Packaging machine
United States Patent 1191 Hunt [ Apr. 15, 1975 PACKAGING MACHINE [75] Inventor: Ernest G. Hunt, Lachine, Quebec,  
  21 Appl. No.: 404,288  
 [30] Foreign Application Priority Data Oct. 12, 1973 Canada 153,800  
 [52] U.S. Cl 53/207; 53/209 [51] Int. Cl B65b 11/18; B65b 49/08 [58] Field of Search 53/207, 208, 209, 218, 53/287, 374; 229/87 R; 93/54 R [56] References Cited UNITED STATES PATENTS 1,908,822 5/1933 Daniell 53/287 2,066,449 l/l937 Barrett 53/218 2,539,390 l/195l Almgren 53/287 X 2,587,663 3/1952 Socke 53/287 X 2,800,224 7/1957 Walter 229/87 R X 2,855,741 10/1958 Shaw .L 53/374 X 3,302,367 2/1967 Talarioo... 53/374 X 3,374,604 3/1968 Roesner 53/374 X 3,445,983 5/1969 Stevens 53/209 X 3,555,777 1/1971 Gentili 53/209 3,673,763 7/1972 Dorfman., 53/209 X FOREIGN PATENTS OR APPLICATIONS 693,716 7/1953 United Kingdom 53/218 Primary Examiner-Travis S. McGehee Assistant Examiner-John Sipos Attorney; Agent, or FirmC. A. Rowley [57] ABSTRACT A packaging machine having a loading station and a pair of side-by-side pressing and folding stations. Blanks are delivered from the loading station to the first pressing and folding station and flaps at two ends of the package are folded and pressed until the adhesive is set-The blanks are then transferred in a second direction to the second pressing and folding station wherein flaps from the remaining two sides of the blank are folded and pressed until the adhesive sets.  
 9 Claims, 11 Drawing Figures P-IENIEDAPRISmFs 3,877,202 sum 2 gr 2 FIG. 3  
  //0 M2 //2 m2 m5 H67 /02 m2 Heel/64 W H68 PACKAGING MACHINE FIELD OF THE INVENTION The present invention relates to a packaging machine, more specifically the present invention relates to a machine for forming a package about a stack of rigid panels such as thermosetting resin impregnated paper laminates.  
 DESCRIPTION OF THE PRIOR ART Thermosetting resin impregnated paper laminates such as those formed from phenol and melamine impregnated paper sheets to provide a decorative panel and other similar thin sheet panel-like material that may have their edges damaged in shipping require special precautions be taken in packaging to protect the edges. Such panels are usually sold in varying quantities so that the height of the stack of panels to be packaged varies depending on the number of panels to be shipped SUMMARY OF THE INVENTION Broadly the present invention relates to a packaging machine comprising a loading station. a pair of side-byside pressing and folding station. means to deliver the blank for forming the container from the loading station to the first of said pressing and folding stations in a first direction and means to transfer said blank from said first to said second pressing and folding station in a direction substantially perpendicular to said first direction. Each of said pressing and folding stations incorporating means to fold flaps at one pair of opposite ends of the package to be formed to a position overlying the package and means for pressing the flap so folded against the top of the package, said means for pressing incorporating resilient means adapted to accommodate different thicknesses of articles being packaged.  
 BRIEF DESCRIPTION OF THE DRAWING Further features. objects and advantages will be evident from the following detailed description of a preferred embodiment of the present invention taken in conjunction with the accompanying drawings in which:  
  FIG. 1 is an isometric view with parts broken away illustrating one form of package to be made with the present invention;  
  FIG. 2 is a schematic plan view illustrating the general layout of the packaging machine;  
  FIG. 3 is a section along the lines 33 of FIG. 2 with parts omitted for clarity and illustrating the pressing, folding and conveying system in the first pressing and folding station;  
  FIG. 4 is a section along the line 4-4 of FIG. 2 illustrating an alignment mechanism for maintaining the wooden side rails of the package in position as the blank is forwarded into the first station;  
  FIG. 5 is a section along the line 55 of FIG. 2 with parts omitted showing the positioning means for laterally positioning the blank in the first folding and pressing station;  
  FIGS. 6, 7 and 8 illustrate in sequence the operation of the folding mechanism;  
  FIG. 9 is an end viewwith parts omitted showing the press in a lowered position and accommodating the folding mechanisms, and  
  FIGS. 10 and 11 are sections through the pressing means illustrating how the press accommodates different thickness of members being packaged.  
