System and method for assembling a package with a flip-top

Abstract

An automatic packaging machine for forming a latching flip-top box from a blank. A plurality of mandrels are coupled to a conveyor system. Each of the mandrels include a mounting block for coupling the mandrel to the automatic packaging machine, a package-holding assembly operatively connected to the mounting block and being rotatable about a first axis from a first position to a second position, and a flap holder assembly operatively connected to the mounting block. The flap holder assembly is rotatable about a second axis substantially perpendicular to the first axis. A plurality of plows and tucker assemblies sequentially manipulate portions of the blank in order to form portions of the box.

1 . A mandrel having a mounting block and for use with an automatic packaging machine and having a mounting block for coupling to the automatic packaging machine, the mandrel comprising:
 a package-holding assembly operatively connected to the mounting block, the package-holding assembly rotatable about a first axis from a first position to a second position; and   a flap holder assembly operatively connected to the mounting block, the flap holder assembly rotatable about a second axis substantially perpendicular to the first axis.   
   
   
       2 . The mandrel of claim l, further comprising a lateral support member coupled to the mounting block, wherein the package-holding assembly is rotapanelly connected to the lateral support member. 
   
   
       3 . The mandrel of  claim 2 , further comprising means for maintaining the package-holding assembly in the first position relative to the lateral support member. 
   
   
       4 . The mandrel of  claim 3 , wherein the maintaining means comprises a latching member coupled to the lateral support member, the latching member releaseably mating with a bushing on the package-holding assembly. 
   
   
       5 . The mandrel of  claim 3 , wherein the package-holding assembly comprises a plurality of gripping arms, the plurality of gripping arms selectively permitting a package blank to be captured by the package-holding assembly. 
   
   
       6 . The mandrel of  claim 5 , wherein the package-holding assembly further comprises a guide mechanism positioned within the plurality of gripping arms, the guide mechanism holding the package blank during the assembly thereof. 
   
   
       7 . The mandrel of  claim 2 , wherein the flap holder assembly includes a plurality of side arms for contacting portions of a package blank. 
   
   
       8 . A mandrel for use with an automatic packaging machine in forming a package with a flip-top, comprising:
 a mounting block for coupling the mandrel to the automatic packaging machine,   a package-holding assembly operatively connected to the mounting block, the package-holding assembly having a free end and a fixed end, the free end having a secured position and an unsecured position and being rotatable about a first axis between the secured position and the unsecured position;   a lateral support member coupled to the mounting block, wherein the package-holding assembly is rotapanelly connected to the lateral support member;   a latch coupled to the lateral support member for releasably connecting the free end of the package-holding assembly; and   a flap holder assembly operatively connected to the mounting block, the flap holder assembly rotatable about a second axis substantially perpendicular to the first axis.   
   
   
       9 . The mandrel of  claim 8 , wherein the package-holding assembly includes a plurality of gripping arms for selectively permitting a package blank to be captured by the package-holding assembly. 
   
   
       10 . The mandrel of  claim 9 , wherein the package-holding assembly further comprises a guide mechanism positioned within the plurality of gripping arms, the guide mechanism holding the package blank during the assembly thereof. 
   
   
       11 . The mandrel of  claim 8 , wherein the flap holder assembly includes a plurality of side arms for contacting portions of a package blank. 
   
   
       12 . A method of forming a latching flip-top box having a flip-top portion hingedly connected to the box along a minor axis of the box, comprising the steps of:
 providing a box blank;   placing the unitary box blank in a mandrel, the mandrel, coupled to a conveyor system and comprising:
 a package-holding assembly rotatable about a first axis from a first position to a second position; and 
 a flap holder assembly operatively connected to the package-holding assembly, the flap holder assembly rotatable from a retracted position to an extended position about a second axis substantially perpendicular to the first axis, 
   folding a first lower flap of the box blank with a first plow;   folding a second lower flap of the box blank onto the first lower flap with a second plow;   folding a third lower flap of the box blank onto the second lower flap with a third plow;   applying an adhesive to the third lower flap;   folding a fourth lower flap of the box blank onto the third lower flap with a fourth plow;   rotating the package-holding assembly about the first axis from the first position to the second position;   folding a first front upper panel of the box blank with a first tucker assembly;   folding a latching panel of the box blank using the first tucker assembly;   folding a second front upper panel of the box blank using a fifth plow;   rotating the flap holder assembly from the retracted position to the extended position, the flap holder assembly folding a flip top panel and first and second flip-top wing panels of the box blank;   folding a first wing panel of the box blank using a second tucker assembly;   folding a second wing panel of the box blank using the second tucker assembly;   applying adhesive to either exposed surfaces on the first and second wing panels or an underside of a front flip-top panel;   folding the front flip-top panel onto the exposed surfaces of the first and second wing panels using a sixth plow;   rotating the flap holder assembly from the extended position to the retracted position;   rotating the package-holding assembly about the first axis from the second position to the first position;   folding a first rear upper panel of the box blank using a seventh plow;   applying adhesive to either an exposed surface on the first rear upper panel or an underside of a second rear upper panel;   folding the second rear upper panel onto the exposed surface of the first rear upper panel using an eighth plow.   
   
   
       13 . The method of  claim 12 , further comprising the step of using a ninth plow to eject the latching flip-top box from the mandrel. 
   
   
       14 . The method of  claim 12 , wherein the mandrel includes a latching mechanism for releasably securing the package-holding assembly in the first position. 
   
   
       15 . The method of  claim 12 , wherein the package-holding assembly includes a plurality of gripping arms, the plurality of gripping arms opening to allow a box blank to enter the package-holding assembly.