US3345796A - Method of packaging a compressible material in a compressible carton - Google Patents

Description

Oct. 10, 1967 s P. BELSINGER 3,345,796

METHOD OF PACKAGING A COMPRESSIBLE MATERIAL IN FIGI 1967. s. P. BELSINGER 3,345, 96

' METHOD OF PACKAGING A COMPRESSIBLE MATERIAL IN A COMPRESSIBLE CARTON Filed Oct. 21, 1963 5 Sheets-Sheet 2 11/1 INVENTOR.

SAMUEL P. BELSINGER JMQ, fir M AT TORNEYS Oct. 10, 1967 s. P. BELSINGER 3,345,796

METHOD OF PACKAGING A COMPRESSIBLE MATERIAL: IN

' A COMPRESSIBLE CARTON Filed Oct. 21, 1963 5 Sheet-Sheet a 8 M ii "Ill 77 III IH Q I INVENTOR. SAMUEL F? BELSINGER ATTORNEYS United States Patent O 3,345,796 METHOD OF PACKAGING A COMPRESSIBLE MATERIAL IN A COMPRESSIBLE CARTON Samuel P. Belsinger, Atlanta, Ga., assignor to Belsinger, Inc., Atlanta, Ga., a corporation of Georgia Filed Oct. 21, 1963, Ser. No. 317,573 1 Claim. (Cl. 53-24) This application is a continuation-in-part of my copending application Ser. No. 232,463 filed Oct. 23, 1963 and now Patent No. 3,262,631.

This invention relates to a process, container and apparatus for confining yieldable material and is more particularly concerned with a fibre board container, an apparatus for compressing the container and the process of packaging compressible material in a compressed condition within the fibre board container.

In the past it has been common practice for cones of synthetic yarns to be packaged in side-by-side relationship in layers separated by fibre board dividers, the dividers having spaced holes through which the ends of the spools project. Since a large quantity of yarn is packed in a single container, the container has usually been provided with an access door for closing a side opening, the packer thereby having access through the opening to a depth in the container in excess of his normal reach. These containers must be closed under compression whereby any tendency of the yarn to shift within the container is 1 eliminated.

Heretofore, the compressible containers generally used were all two piece containers having a body and a cap, the cap telescoping onto the body and being urged by a ram against the upper edge of the body so as to compact or compress spools of yarn into the dividers as a metal strap or straps were passed around the container to retain the cap in its seated condition.

The two piece prior art containers, while holding the yarn firmly in place for shipping, are bulky, expensive and require considerable floor space for packing. Hence, the trade has long sought a one piece fibre board container which may be packed under compression.

Heretofore, it has been believed that it was impossible to pack a one piece fibre board container under compression since, in so doing the top flaps must be progressively closed over the protruding top of the yarns, thereby breaking the top flaps and causing them to roll around this protruded material.

Contrary to prior art beliefs and practices, I have devised a one piece container and a method of packing the container whereby, the flaps forming the top are closed over the top of the compressible material within the container, prior to compression and, thereafter, the top is urged downwardly to a seated position adjacent the top edges of the panels. Then, the top is locked in its seated position, holding the compressible material in a compressed condition. For this purpose, the top flaps are respectively joined to the upper edges of the panels, which define the tubular portion of the container, through toggle-like complementary intermediate flaps which initially space the top flaps from the top edge of the panels. The intermediate flaps have the ability, however, to be jack knifed outwardly as the top flaps, in their closed conditions, are urged toward the edges of the panels. As the top is seated on the upper edges of the panels, the intermediate flaps are brought into horizontal juxtaposition with each other and the top flap score lines are brought into coincidence respectively with the panel score lines whereby the intermediate flaps may be folded, along the coincident score lines, to vertical positions against the outer surfaces of the upper portions of the panels. Next, a strap or other arresting member is passed around the intermediate flaps to secure the intermediate flaps in posi- 3,345,796 Patented Oct. 10, 1967 tion so that they, in turn, hold the top i.e. top flaps seated in position compressing the yarns within the container.