 DESCRIPTION OF THE PREFERRED EMBODIMENTS The package 10 illustrated in FIG. 1 is composed of a peripheral frame formed of pairs of wood members 12 and 14 that protect the side edges of the laminates or panel members 16 contained within the frame. A container blank 18, provided with a pair of end flaps 20 each of which is divided by a fold line 22 into a side wall 24 and a top flap 26 and with a pair of end flaps 28 each of which is divided by a fold line 30 into a side wall 32 and a top closure flap 34 forms the body of the package. A top panel 36 is laid over the top of the laminate l6 and the peripheral frame formed by the members l2 and 14 and is secured in position by the top flaps 26 and 34 which are adhesively secured thereto thereby closing the package I0.  
  As shown in FIG. 2, the basic equipment of the present invention includes a loading station 38, a first pressing and folding station 40 and a second pressing and folding station 42.  
  The loading station 38 may simply be composed of a plurality of rolls 44 some of which may be driven to deliver the container blank l8 and articles to be packaged in the direction of the arrow 46 to the station 40. Alternatively, a flight conveyor may be used to more precisely locate the package and operate the timing mechanism of the machine. As the blank 18 is delivered to the station 40, the flaps 20 pass beneath a pair of gluing heads 48 and 50 which apply adhesive to these flaps 20.  
  The station 40 is provided with a pair of guiding and aligning devices 52 which cooperate with a positioning device 54 to laterally position the package. Also provided in the station 40 are a pair of substantially identical presses 56 which overlie folding mechanisms generally indicated at 58 (see FIG. 3) and which cooperate with the folding mechanisms 58 to move the flaps 20 into their final position relative to the package 10.  
  A cylinder 60 provided with a plate 62 on its free end may be provided. The plate 62 contacts the end wall 24 adjacent thereto and aids in folding the flaps 20. This cylinder 60 is not a necessity, but permits wider spacing between some of the folding mechanisms 58.  
  A pair of chain conveyors 64 each of which is provided with flights 66 move the package from the station 40 into the station 42.  
  Each of theguiding and aligning devices 52 are substantially identical and therefore only one of these devices will be described in detail (see FIGS. 3 and 4). Each of these devices 52 is composed of an elongated guide channel 68 extending across the station 40. A carriage 70 having a pair of wheels 72 which ride on the internal flanges 74 of the channel 68 is contained within the channel 68 and supports a weight member 76 and a wheel 78 which is free to rotate on the axle 80 (see FIG. 4). A cable 82 extends about pulleys 84 and 86 and is connected at one end to the carriage 70 and at its opposite end to a weight 88 contained within a housing 90. The weight 88 tends to move the carriage 70 and thus the roller 78 to the left in FIG. 4 (toward the loading station 38 in FIG. 2).  
  The positioning mechanism 54 is composed of a bell crank arm 92 pivotably mounted on pivot pin 94 to the frame of the machine adjacent the loading station 38. One end of the bell crank arm 92 is provided with a face 98 to contact the wooden rail 12 at that side of the package and push it into position when a piston and cylinder arrangement 96 connected between the opposite end of the bell crank arm 92 and the frame of the machine is actuated. The piston and cylinder arrangement 96 moves the bell crank arm 92 from the operative position illustated in FIG. to a retracted position wherein the face 98 is positioned well above the packbetween&#39;the free end of the arm l&#39;08 and the piston rod of the piston and cylinder arrangement 111. It will be.  
