gussets folds connected to the inside of the container body B65D5/247 and B65D5/248 take precedence
• CPC Class Codes: B65D 5/4266 Folding lines, score lines, crease lines
• CPC Class Codes: B65D 5/46112 either the handle elements being formed with lugs which engage with the other side walls or closure flaps, or the other closure flaps folding over a part of the handle to maintain the handle in position
• CPC Class Codes: B65D 5/563 Laminated linings; Coatings
• CPC Class Codes: B65D 81/386 formed of corrugated material

Abstract

A machine for transitioning a box cutout from a flat configuration to a collapsed box configuration includes a first drive wheel configured to drive a box cutout towards a plunging area; a plunger configured to apply force to a central portion of a bottom panel of the box cutout so as to fold the box about a lateral bisecting axis and propel at least a portion of the box cutout downward; and opposed second and third drive wheels configured to grab a box cutout propelled downward by the plunger and further draw the box cutout downward into a collapsed box configuration within a collection area. A box cutout transitioned to a collapsed box configuration in this manner may include a bottom panel having plurality of unbroken minor score lines and broken major score lines.

Claims

1. A method of transitioning a box cutout from a flat unfolded configuration to a collapsed box configuration, the method comprising:

(a) driving, via one or more drive wheels, a box cutout toward a plunging area;

(b) detecting, via a first detector, the presence of the box cutout;

(c) applying, via one or more glue applicators, glue to the box cutout;

(d) facilitating halting, via a backstop, the movement of the box cutout when it is located within the plunging area;

(e) detecting, via a second detector, the presence of the box cutout;

(f) in response to the step of detecting, via the second detector, the presence of the box cutout, applying downward force, via a plunger, to a central portion of the box cutout disposed below the plunger so as to effect at least partial collapsing of the box cutout and downward movement of the box cutout, the partial collapse being facilitated by one or more structures positioned and configured to effect at least partial folding of a box cutout being plunged by the plunger;

(g) guiding, via one or more guide wheels located below the plunging area, the descent of the box cutout as the box cutout is being plunged by the plunger;

(h) engaging, via opposed grab wheels located below the one or more guide wheels, the box cutout that has been plunged downward by the plunger, the opposed grab wheels pressing opposite sides of the box cutout together and propelling the box cutout in a downward direction; and

(i) effecting placement, using a collector, of the box cutout in a collection pen.

2. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the one or more structures comprise one or more fingers.

3. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 2, wherein the method further includes a step of adjusting an angle of one or more of the one or more fingers.

4. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 2, wherein the one or more fingers are fixed at a forty five degree angle relative to vertical.

5. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 2, wherein at least some of the fingers are fixed at a forty five degree angle relative to the direction the one or more drive wheels drive box cutouts.

6. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the method further includes a step of adjusting a position of one of the one or more structures.

7. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the backstop and one of the drive wheels are each positioned relative to the plunger based on dimensions of a particular box cutout.

8. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein a width of a plunging head of the plunger corresponds to the length of a portion of a score line of a particular box cutout.

9. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the method further includes a step of deflecting, using a deflector adjacent the plunger, the box cutout downward.

10. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the method further includes a step of detecting, via a third detector, plunging of the plunger, and wherein the collector is configured to, based on a count of plunges detected by the third detector, elevate the particular collected box cutout when effecting placement of the collected box cutout in the collection pen.

11. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the one or more drive wheels comprise two drive wheels.

12. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the one or more guide wheels comprise two opposed sets of two guide wheels.

13. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the method further includes a step of dropping the cutout down from a cutout receiving area in which the cutout was received, the cutout receiving area being configured to receive a plurality of box cutouts for processing.

14. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 1, wherein the method further includes a step of removing a plunging head of the plunger and replacing it with a different plunging head.

15. The method of claim 1, further comprising performing the method using a machine wherein more than sixty boxes are manufactured one after another using the same machine each minute.

16. A method of transitioning a box cutout from a flat unfolded configuration to a collapsed box configuration, the method comprising:

(a) facilitating halting, via a backstop, movement of a box cutout when it is located within a plunging area;

(b) detecting, via a detector, the presence of the box cutout;

(c) in response to the step of detecting, via the detector, the presence of the box cutout, applying downward force, via a plunger, to a central portion of the box cutout disposed below the plunger so as to effect at least partial collapsing of the box cutout and downward movement of the box cutout, the partial collapse being facilitated by one or more structures positioned and configured to effect at least partial folding of a box cutout being plunged by the plunger; and

(d) engaging, via opposed grab wheels located below the plunging area, the box cutout that has been plunged downward by the plunger, the opposed grab wheels pressing opposite sides of the box cutout together and propelling the box cutout in a downward direction.

17. The method of claim 16, further comprising performing the method using a machine wherein more than sixty boxes are manufactured one after another using the same machine each minute.

18. A method of transitioning a box cutout from a flat unfolded configuration to a collapsed box configuration, the method comprising:

(a) driving, via one or more drive wheels, a box cutout toward a plunging area;

(b) detecting, via a first detector, the presence of the box cutout;

(c) applying, via one or more glue applicators, glue to the box cutout;

(d) facilitating halting, via a backstop, the movement of the box cutout when it is located within the plunging area;

(e) detecting, via a second detector, the presence of the box cutout;

(f) in response to the step of detecting, via the second detector, the presence of the box cutout, applying downward force, via a plunger, to a central portion of the box cutout disposed below the plunger so as to effect at least partial collapsing of the box cutout and downward movement of the box cutout, the partial collapse being facilitated by one or more structures positioned and configured to effect at least partial folding of a box cutout being plunged by the plunger;

(g) guiding, via one or more guide wheels located below the plunging area, the descent of the box cutout as the box cutout is being plunged by the plunger;

(h) engaging, via opposed grab wheels located below the one or more guide wheels, the box cutout that has been plunged downward by the plunger, the opposed grab wheels pressing opposite sides of the box cutout together and propelling the box cutout in a downward direction; and

(i) effecting placement, using a collector, of the box cutout in a collection pen;

(j) wherein the method further includes a step of deflecting, using a deflector adjacent the plunger, the box cutout downward; and

(k) wherein the method further includes a step of detecting, via a third detector, plunging of the plunger, and wherein the collector is configured to, based on a count of plunges detected by the third detector, elevate the particular collected box cutout when effecting placement of the collected box cutout in the collection pen.

19. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 18, wherein the one or more drive wheels comprise two drive wheels, and the one or more guide wheels comprise two opposed sets of two guide wheels.

20. The method of transitioning a box cutout from a flat configuration to a collapsed box configuration of claim 18, wherein the method further includes a step of dropping the cutout down from a cutout receiving area in which the cutout was received, the cutout receiving area being configured to receive a plurality of box cutouts for processing.