The present invention also includes a ram mechanism having a platen by which the top flaps, after forming the top, are urged toward the panel edges and pivoted fingers which move in arcuate paths inwardly so as simultaneously to urge all intermediate flaps from their horizontal positions to essentially vertical positions respectively abutting the outer surfaces, of the panels. The fingers are sufiiciently flat and occupy little space outwardly of the intermediate flaps to permit the installation of the compression strap thereabout for retaining the intermediate flaps and therefore may be withdrawn as the strap remains around the intermediate flaps.

Accordingly, it is an object of the present invention to provide a process by which compressible material may be quickly, easily, inexpensively and efiiciently packaged in a compressed condition within a container.

Another object of the present invention is to provide a new use for a one piece slotted box.

Another object of the present invention is to provide an automatic ram which is particularly suited for compressing a one piece container having intermediate flaps.

Another object of the present invention is to provide a strong, inexpensive, one piece container which is capable of receiving compressible material, of being quickly and easily compressed while containing the material and of being secured for retaining the compressible material in its compressed condition.

Another object of the present invention is to provide a container which is suitable for forming either a relatively short or a relatively long container.

Other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings wherein like characters of reference designate corresponding parts throughout the several views and wherein:

FIG. 1 is a perspective view of a one piece compressible container constructed in accordance with the present invention for enclosing and compressing compressible material and for retaining the material in a compressed condition.

FIG. 2 is a fragmentary perspective view of a ram mechanism constructed in accordance with the present invention for urging the top of the compressible container shown in FIG. 1 against the edges of panels of the container and for thereafter folding the intermediate flaps to their locking positions.

FIG. 3 is a fragmentary schematic vertical sectional view of the ram mechanism of FIG. 2 compressing the container of FIG. 1, the fingers of the ram mechanism being in position for folding the intermediate flaps.

FIG. 4 is a view similar to FIG. 3 and showing the position of the fingers after the fingers have been actuated and a strap has been passed around the container.

FIG. 5 is a view similar to FIGS. 3 and 4 and showing the ram mechanism withdrawn from the container.

FIG. 6 is a vertical sectional View on a reduced scale of the container of FIG. 1, the container being packed with compressible material, yarn, and the top being closed in a non compressing condition.

FIG. 7 is a view similar to FIG. 6 and showing the container and the yarn when the top of the container has been compressed to the condition of the container shown in FIG. 3.

FIG. 8 is a view similar to FIG. 7 and showing the container and yarns after the intermediate flaps have been folded.

FIG. 9 is a perspective view of the container in its closed condition after the strap has been secured around a the intermediate fiaps but prior to the time the fingers are removed therefrom, the container corresponding to the condition of the container as illustrated in FIG. 4.

FIG. is a view similar to FIG. 9 and showing the container after the fingers have been removed, the container corresponding to the condition of the container as illustrated in FIG. 5.

Referring now in detail to the embodiment chosen for the purpose of illustrating the present invention, it being understod that in its broader aspects, the present invention is not limited to the exact details herein depicted, numeral 11 denotes generally the container of the present invention which is essentially identical to the container disclosed in FIGS. 1 through 4 of my copending application Ser. No. 232,463 filed Oct. 23, 1962, except that, in the present embodiment, intermediate flaps are provided between the panels and the top flaps, as will be described hereinafter.

The container 11 is formed from a fiat rectangular blank of fibre board scored to define four side panels, namely panels 20, 21, 22 and 23. More specifically, the numerals and 21 denote the opposed side panels of the container 11 while the numeral 22 denotes the front panel and numeral 23 denotes the rear panel.

The panels are initially in side-by-side relationship, the panels 28 and 22 being joined by a common edge or score line 24, the panels 22 and 21 being joined by a common score line 25 and the panels 21 and 23 being joined by a common score line 26. One of the outer panels 21) or 23, such as panel 23, is provided with the usual flange 27 on its outer edge, the flange 27, and panel 23 being joined on a common score line 28. When the container 11 is squared and the bottom flaps, such as flaps and 47, closed in the usual way to form the bottom, the score lines 24, 25, 26 and 28 form the vertical edges of the container 11.

The panels 20, 21, 22 and 23 are each rectangular members provided respectively with top flap members. The top flap members extend from the upper edges of the panels 20, 21, 22 and 23. Specifically, panel 20 is provided with top flap member 29, panel 21 is provided with top flap member 31, panel 22 is provided with top flap member 33 and panel 23 is provided with top flap member 35.