 noted that the projection 112 of the &#39;of the L-shaped link 104 engages the rear face 114 of the L-shaped arm 108 in the initial stages of movement of the folding mechanisms 58 (see FIG. 6). Upward movement of the connecting rod110 in the direction of the arrow 116 tends to pivot the arm 106 about its pivot connection 119 in the direction of the arrow 1l8 so that the faces 120 and 122 of the link 104 and the arm 106 respectively remain in substantially the same plane whilethe link 104 and arm 106 are pivoted relative to the frame 102 onthe pivot connection 124 between the link 1&#39;04 and the frame 102. 7  
  At a certain point in the movement of the link 104 and arm 106 about the pivot point 124 the relative poarrangement 134 pivots the bar 130 on pivot point 136 to move the bar 130 from its inoperative position shown in FIG. 3 to its operative position shown in section in FIGS. and 11. It is very important that the bottom of each presser bar 130 be provided with a resilient means such as the pad member 138 which is adapted to accommodate different thickness of laminates or plate-like members being packaged. The pad 138 in the illustrated arrangement is formed of compressible rubber, but it will be apparent that other resilient means may be used. for example an inflatable bag may be provided and/or the resiliency of the bar may be supplemented by springs or other means to accommodate the required differences in height of the articles to be packaged. Each of the pads 138 is formed with cutouts 140 to accommodate the various elements 106 of the folding mechanisms 58 which are positioned at spaced locations across the machine (see FIG. 9). In  
 the arrangement illustrated. three such folding mechanisms 58 are provided across the station at each end of the station 40. n  
  The folding and pressing station. 42 is quite similar to the station 40 in that it is provided with a pair of presses 56&#39; and a plurality of folding mechanisms equivalent to the mechanisms 58 strategically located under the pressing mechanisms 56&#39; in the same manner as the sitions of the free end of the arm 108 and the pivot I point 119 between the link 104 and the arm 106 is such that the arm 106 begins&#39;to pivot on the pivot point 119 relativeto the link 104. In the arrangement shown, this does not occur until the faces 120 and 122 are&#39;almost vertical and it is only in the last short length of movemembers 58 are located relative to the press mechanism 56. Because of the length of the presses 56&#39; a pair of piston and cylinders 134 is provided for each of the presses 56. The presses 56&#34; otherwise are substantially identical to the presses 56 in that they incorporate the resilient padding, etc. In the illustrated arrangement. the station 42 also includes a pair of cylinders 150 equivalent to the cylinder 60 of station 40. A pair of cylinders 150 is shown on each side of the station 42. These cylinders operate simultaneously to complete the folding operation. The cylinders 150 similar to the cylinders 60 in FIG. 3 for the station 40 may be omitted by simply locating the folding mechanisms 58 closer togethe&#39;r.  
 The station 42 also differs from the station 40 in the mode of transporting of the article or package through the station. In station 42, a plurality of driven rolls 152 are provided. These rolls are controllably driven to position the package relative to the folding instrumentality and t&#39;hen to deliver the package from the station. The rolls also are preferably mounted on a frame (not shown) that lifts them to an operative position project-.  
 ing above the table in station 42, when the rolls 152 are driven and an inoperative position below the table when they are inactive whereby the table provides a ably connected to the connecting rod-110 and the pressure plate against which the press 56&#39; operates.  
  Interposed between the stations 40 and 42 are a pair of adhesive applicators 154 which apply adhesive to the flaps 28 as the blank is fed from the station 40 to the station 42.  
  In the illustrated arrangement, the various mechanisms have been shown as fixed to a frame. It iscontemplated that these mechanisms may be made adjustable so that different size packages can be handled on the same equipment.  
  The operation of the device is as follows: First, a blank 18 is laid onthe rollers 44in the loading station 38 and the laminates or panels 16 to be packaged are laid on top of the bottom panel of the blank. These panels 16 are surrounded peripherally by pairs of wooden strips 12 and 14 and a top panel 36 is laid on top of the wood strips and panels 16. The operator then activates a switch which actuates the flight conveyors 64 and rollers 152 to clear the station 40 by moving a package therein to station 42 and by removing a package from station 42. This switch will only actuate after a package has been in station 40 and 42 a preset time sufficient to permit the adhesive to set and for the stations 40 and 42 to complete their cycles. The rollers 44 are then automatically powered to deliver the formed lay-up from the loading station 38 in the direction of the arrow 46 to the first pressing and folding station 40. As the blank 18 is moved to the station 40 the flaps projecting from opposite ends thereof pass beneath adhesive applicators 48 and 50 which apply adhesive to these flaps.  
