Method and apparatus for forming containers

Abstract

A system is claimed for forming a container from a tubular blank comprising a plurality of panels and flaps interconnected to provide a generally flattened tubular configuration. A first and second panels are provided with the second panel being rotatable relative to the first panel. The system may comprise a first engagement device for engaging the first panel and a second engagement device for engaging the second panel, and being located on a panel rotating apparatus operable to rotate the second panel from an orientation generally parallel to the first panel to a second orientation at an angle to the first panel. The generally flattened tubular blank may be reconfigured from a generally flattened configuration to an open configuration.

1 . A system for forming a container from a tubular blank comprising a plurality of panels and flaps interconnected to provide a generally flattened tubular configuration, wherein said plurality of panels comprise a first panel, and a second panel interconnected to said first panel, said second panel being rotatable relative to said first panel, said system comprising:
 a first engagement device for engaging said first panel of said blank;   a second engagement device for engaging said second panel of said blank, said second engagement device being located on a panel rotating apparatus operable to rotate said second panel of said bank from a first orientation wherein said first panel is generally parallel to said first panel, to a second orientation wherein second panel is oriented at an angle to said first panel, such that said generally flattened tubular blank may be reconfigured from a generally flattened configuration to an open configuration.   
     
     
         2 . A system as claimed in  claim 1  further comprising an erector device and wherein said first engagement member, said second engagement member and said panel rotating apparatus comprise part of said erector device. 
     
     
         3 . A system as claimed in  claim 1  wherein said first engagement device comprises a first suction cup device and said second engagement device comprises a second suction cup device. 
     
     
         4 .- 6 . (canceled) 
     
     
         7 . A system as claimed in  claim 1 , wherein said second angle is approximately 90 degrees. 
     
     
         8 . A system as claimed in  claim 7  wherein first engagement device comprises a plurality of suction cup devices having suction cup surfaces generally arranged in a first plane and said second engagement device comprises a plurality of suction cup devices having suction cup surfaces generally arranged in a second plane. 
     
     
         9 .- 29 . (canceled) 
     
     
         30 . A system as claimed in  claim 2  further comprising a movement sub-system, said movement sub-system comprising at least one movement apparatus, said at least one movement apparatus comprising:
 a vertical movement device, said vertical movement device being connected to said erector device; 
 a horizontal movement device connected to a frame, said horizontal movement device operable sliding longitudinal movement relative to said frame; 
 said vertical movement device being interconnected to said horizontal movement device and operable for vertical sliding movement relative to said horizontal movement device; 
 a drive apparatus operable to drive said horizontal movement device horizontally and to drive said vertical movement device vertically relative to said horizontal movement device; 
 a controller operable to control said drive apparatus; 
 whereby through operation of said drive apparatus, said controller is operable to cause said vertical movement device and said horizontal movement device to move said erector device along a path in space having vertical and longitudinal components. 
 
     
     
         31 . A system as claimed in  claim 30  wherein at least one movement sub-system comprises first and second movement apparatuses arranged in opposed relation to each other, said first movement apparatus for moving a first erector device along a path, and said second movement apparatus for moving a second erector device along said same path, said first erector head being out of phase with said second erector head along said path such that the movement of said first erector head does not interfere with the movement of said second erector head. 
     