The top flap members 29, 31, 33 and 35 are separated from their respective panels by horizontal or transverse panel score lines or fold lines 40, 41, 42 and 43, respectively.

As best seen in FIG. 1, an access door is formed in the front panel 22. This access door 50 is defined by a pair of straight parallel, vertical or longitudinal cuts which are spaced inwardly from and parallel to the score lines 24 and 25. The upper ends of these vertical cuts intersect outwardly extending cuts on score line 42 while the lower ends of the vertical cuts terminate in the central portion of panel 22. A straight horizontal transverse score line or fold line 53 joins the lower ends of the cuts. Thus the access door 50 is defined by the score lines 42 and 53 and side edges 51 and 52, formed by the vertical cuts, these side edges 51 and 52 being spaced inwardly from and parallel to the score lines 24 and 25 respectively. The panel 22 now forms a U-shaped fixed panel which receives the access door 50, the door 50 being in essentially the same plane with the remaining portion of panel 22 when door 50 is closed.

Referring now to the top flap members 29, 31, 33 and 35, it will be seen that each of these is provided with a pair of intermediate flaps and a top flap. In other words, the flap member 29 is provided with a pair of parallel score lines 54 and 55 which are parallel to the score line 40 and to the outer edge 56 of the flap member 29. This divides the flap member 29 into an inner intermediate flap 57, and outer intermediate flap 58, hingedly secured together along score line 54, and a top flap 59 secured to the outer intermediate flap 58 along the top flap score line 55. In identical manner, the flap member 31 is provided with a pair of score lines 64 and 65 which separate the flap member 31 into an inner intermediate flap 67, and outer intermediate flap 68, a top flap 69 having an outer edge 66. Likewise, the fiap member 33 has score lines 74 and 75, inner intermediate flap 77, outer intermediate flap 78, top flap 79 and outer edge 76 while flap member 35 has score lines 84 and 85, inner intermediate flap 87, outer intermediate flap 88, top flap 89 and outer edge 86.

It is important, in most embodiments of the present invention, that all intermediate flaps be of approximately equal width. In other words, the panel score lines 40, 41, 42, and 43 should lie in essentially the same common plane when the access door 50 is closed. Furthermore, the common intermediate flap score lines 54, 64, 74 and 84, when the blank for the container 11 is formed, should be in alignment with each other while the flap score lines 58, 68, 78 and 88 should, likewise, be in alignment when the blank is initially scored. Also, the distance from score line 40 and 54, from score line 41 to score line 64, from score line 42 to score line 74 and from score line 43 to score line 84 should be equal, or approximately equal to the distance from the score line 54 to score line 55 which in turn is equal to the distance from score line 64 to score line 65 and the distance from score line 74 to score line 75 and the distance from score line 84 to score line 85, thereby assuring that all of the intermediate panels 57, 58, 67, 68, 77, 78, 87, and 88 are of equal width. The purpose of providing the equal width intermediate fiaps is that the score lines which are common to both intermediate flaps, namely score lines 54, 64, 74 and 84 should be moved outwardly in synchronization as the inner and outer intermediate flaps hinge together in response to movement of the top downwardly, as will be explained more fully hereinafter.

Referring now to FIG. 2 of the drawings, the mechanism for compressing the container 11 includes a hydraulic ram mechanism having a main piston rod 90 which is carried, for reciprocation in a vertical path, by a piston (not shown) within a double acting hydraulic cylinder 91 suitably mounted in a vertical position. Any suitable hydraulic fluid may be utilized for actuating the piston (not shown) both in a downward direction and in an upward direction to extend and retract the piston rod 90. Since the operation of hydraulic rams is well known, the details thereof are not included in the disclosure, it being sufficient to note that through hydraulic actuation of appropriate mechanisms (not shown) the piston rod 90 is caused to be retracted or extended, as desired.

On the lower or outer end of the piston rod 90 is a fiat, square or rectangular horizontally disposed, plate or platen 92 which corresponds generally to the dimensions of the top of a container, such as container 11. The plane of platen 92 is perpendicular to the axis of rod 90. Adjacent the periment-al edges, respectively, of platen 92 are a plurality of upstanding brackets 93 to which are respectively secured a plurality of pillow blocks 94, the pillow blocks along each edge of the platen 92 being in alignment.