  As the lay-up enters the folding station 40, the leading wood strip 12 contacts the pair of rollers 78 of the aligning and guiding mechanism 52. These rollers resist the advance of the lay-up since movement of the rollers or wheels 78 move the carriage 72 which is connected by cable 82 with the weight 88 and requires the weight 88 be lifted as the lay-up is advanced. A suitable adjustable stop (not shown) may be provided to limit the movement of each of the carriages 72 and thereby better ensure more accurate positioning of the lay-up.  
  After the lay-up has been advanced into the station 40, the positioning mechanism 54 is actuated (automatically) to extend the piston and cylinder arrangement 96 and thus move the face 98 in contact with the trailing wood strip 12 and force the lay-up against the rollers 78. This piston and cylinder arrangement 96 may be actuated by any suitable means for example by means of a limit switch sensing a position of the rollers 78 or by a suitable sensing means sensing the position of the blank 18. Operation of the cylinder 96 may then automatically actuate folding mechanisms 58 and the pressing mechanisms 56.  
  After actuation of the positioning mechanisms 45 the folding mechanisms 58 at each end of the station 40 are actuated. This results in the piston and the cylinders lll extending to move the connecting rod 110 upwardly to pivot the link 104 and arm 106 about the pivot point 124 followed by pivoting of the arm 106 about the pivot connection 119 to fold the flaps 20 and to form the side wall 24 followed by folding of the top flap 26 on the fold line 22 to position the top flap 26 in an overlying relation with the wood strip 14 and the top panel 36. At this time, the positioning cylinder 60 is actuated to move the plate 62 against the in wall of the container and complete the fold.  
  After actuation of the piston and cylinder 60 the piston and cylinders 134 operate to pivot the plates 130 on arms 132 about pivot points 136 to move the pads 138 down against the upper surface of the flaps 26 to force these flaps 26 into intimate contact with the panel 36 and to deflect the panel 36 about the wood strips 14 to apply the requisite pressure between the panel 36 and the flap 26 to ensure that the two are properly adhesively secured together. As above indicated, this is accomplished through the resilience of the pad 138 which accommodates different thickness of articles to be packaged while applying the requisite pressure to both the area between the pad 138 and the wood strip 14 and between the pad 138 and the laminates or panels being packaged.  
  After the flaps 26 have been secured to the top panel 36 as above described, the pressing mechanisms 56 and folding mechanisms 58 may be automatically retracted by moving their piston and cylinder arrangements in the opposite directions to move these mechanisms to their position as shown in FIG. 3. (The piston and cylinder 60 automatically retracts after thepress 56 has operated). The conveyor mechanism 64 may then be actuated as above described to advance the flights 66 in contact with the end wall formed by the flap 24 and move the partially finished package in the direction of the arrow 160 (in FIG. 2) into the station 42. The wheels 78 contact the wooden rail 12 at the side of the package and guide the movement of the packageto the station 42. As the package is advanced, the flaps 28 pass beneath the glue applicators 154 which apply adhesive to these flaps as the package is advanced into the station 42. The rollers 152 are also actuated to advance the package into proper position in the station 42 and to remove a previously folded package from the station 42.  
  After the package has been positioned in the station 42 the drive to the rollers 152 and chain 64 is stopped, for example, by means of a photoelectric cell sensing the position of the package. The folding mechanism 58 (equivalent to the mechanisms 58 in station 40) positioned on opposite sides of the station 42 beneath the press mechanisms 56&#39; are automatically operated at the same time as those in station 40, after the switch has been actuated and a fresh lay-up is in position in station 40. These mechanisms 58 fold the flaps 28 thereby moving the panels 32 to form the side walls of the container and by folding on fold line 30 position the flaps 34 in overlying relation with the previously folded flaps 26 and with the panel 36. The folding mechanisms 58 in the station 42 are substantially the same as those in station 40 and are actuated in the same manner to produce substantially the same fold. As soon as the folding mechanisms 58 have operated the cylinders (equivalent to the piston and cylinder arrangement 62) on both sides of the station 42 are actuated to complete the fold. These piston and cylinder arrangements 150 automatically retract after the presses 56&#39; have operated.  