     
         32 . A system as claimed in any one of claimsclaim  2  to  29  further comprising a movement sub-system, said movement sub-system comprising at least one movement apparatus, said at least one movement apparatus comprising-:
 a continuous belt; 
 a generally vertically oriented support member having a first pulley positioned proximate an upper end of said belt support member, said support member adapted for connection to a first erector device; 
 a slidable pulley block, said block being adapted for sliding longitudinal movement on a support member, and said block having a series of spaced pulleys, said vertical support member being interconnected to said pulley block for vertical sliding movement relative to said pulley block; 
 first and second longitudinally spaced belt drives, each of said belt drives being independently operable to rotate at varying speeds and in the same and opposite directions to each other, said belt drives both operable to drive said belt on opposed sides of said vertical support member; 
 a controller to control the speed and direction of rotation of said belt drives; 
 said vertical support member being received adjacent said block and being supported by said belt for vertical sliding movement relative to said block, said belt extending from a fixed location on said vertical support tube upwards to a first pulley on said block, longitudinally to said first belt drive, from said first belt drive over a second pulley of said block, upwards to said first pulley of said vertical member, downwards to a third pulley of said block to said second belt drive; from said second belt drive and longitudinally to over a fourth pulley of said slide block, and then downward to a second fixed location of said vertical member; 
 whereby through operation of said first and second belt drives, said controller can cause said vertically oriented support member and said first erector device connected thereto, to be moved up and down relative to said block and move longitudinally right and left with said block between said first and second belt drives with said block on said block support member such that said erector device follows a path in space having vertical and longitudinal components. 
 
     
     
         33 . A system as claimed in  claim 32  wherein at least one movement apparatus comprises first and second movement apparatuses, said first movement apparatus for moving a first erector device along a path, and said second movement apparatus for moving a second erector device along said same path, but said first erector head being out of phase with said second erector head along said path. 
     
     
         34 . A system as claimed in  claim 1  wherein said container is a carton. 
     
     
         35 . A system as claimed in  claim 34  wherein said carton is regular slotted case. 
     
     
         36 . A system as claimed in  claim 30 , wherein said path in space is a cyclical path extending between said magazine and said folding and sealing apparatus. 
     
     
         37 . A system as claimed in  claim 36  wherein said movement apparatus is operable to move said erector head, while said erector head is engaged with said first and second panels of said blank, and said blank is in an open configuration, towards said folding and sealing apparatus, so that a flap of said carton blank can be rotated relative to said first and second panels and said first flap by co-operation of said movement of said erector head relative to a plough member of said folding and sealing apparatus. 
     
     
         38 . A system a claimed in  claim 37  wherein said erector head is operable to be moved by said movement apparatus: from a first position where said erector device is operable to retrieve a blank from said magazine; to a second position where said erector head is operable to open said blank to said open configuration; to a third position, such that during said movement of said erector head from said second position to said third position, a folding apparatus is operable to fold said second to at least partially form a container bottom. 
     
     
         39 . A system a claimed in  claim 38  wherein said erector head is operable to be moved from said third position to a fourth position wherein said erector device is operable to disengage from said container. 
     
     
         40 .- 70 . (canceled) 
     
     
         71 . A system as claimed in  claim 36 , further comprising a magazine, said magazine comprising:
 a conveyor for moving a stack of blanks longitudinally;   a lateral stack alignment apparatus operable to align the blanks in the stack of laterally;   a longitudinal stack alignment apparatus operable to align the blanks in the stack longitudinally.   
     
     
         72 . A system as claimed in  claim 71  wherein said longitudinal alignment apparatus comprises first and second, spaced apart, generally parallel, longitudinally oriented side members, the spacing between said first and second side members being adjustable relative to each other, such that a stack of blanks positioned between said first and second side members may have their side edges longitudinally and vertically aligned. 
     
     
         73 . A system as claimed in  claim 72  wherein said first and second side members are side wall members, said first side wall member being operable to move towards and away from the right side edges of said blanks in said stack. 
     
     
         74 . A system as claimed in  claim 73  wherein said lateral stack alignment apparatus comprises (i) an tamper actuator secured to a first side wall member (ii) a vertical bar member connected to said actuator and operable to extend to engage rear edges of said blanks in said stack and operable to retract (iii) a front wall member; whereby said stack of blanks positioned between said first and second side members and said vertical bar member and aid front wall member may have their front and rear edges laterally and vertically aligned. 
     
     
         75 . A system as claimed in  claim 74  further comprising a controller operable to control the operation of said first side wall and said tamper actuator. 
     
     
         76 .- 110 . (canceled)