CONTAINER SIZING APPARATUS AND METHODS FOR FIXED FOOTPRINT CONTAINERS

BACKGROUND

1. Field

[0001]This disclosure relates generally to container sizing methods and devices or systems for modifying the dimensions of a container. More specifically, although not exclusively, this disclosure relates to container or box or carton sizing methods and devices or systems for altering the size of a box or carton to suit its contents.

2. Description of Related Art

[0002]One application in which carton sizing devices are particularly useful is in the field of made-to-order packages, wherein orders are placed for varying product types and quantities and packages containing such products must be prepared for shipment. These applications result in an infinite number of combinations of products that are placed in standard sized cartons and so they occupy varying heights and volumes within such cartons. Package shipment costs are generally dependent upon both the weight and dimensions of the package to be shipped. The wide variation in filling level often results in a void at the top of the carton, requiring additional packing material, leading to waste, and unnecessarily large carton sizes, leading to higher shipping costs. Known systems for made-to-order packages tend to require a finite number of discrete container size options, cut way and discard excess (waste) material from the container to size it down, utilize costly custom-sizing machinery such as robot arms or gantries, and/or require relatively slow processing speeds for the customization of containers.

[0003]The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever-present need for improved systems and methods for custom sizing containers. This disclosure provides a solution for this need.

SUMMARY

[0004]A container forming system includes a frame having a first deck level and a second deck level above the first deck level. A cut and crimp station is included at the second deck level. The cut and crimp station includes at least one cutter configured to form vertical cuts along upper portions of vertical corners of an open container to form a plurality of top flaps in the open container, and at least one crimper configured to form horizontal fold lines for the top flaps. A folding station is included at the second deck level, including a folder configured to fold down the plurality of top flaps of the open container to enclose contents therein, thereby forming the open container into a closed container. The system includes a conveyor operatively connected to the frame to receive the open container with product therein at the first deck level and raise the open container up to the crimp and cut station at the second deck level, for forming vertical cuts in vertical corners of the open container to form the plurality of top flaps in the open container, and for crimping the horizontal fold lines into the open container for folding the plurality of top flaps. The conveyor is operatively connected to the frame to transport the open container from the cut and crimp station to the folding station for folding down the plurality of top flaps.

[0005]The cut and crimp station can include a measuring plate that is fixed relative to the frame, configured so that contents of the open container contact the measuring plate as the conveyor raises the open container up against the measuring plate to establish where the cutter must terminate cut lines in the open container, and where the crimper must form the horizontal fold lines in the open container. The system can include a controller operatively connected to control the conveyor, the cutter, the crimper, and the folder. A contact sensor can be operatively connected to the measuring plate and to the controller to detect contact between the measuring plate and the contents of the open container, and to use height of the conveyor at the point where the controller detects contact to establish the cut lines and the fold lines. The controller and the conveyor can be configured to raise the open container to a height where the measuring plate contacts the contents of the open container, use the cutter to form the cut lines downward from a top opening of the open container down to a level where the measuring plate contacts the contents, use the crimper to form the fold lines, and lower the open container after forming the fold lines to clear space for the open container to clear the cutter, the crimper, and the measuring plate for egress from the cut and crimp station to the folding station.

[0006]The cutter can include a set of shears having a shear pivot that is fixed relative to the frame. The crimper can include a set of pinchers including a creaser and opposed anvil configured for forming fold lines by pinching toward one another on opposite sides of a container wall, and a pincher pivot that is fixed relative to the frame. The folding station can include a folding armature fixed to the frame and configured to fold the plurality of flaps.

[0007]A lid magazine can be operatively connected to the frame to feed lid blanks into the conveyor. The lid magazine can be at the second deck level. The conveyor can be configured to transfer a lid blank from the lid magazine to a lid apply station along a main feed direction. The lid apply station can be at the second deck level. The conveyor can be configured and to transfer a closed container from the folding station to the lid apply station laterally relative to the main feed direction at the second deck level.

[0008]The lid apply station can include a lid blank folder and glue applicator each operatively connected to the frame to form the lid blank into a lid and to adhere the lid to the closed container. The glue applicator can be configured to apply beads of glue to two opposing flaps of the lid blank and to two opposing sidewalls of the closed container for adhering the lid to the closed container around four sides of the closed container. The conveyor can be configured to outfeed the closed container with the lid adhered thereto from the frame. The conveyor can lower the closed container to the first deck level while outfeeding.

[0009]A method includes receiving an open container with product therein at a first deck level, raising the open container up to a crimp and cut station at the second deck level, forming vertical cuts in vertical corners of the open container to form the plurality of top flaps in the open container, and crimping horizontal fold lines into the open container for folding the plurality of top flaps. The method includes transporting the open container from the cut and crimp station to a folding station for folding down the plurality of top flaps.

[0010]The open container can have a non-square footprint. The open container can be transported narrow face first into and out of the cut and crimp station relative to a main feed direction through the cut and crimp station. Raising the open container up to a crimp and cut station can include raising the open container until contents of the open container contact a measuring plate to establish where to terminate cut lines in the open container, and where to form the horizontal fold lines in the open container.

