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

• US 8,348,820 B2
• Filed: 05/07/2012
• Issued: 01/08/2013
• 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:
  US13/465,030
• Publication Number:
  US 20120238424A1
• Time in Patent Office: 246 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 machine configured to transition a box cutout from a flat unfolded configuration to a collapsed folded box configuration, the machine comprising:

(a) one or more drive wheels configured to drive a box cutout towards a plunging area;

(b) one or more freely rotating wheels, each freely rotating wheel being disposed directly opposite to one of the one or more first drive wheels;

(c) one or more glue applicators configured to apply glue to the box cutout;

(d) a first detector configured to detect the presence of the box cutout and trigger application of glue thereto;

(e) a backstop configured to halt movement of the box cutout in the plunging area;

(f) one or more rotational fingers configured to effect folding of the box cutout disposed in the plunging area;

(g) one or more clamps configured to hold the box cutout in position during folding by the one or more rotational fingers;

(h) a plunger located in the plunging area configured to apply force to a central portion of the box cutout disposed below the plunger so as to effect,

(1) at least partial collapsing of the box cutout, and

(2) downward movement of the box cutout;

(i) a second detector configured to detect the presence of the box cutout and trigger folding thereof by the one or more rotational fingers and plunging thereof by the plunger;

(j) one or more guide wheels located below the plunging area, the guide wheels being configured to engage the box cutout being plunged by the plunger;

(k) opposed grab wheels located below the one or more guide wheels, the grab wheels being configured to engage the box cutout that has been plunged downward by the plunger, facilitate collapse of the box cutout, and propel the box cutout further downward; and

(l) a collector configured to collect the box cutout propelled downward by the grab wheels and place such collected box cutout in a collection pen;

(m) wherein the backstop and one of the drive wheels are each positioned relative to the plunger based on dimensions of the particular box cutout being constructed; and

(n) wherein a length of a plunging head of the plunger corresponds to the length of a portion of a score line of the particular box cutout.

2. The machine of claim 1, wherein the machine further includes a third detector configured to detect plunging of the plunger, and wherein the collector is configured to, based on a count of plunges detected by the third detector, elevate a particular collected box cutout when placing that particular collected box cutout in the collection pen.

3. The machine of claim 1, wherein the one or more drive wheels comprise two drive wheels.

4. The machine of claim 1, wherein the one or more guide wheels comprise two opposed sets of two guide wheels.

5. The machine of claim 1, wherein the grab wheels are configured to press together opposite sides of a box cutout passing therebetween.

6. The machine of claim 1, wherein the machine further includes a cutout receiving area configured to receive a plurality of box cutouts for processing by the machine.

7. The machine of claim 1, wherein the one or more glue applicators include one or more first glue applicators configured to apply glue to a top side of a box cutout and one or more second glue applicators configured to apply glue to a bottom side of a box cutout.

8. The machine of claim 1, wherein each detector comprises a laser detector.

9. The machine of claim 1, wherein the plunging head of the plunger has a blunt end.

10. The machine of claim 1, wherein the plunging head of the plunger is tapered.

11. The machine of claim 1, wherein the plunging head of the plunger has a planar face configured to engage a box cutout.

12. The machine of claim 1, wherein the plunging head of the plunger has a curved face configured to engage a box cutout.

13. The machine of claim 1, wherein the plunging head of the plunger is configured to be removable and interchangeable with other plunging heads.

14. The machine of claim 1, wherein the machine further includes a deflector disposed adjacent the plunger, the deflector being shaped and positioned to deflect a box cutout downward in the event that such a box cutout has drifted upward.

15. The machine of claim 1, wherein a position of the backstop is adjustable;

a position of at least one of the drive wheels and the guide wheels is adjustable;

a position of at least one of the one or more glue applicators is adjustable; and

a distance the plunger plunges is adjustable.

16. The machine of claim 1, wherein a position of each of the one or more rotational fingers is adjustable.

17. A machine configured to transition a box cutout from a flat unfolded configuration to a collapsed folded box configuration, the machine comprising:

(a) a backstop configured to halt forward movement of a box cutout in a plunging area;

(b) one or more rotational fingers configured to effect folding of a box cutout disposed in the plunging area;

(c) a plunger configured to apply force to a central portion of a box cutout disposed below the plunger so as to effect (1) at least partial collapsing of that box cutout and (2) downward movement of that box cutout, the plunger comprising a plunging head configured to engage such a box cutout;

(d) a detector configured to detect the presence of a box cutout and trigger folding thereof by the one or more rotational fingers and plunging thereof by the plunger; and

(e) opposed grab wheels located below the plunging area, the grab wheels being configured to engage a box cutout that has been plunged downward by the plunger, facilitate collapse of such box cutout, and propel such box cutout further downward;

(f) wherein the backstop is positioned relative to the plunger based on dimensions of a particular box cutout; and

(g) wherein a length of the plunging head of the plunger corresponds to the length of a portion of a score line of the particular box cutout.

18. The machine of claim 17, wherein the box cutout is folded into a collapsed folded box configuration from the flat unfolded configuration upon application of the force by the plunger.

19. A machine configured to transition a box cutout from a flat unfolded configuration to a collapsed folded box configuration, the machine comprising:

(a) one or more drive wheels configured to drive a box cutout towards a plunging area;

(b) one or more freely rotating wheels, each freely rotating wheel being disposed directly opposite to one of the one or more first drive wheels;

(c) one or more glue applicators configured to apply glue to the box cutout;

(d) a first detector configured to detect the presence of the box cutout and trigger application of glue thereto;

(e) a backstop configured to halt movement of the box cutout in the plunging area;

(f) one or more rotational fingers configured to effect folding of the box cutout disposed in the plunging area;

(g) one or more clamps configured to hold the box cutout in position during folding by the one or more rotational fingers;

(h) a plunger located in the plunging area configured to apply force to a central portion of the box cutout disposed below the plunger so as to effect at least partial collapsing and downward movement of the box cutout;

(i) a second detector configured to detect the presence of the box cutout and trigger folding thereof by the one or more rotational fingers and plunging thereof by the plunger;

(j) one or more guide wheels located below the plunging area, the guide wheels being configured to engage the box cutout being plunged by the plunger;

(k) opposed grab wheels located below the one or more guide wheels, the grab wheels being configured to engage the box cutout that has been plunged downward by the plunger, facilitate collapse of the box cutout, and propel the box cutout further downward; and

(l) a collector configured to collect the box cutout propelled downward by the grab wheels and place such collected box cutout in a collection pen;

(m) wherein the backstop and one of the drive wheels are each positioned relative to the plunger based on dimensions of the particular box cutout being constructed;

(n) wherein a length of a plunging head of the plunger corresponds to the length of a portion of a score line of the particular box cutout;

(o) wherein the machine further includes a cutout receiving area configured to receive a plurality of box cutouts for processing by the machine; and

(p) wherein the machine further includes a deflector disposed adjacent the plunger, the deflector being shaped and positioned to deflect a box cutout downward.

20. The machine of claim 19, wherein the one or more glue applicators include one or more first glue applicators configured to apply glue to a top side of a box cutout and one or more second glue applicators configured to apply glue to a bottom side of a box cutout.