Methods and machine for forming a shipping container with an article retaining web

Patent metadata

Field	Value
Publication number	US-10987889-B2
Application number	US-201514860457-A
Country	US
Kind code	B2
Filing date	Sep 21, 2015
Priority date	Sep 21, 2015
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

A machine for forming a blank assembly having a blank and a retaining web coupled to the blank includes a deck coupled to a frame, and a blank transfer assembly coupled to the frame. The blank transfer assembly is configured to position the blank on the deck. The machine also includes a web transfer assembly coupled to the frame. The web transfer assembly includes a pick-up assembly moveable between a first end and a second end of the web transfer assembly. The pick-up assembly is configured to pick up the web proximate the first end and deposit the web proximate the second end in an at least partially overlying relationship with the blank positioned on the deck. A first compression member is configured to compress a coupling region of the web against the blank on the deck to form the blank assembly.

First claim

What is claimed is:

1. A machine for forming a blank assembly having a blank and a retaining web coupled to the blank, said machine comprising:
a deck coupled to a frame;
a blank transfer assembly associated with said frame, said blank transfer assembly configured to place the blank on said deck in a first position, wherein the blank includes a plurality of adjacent panels for forming sidewalls of a container formed from the blank assembly, each panel including at least one side flap extending therefrom;
a web transfer assembly associated with said frame and extending from a first end to a second end, said web transfer assembly comprising a pick-up assembly moveable between said first end and said second end, said pick-up assembly configured to lift the web from a platform proximate said first end using a plurality of vacuum cups, transfer the web from a position proximate said first end to a position proximate said second end, and lower the web to deposit the web proximate said second end in an at least partially overlying relationship with the blank placed on said deck in which a first offset distance is defined between a bottom free edge of the web and a leading edge of the blank; and
a first compression member coupled to the web transfer assembly via at least one spring and extending parallel to a transverse longitudinal edge of the blank when the blank is placed on said deck and configured to compress a coupling region of the web against a corresponding region of the plurality of panels of the blank on said deck to form the blank assembly, wherein a downstream edge of the first compression member is offset upstream, with respect to a blank loading direction X, by the first offset distance from the leading edge of the blank, wherein the coupling region of the web includes an adhesive material applied to a portion of the web along only one transverse edge of the web, the coupling region defining an adhered portion of the blank assembly in which the coupling region of the web is adhered to the corresponding region of the plurality of panels of the blank, the web further including a free portion in which the web is not adhered to the plurality of panels of the blank, wherein the free portion extends from a free edge of the web to the coupling region, and the free portion of the web is foldable inside the container formed from the blank assembly for retaining product within the container.

2. The machine in accordance with claim 1 , wherein said blank transfer assembly is configured to move the blank in the horizontal blank loading direction X that is parallel to said deck, and said pick-up assembly is configured to move the web from proximate said first end of said web transfer assembly to proximate said second end of said web transfer assembly in a direction Y that is generally perpendicular to the X direction.

3. The machine in accordance with claim 1 , wherein said web transfer assembly comprises a gantry operable for bi-directional translation between said first end and said second end of said web transfer assembly, said pick-up assembly being coupled to said gantry.

4. The machine in accordance with claim 3 , wherein said web transfer assembly further comprises a lift arm coupled to said gantry and operable for translation with respect to said gantry bi-directionally in a vertical Z direction, said lift arm extending from a first end to an opposite second end, said lift arm moveable between an extended position wherein said first end of said lift arm is proximate to said gantry, and a retracted position wherein said second end of said lift arm is proximate to said gantry, said second end of said lift arm being coupled to said pick-up assembly.

5. The machine in accordance with claim 4 , wherein said web transfer assembly further comprises a first servomechanism coupled proximate said first end of said web transfer assembly and a second servomechanism coupled proximate said second end of said web transfer assembly, each of said first and second servomechanisms operable for bi-directional rotation and coupled to a belt that extends from a belt first end to a belt second end, each of said belt first end and said belt second end being coupled to said lift arm proximate said lift arm second end, said belt being looped in a circuit from proximate said lift arm second end, around said second servomechanism, around said lift arm first end, around said first servomechanism, and back to proximate said lift arm second end, such that said lift arm is carried by said belt.

6. The machine in accordance with claim 1 , wherein said first compression member is coupled to said pick-up assembly, and wherein said machine further comprises a second compression member coupled to said frame, said second compression member being positioned to provide a compression surface against which said first compression member is operable to compress the coupling region of the web and the blank.

7. The machine in accordance with claim 6 , wherein said second compression member is operably coupled to at least one actuator operable to move said second compression member between a first position, in which said second compression member is positioned proximate the blank to provide the compression surface, and a second position, in which said second compression member is positioned out of a path travelled by a forwarding assembly configured to transfer the blank assembly along said deck.

8. The machine in accordance with claim 1 , further comprising a web adhesive applicator associated with said frame, said web adhesive applicator being operable to apply the adhesive material to the portion of the coupling region of the web along the one transverse edge of the web as said pick-up assembly carries the web between said first end and said second end of said web transfer assembly to define the coupling region and the free portion of the web.

9. The machine in accordance with claim 1 , further comprising a forwarding assembly associated with said frame, said forwarding assembly configured to transfer the blank assembly along said deck in the blank loading direction X.

10. The machine in accordance with claim 1 , further comprising a web separator proximate to said first end of said web transfer assembly and comprising the platform, said web separator configured to cut the web from a spool of web material and deposit the web on said platform, said web separator positioned such that the web deposited on said platform is offset in the blank loading direction X by the predetermined offset distance from the blank placed on said deck prior to the web being lifting from said platform by said pick-up assembly such that no registration of the web with respect to the blank is required.

11. A method for forming a blank assembly using a machine, the blank assembly including a blank and a retaining web coupled to the blank, said method comprising:
placing the blank in a first position on a deck coupled to a frame of the machine, wherein the blank includes a plurality of adjacent panels for forming sidewalls of a container formed from the blank assembly, each panel including at least one side flap extending therefrom;
lifting the web from a platform proximate a first end of a web transfer assembly using a plurality of vacuum cups of a pick-up assembly of the machine;
transferring the web from proximate the first end of the web transfer assembly to proximate a second end of the web transfer assembly using the pick-up assembly of the machine;
lowering the web, using the pick-up assembly, to deposit the web proximate the second end of the web transfer assembly in an at least partially overlying relationship with the blank placed on the deck in which a first offset distan

Assignees

• Westrock Shared Services Llc

Inventors

• Graham Thomas Dean
• Aganovic Amer
• D'Alesio Claudio

Classifications

• B31B50/00 Primary

  Making rigid or semi-rigid containers, e.g. boxes or cartons · CPC title

• B65D5/606

  Bags or bag-like tubes loosely glued to the wall of a "tubular" container · CPC title

• B31B2105/00

  Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs · CPC title

• B31B50/06

  from stacks · CPC title

• B31B2120/30

  collapsible; temporarily collapsed during manufacturing · CPC title