  Next, the pressing devices 56&#39; are actuated (simultaneously with the devices 56 of station 40) to press the flaps 34 against the top of the panel 36 and apply sufficient pressure between the flap 34 and panel 36 to secure these two together in the same manner as the press 56 in the station 40 operated, i.e., the resilient pad 138 presses the flap 34 into contact with the top panel 36 in the area both overlying the strips 12 and overlying the laminates l6.  
  After the adhesive has secured the flaps 34 and the panel 36 together, the mechanisms 56&#39; are retracted followed by retraction of the folding mechanisms 58. The formed and sealed package is then advanced from the station 42 to a suitable receiving table or the line (not shown) when the next package being formed is being advanced from the station 40 to the station 42, i.e., when the rollers 152 are actuated to assist in bringing the next package into the station 42.  
  Having described one form of the invention, modifications will be evident to those skilled in the art without departing from the spirit of the invention as defined in the appended claims.  
 I claim:  
  1. A packaging machine for forming packages each composed of a stack of elements surrounded by a peripheral frame and wherein the height of said stack may vary from package to package while the height of said peripheral frame remains substantially constant from package to package, each said package including a bottom forming blank and a top panel overlying said stack and said frame, said machine comprising, a loading station, a pair of side by side pressing and folding stations, means to deliver said package from the loading station to the first of said pressing and folding stations in a first direction, means to transfer said blank from said first to the other of said pair of pressing and foldingstations in a direction substantially perpendicular to said&#39;first direction, each said pressing and folding station incorporating folding means to fold flaps at one pair of opposite ends of the package into a position overlying said top panel and said frame, said flaps projecting inwardof said package relative to said frame, pressing means, means to move said pressing means from an inoperative position to an operative pressing position wherein the flaps so folded are pressed against the top of the package, resilient means on a pressing face of said pressing means, said resilient means in said pressing position overlying said frame and projecting inwardly thereof thereby to force said flaps towards said frame and past the inner edge of said frame toward the top of said stack and means defining spaces in said resilient means to accommodate portions of said folding means when said pressing means is in pressing positron.  
  2. A machine as defined in claim 1 further comprising adhesive applying means between said loading and said first pressing and folding station positioned to apply adhesive to said flaps folded in said first pressing and folding station as said blank is advanced into said first pressing and folding station and second adhesive applying means positioned between said first and said other of said pressing and folding stations to apply adhesive to said flaps folded in said other of said pressing and folding stations.  
  3. A machine as defined in claim 1 wherein said folding means comprises an L-shaped link pivoted at one end to a frame member, a lever pivoted to said L- shaped link, an L-shaped arm projecting from said lever and having one section thereof in face-to-face relation with one arm of the L-shaped link, a connecting rod pivotably connected to the free end of said L- shaped arm and connecting said L-shaped arm to an actuating mechanism.  
  4. A machine as defined in claim 1 further comprising piston and cylinder means in said first pressing and folding stations for aligning said blanks.  
  5. A packaging mechanism as defined in claim 1 further comprising an aligning mechanism in said first pressing and folding station, said aligning mechanism comprising guiding wheels to be contacted by a part of said package as said blank is moved into said first pressing and folding station and to move with said blank into said pressing and folding station and means to bias said wheels against movement with said blank.  
  6. A machine as defined in claim 2 further comprising piston and cylinder means in said first pressing and folding stations for aligning said blanks.  
  7. A packaging mechanism as defined in claim 2 further comprising an aligning mechanism in said first pressing and folding station, said aligning mechanism comprising guiding wheels to be contacted by a part of said package as said blank is moved into said first pressing and folding station and to move with said blank into said pressing and folding station and means to bias said wheels against movement with said blank.  
  8. A machine as defined in claim 3 further comprising piston and cylinder means in said first pressing and folding stations for aligning said blanks.  
 9. A packaging mechanism as defined in claim 3 further comprising an aligning mechanism in said first pressing and folding station, said aligning mechanism comprising guiding wheels to be contacted by a part of said package as said blank is moved into said first pressing and folding station and to move with said blank into said pressing and folding station and means to bias said wheels against movement with said blank.