[0011]Raising the open container up to the crimp and cut station can include raising the open container to a height where the measuring plate contacts the contents of the open container. The method can include using a cutter to form the cut lines downward from a top opening of the open container down to a level where the measuring plate contacts the contents, using a crimper to form the fold lines, and lowering the open container after forming the fold lines to clear space for the open container to clear the cutter, the crimper, and the measuring plate for egress from the cut and crimp station to the folding station.

[0012]The method can include folding the plurality of flaps down in the folding station to form a closed container, transporting the closed container lateral to the main feed direction to a lid apply station, transporting a lid blank into the lid apply station in the main feed direction, applying adhesive to the lid blank and/or to the closed container, folding the lid blank into a lid, and adhering the lid to the closed container. The method can include outfeeding the closed container and lid.

[0013]A container forming system includes a frame having a first deck level and a second deck level above the first deck level. A cut and crimp station is at the second deck level, including one or more mechanisms configured to form a plurality of top flaps in an open container. A conveyor is operatively connected to the frame for movement relative to the frame to receive the open container with product therein at the first deck level and raise the open container up to the crimp and cut station at the second deck level, for forming the plurality of top flaps in the open container.

[0014]A method includes receiving an open container with product therein at a first deck level, raising the open container up to a crimp and cut station at the second deck level, and forming a plurality of top flaps in the open container. The method includes transporting the open container from the cut and crimp station to a folding station for folding down the plurality of top flaps.

[0015]These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

[0017]FIG. 1 is a schematic side elevation view of an embodiment of a system constructed in accordance with the present disclosure, showing the frame, the conveyor, the cut and crimp station, and the lid apply station;

[0018]FIG. 2 is a schematic plan view of the system of FIG. 1, showing the folding station, the lid magazine, and the lid apply station;

[0019]FIG. 3 is a schematic perspective view of a portion of the system of FIG. 1, showing one of the cutters;

[0020]FIG. 4 is a schematic perspective view of the system of FIG. 1, showing one of the crimpers; and

[0021]FIG. 5 is a schematic perspective view of the a container in the process of being processed through the system of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022]Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a system in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of systems in accordance with the disclosure, or aspects thereof, are provided in FIGS. 2-5, as will be described. The systems and methods described herein can be used to provide custom heights on fixed footprint size containers, to provide custom sized containers appropriate for their given content, with speed and reliability that exceeds more conventional systems.

[0023]A container forming system 100 includes a frame 102 having a first deck level 104 and a second deck level 106 above the first deck level, i.e. relative to the direction of gravity forces G. A cut and crimp station 108 is included at the second deck level 106. The cut and crimp station 108 includes four cutters 110 positioned at the four corners of the cut and crimp station 108, configured to form vertical cuts 112 (labeled in FIG. 5) along upper portions of vertical corners 114 of an open container 116 to form a plurality of top flaps 118 in the open container 116. The cut and crimp station 108 also includes four crimpers 120 positioned along the four edges of the cut and crimp station 108 and configured to form horizontal fold lines 122 for the top flaps 118 (labeled in FIG. 5).

[0024]With reference to FIG. 2, a folding station 124 is included at the second deck level 106 (labeled in FIG. 1). The folding station 124 includes a folder 126, such as a set of folder bars or the like, configured to fold down the plurality of top flaps 118 of the open container 116 to enclose contents 128 therein, thereby forming the open container 116 into a closed container 130.

[0025]With reference again to FIG. 1, the system 100 includes a conveyor 132 operatively connected to the frame 102 to receive the open container 116 with contents 128 therein at the first deck level 104, transport the open container 116 along a main feed direction A, and raise the open container 116 up to the crimp and cut station 108 at the second deck level 106 for forming vertical cuts 112 in vertical corners 114 (labeled in FIG. 5) of the open container 116 to form the plurality of top flaps 118 in the open container, and for crimping the horizontal fold lines 122 into the open container 116 for folding the plurality of top flaps 118. The conveyor 132 is operatively connected to the frame 102 to transport the open container 116 along the main feed direction A from the cut and crimp station 108 to the folding station 124 (shown in FIG. 2) for folding down the plurality of top flaps 118.

[0026]The cut and crimp station 108 includes a measuring plate 134 that is fixed relative to the frame 102. The measuring plate 134 is configured so that contents 128 of the open container 116 contact the measuring plate 134 as the conveyor 132 raises the open container 116 up against the measuring plate 134 to establish where the cutters 110 must terminate cuts 112 (labeled in FIG. 5) in the open container 116, and where the crimpers 120 must form the horizontal fold lines 122 (labeled in FIG. 5) in the open container 116.

