Web packaging machines with variable depth forming

Abstract

A packaging machine is for forming a product cavity in a web including a forming die box defining a recess into which the product cavity is formed. An insert is axially movable in the recess to thereby vary a depth of the recess. A variable depth mechanism selectively moves the insert to vary the depth of the recess. The packaging machine includes a latching mechanism that moves the forming die box into and between a first position in which the forming die box is spaced apart from the die box base and a second position in which the forming die box is supported by the die box base.

What is claimed is: 
     
         1 . A method of forming a product cavity in a web, the method comprising:
 providing a die box base and a forming die box, the forming die box being moveable relative to the die box base and defining a recess in which the product cavity is formed;   moving the forming die box from a staging position in which the forming die box is laterally offset from the die box base to a position in which the forming die box is vertically above the die box base;   moving an insert in the recess with a variable depth mechanism to thereby vary depth of the recess and the product cavity formed therein; and   moving the forming die box and the die box base together relative to the web such that the product cavity is formed in the recess.   
     
     
         2 . The method according to  claim 1 , wherein the moving of the forming die box from the staging position comprises:
 moving the forming die box into a first position in which the forming die box is vertically offset and disengaged from the die box base; and   further moving the forming die box from the first position to a second position in which the forming die box engages the die box base.   
     
     
         3 . The method according to  claim 2 , wherein a gasket is sandwiched between the die box base and the forming die box when the forming die box is in the second position. 
     
     
         4 . The method according to  claim 2 , wherein the moving the forming die box from the first position to the second position comprises actuating a latching mechanism to thereby move the forming die box to the second position. 
     
     
         5 . The method according to  claim 4 , wherein the latching mechanism comprises a rotatable eccentric member and a rail member that engages the forming die box, and wherein rotation of the eccentric member moves the rail member such that the forming die box is moved into the first position or the second position. 
     
     
         6 . The method according to  claim 5 , wherein rotation of the eccentric member in a first direction causes the rail member to move downward such that the forming die box is moved from the first position to the second position. 
     
     
         7 . The method according to  claim 6 , wherein rotation of the eccentric member in a second direction opposite the first direction causes the rail member to move upward such that the forming die box is moved from the second position to the first position. 
     
     
         8 . The method according to  claim 7 , wherein the latching mechanism comprises a handle operably coupled to the eccentric member and for rotating the eccentric member. 
     
     
         9 . The method according to  claim 4 , wherein the latching mechanism is a first latching mechanism, and wherein the moving the forming die box from the first position to the second position further comprises actuating a second latching mechanism to thereby move the forming die box to the second position. 
     
     
         10 . The method according to  claim 9 , wherein the first latching mechanism is adjacent to a first side of the die box base and the second latching mechanism is adjacent to an opposite second side of the die box base. 
     
     
         11 . The method according to  claim 1 , wherein the die box base comprises a hole and the variable depth mechanism comprises an engagement member extending through the hole; and
 wherein the moving the insert in the recess with the variable depth mechanism comprises moving the engagement member through the hole and relative to the insert to thereby move the insert and change the depth of the recess.   
     
     
         12 . The method according to  claim 11 , wherein moving the engagement member in a direction toward the insert moves the insert away from the die box base and moving the engagement member in a direction away from the insert causes the insert to move toward the die box base. 
     
     
         13 . The method according to  claim 11 , wherein the variable depth mechanism comprises a platform to which the engagement member is coupled and a drive shaft; and
 wherein the moving of the engagement member comprises rotating the drive shaft such that the platform moves relative to the die box base and the engagement member moves relative to the insert.   
     
     
         14 . The method according to  claim 1 , wherein the moving the forming die box from the staging position to the first position comprises moving the forming die box along a guide track assembly. 
     
     
         15 . The method according to  claim 14 , wherein the guide track assembly comprises a rail moveable into an extended position in which rail supports the forming die box in the staging position. 
     
     
         16 . A method for forming a product cavity in a web, the method comprising:
 providing a die box base and a forming die box, the forming die box moveable relative to the die box base and defining a recess in which the product cavity is formed;   moving the forming die box from a staging position in which the forming die box is laterally offset from the die box base into a first position in which the forming die box is vertically offset above the die box base; and   actuating a latching mechanism to thereby move the forming die box into and between the first position to a second position in which the forming die box engages the die box base.   
     
     
         17 . The method according to  claim 16 , wherein the latching mechanism comprises a rotatable eccentric member and a rail member that engages the forming die box, and wherein rotation of the eccentric member moves the rail member such that the forming die box is moved into the first position or the second position. 
     
     
         18 . The method according to  claim 17 , wherein rotation of the eccentric member in a first direction causes the rail member to move vertically downward such that the forming die box is moved from the first position to the second position; and
 wherein rotation of the eccentric member in a second direction opposite the first direction causes the rail member to move vertically upward such that the forming die box is moved from the second position to the first position.   
     
     
         19 . The method according to  claim 17 , wherein the latching mechanism comprises a handle operably coupled to the eccentric member and for rotating the eccentric member. 
     
     
         20 . The method according to  claim 19 , wherein the moving the forming die box from the staging position to the first position comprises moving the forming die box along a guide track assembly, and wherein the guide track assembly comprises a rail moveable into an extended position in which rail supports the forming die box in the staging position.