[0027]The system 100 includes a controller 136 operatively connected to control the conveyor 132, the cutters 110, the crimpers 120, and the folder 126 (labeled in FIG. 2). A contact sensor 138 is operatively connected to the measuring plate 134 and to the controller 136 to detect contact between the measuring plate 134 and the contents 128 of the open container 116, and to use height of the conveyor 132 at the point where the controller 136 detects contact to establish the height for the cuts 112 and the fold lines 122 (labeled in FIG. 5). In one embodiment, the cutters 110 and the crimpers 120 will move to the appropriate height by servo controlled motor adjustment. In other words, the controller 136 controls the conveyor 132 to raise the open container 116 from the first deck level 104 into the second deck level 106 and keeps raising until the contact sensor 138 registers to the controller 136 that the contents 128 of the open container 116 have contacted the measuring plate 134, upon which the controller 136 controls the conveyor 132 to stop raising the open container 116.

[0028]The controller 136 and the conveyor 132 are configured to raise the open container 116 to the height where the measuring plate 134 contacts the contents 128 of the open container 116, use the cutters 110 to form the cuts 112 (labeled in FIG. 5) downward from a top opening of the open container 116 down to the level where the measuring plate 134 contacts the contents 128, use the crimpers 120 to form the fold lines 122 (labeled in FIG. 5). Then the controller 136 controls the conveyor 132 to lower the open container 116 after forming the fold lines 122 (labeled in FIG. 5) to clear space for the open container 116 to clear below the cutters 110, the crimpers 120, and the measuring plate 134 for egress from the cut and crimp station 108 to the folding station 124 labeled in FIG. 4.

[0029]With reference not to FIG. 3, each cutter 110 includes a set of shears 140 having a shear pivot 142 that is fixed relative to the frame 102. The controller 136 (labeled in FIG. 1) is operatively connected to the actuator 144 of the shears 140 to form the cuts 112 (labeled in FIG. 5) when the open container 116 is in position. As shown in FIG. 4, each crimper 120 includes a set of pinchers 146 each including a creaser 148 and opposed anvil 150 configured for forming fold lines 122 (labeled in FIG. 5) by pinching toward one another on opposite sides of a wall of the open container 116. Each set of pinchers 146 has a pincher pivot 152 that is fixed relative to the frame 102. The controller 136 (labeled in FIG. 1) is operatively connected to the actuator 154 of the pinchers 146 to form the fold lines 122 (labeled in FIG. 5) when the open container 116 is in position.

[0030]With reference now to FIG. 2, after forming the cuts 112 and fold lines 122, the controller 136 controls the conveyor 132 to transport the open container 116 to the folding station 124. The folding station includes a folding armature 156 fixed to the frame 102 and configured to fold down the plurality of flaps 118 (labeled in FIG. 5). This forms a closed container 130 from the open container, enclosing the contents 128 within the closed container 130. From the folding station 124, the controller 136 controls the conveyor 132 to transport the closed container 130 lateral to the main feed direction A to a lid apply station 158 that is also at the second deck level 106 as shown in FIG. 1.

[0031]With continued reference to FIG. 2, a lid magazine 160 is operatively connected to the frame 102 to feed lid blanks 162 into the conveyor. The lid magazine 160 is at the second deck level 106 of FIG. 1. The controller 136 (labeled in FIG. 1) controls the conveyor 132 to transfer a lid blank 162 from the lid magazine 160 to the lid apply station 158 along the main feed direction A. The lid apply station 158 is adjacent to and lateral from the folding station 124, and the conveyor 132 positions the closed container 130 under the lid blank 162 in the lid apply station 158 as shown in FIG. 1. In the lid apply station 158, adhesive can be applied to the lid blank 162 and/or to the closed container 130, the lid blank 162 is folded lid 164, the lid 164 can be adhering to the closed container 130. The lid apply station 158 includes a lid blank folder 166 and glue applicator 168 each operatively connected to the frame 102 to form the lid blank 162 into a lid 164 and to adhere the lid 164 to the closed container 130. The glue applicator 168 is configured to apply beads of glue 170 to two opposing flaps of the lid blank 162/164 and to two opposing sidewalls of the closed container 130 (as indicated schematically in FIG. 5) for adhering the lid 164 to the closed container 130 around four sides of the closed container 130.

[0032]Then the controller 136 of FIG. 1 controls the conveyor 132 to outfeed the closed container 130 and lid 164, e.g. moving down a ramp from the second deck level 106 toward the first deck level 104 and out of the frame 102 of the system 100. The process outlined above can be repeated for a stream of containers 116/130 each having bespoke top flaps 118 (labeled in FIG. 5) customized to the unique content of each successive container 116/130. Although the height of each container 116/130 is custom or bespoke to its contents 128, the footprint size of each container 116/130 is constant. It is therefore unnecessary to move the cutters 110 and crimpers 120. Moreover, since each open container 116 is moved up into the cutters 110 and crimpers 120, there is little or no vibration in the cutters 110 and crimpers 120, allowing for rapid throughput of containers 116/130 through the system 100. The open containers 116 can have a non-square footprint, in which case the open containers 116 can be transported narrow face first into and out of the cut and crimp station 108 relative to the main feed direction A.

[0033]The methods and systems of the present disclosure, as described above and shown in the drawings, provide for creating custom heights in fixed footprint size containers, to provide custom sized containers appropriate for their given content, with speed and reliability that exceeds more conventional systems. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.