The pillow blocks 94 along one edge of platen 92 journal for rotation a shaft 95 while the pillow blocks 94 along an adjacent edge journal a shaft 96. The pillow blocks 94 along still another edge of platen 92 journal the shaft 97 while the pillow blocks 94 along the fourth edge journal the shaft 98. The shafts 95 and 96 terminate outwardly of the pillow blocks 94, adjacent each other and are provided with beveled gears 100, respectively, the gears meshing so that rotation of shaft 95 will cause equal rotation of shaft 96. In like manner, shafts 97 and 98 are coupled together for simultaneous rotation.

The shafts 95, 96, 97 and 98 are provided with a plurality of radially extending, axially spaced, fingers 101 formed of relatively rigid flat metal, the fingers 101 extending generally outwardly from their associated shafts and terminating in rounded ends 102.

The outer fingers 101 on shaft 95 extend upwardly and inwardly above the shaft 95 and are pivotally connected respectively to the ends of rigid link members 103 and 104 which extend inwardly over the platen 92 and are, in turn, pivotally connected to the lower ends of levers 105 and 106. In like manner the fingers 101 on shaft 97 extend upwardly and inwardly and are pivotally connected to links 107 and 108 respectively, the links 107 and 108, in turn, being pivotally connected to the upper ends of levers 105 and 106. The central portion of levers 105 and 106 are fixed to the ends of a transverse shaft 110 so as to rotate together.

The shaft of 110 is supported by pillow blocks 111 on a T-shaped block 112 carried on the upper surface of platen 92. The central portion of the T-shaped block 112 supports a hydraulic cylinder 113 which actuates a piston rod 114, the piston rod 114 being connected pivotally to the outer end of an operating lever 115, the inner end of which is secured to the central portion of shaft 110. Thus, upon actuation of the cylinder 113, the levers 105 and 106 are rotated, or rocked, in a clockwise or counter clockwise direction to thereby rotate by the links 103, 104, 107 and 108 the shafts 95 and 97; the shafts 95 and 97 through the beveled gears, such as gears 99 and 100, also rotating the shafts 96 and 98.

It is now seen that the fingers 101 are controlled by piston rod 114 to pivot'simultaneously in arcuate paths from generally outwardly extending or horizontal positions to generally downwardly extending or vertical positions when the piston rod 114 is extended. When piston rod 114 is retracted, the fingers 101 are returned from their downwardly extending positions to their outwardly extended positions.

The introduction of hydraulic fluid to cylinder 113 on one side of its piston or the other is controlled by solenoid (not shown) which are respectively actuated by actuation of limit switches 121 and 123 carried on a vertical rod 122 adjacent and parallel to piston rod 90. Projecting from the central portion of piston rod 90 is a limit switch actuator 120 which, when the piston rod 90 approaches its downrnost extended position, engages and throws the bottom limit switch 121. In like manner, the actuator 120 throws an upper limit switch 123 when the piston rod 90 approaches its most retracted position. The throwing of bottom limit switch 121 causes cylinder 113 to extend piston rod 114 and the closing of limit switch 123 causes the cylinder 113 to retract piston 114. Thus, when the limit switch 121 is actuated, the fingers 101 which remain extended generally outwardly, are pivoted to downwardly extending positions and when limit switch 123 is actuated, the fingers 101 are returned to their outwardly extended positions.

Operation From the foregoing description, the operation of the present invention should be apparent. When a container, such as container 11 is received, it is righted to the condition shown in FIG. 1 and the bottom flaps 45 and 47 are closed in the usual way. Thereafter, the door 50 is opened to permit access to the interior of the container 11. Furthermore, the flap members 29, 31, 33 and 35 are folded generally outwardly, along the score lines 40, 41, 42 and 43. In such condition, the packer packs the container 11 with a plurality of cones of yarn 130 on spools 132. After each layer of cones 130 is placed in the container 11, the packer places a divider or spacer member 131 therebetween. The spacer members 131 function to hold the spools 132 apart and form bases for additional layers of cones 130 so that when the packer completes the packing of the yarns, there are a plurality of layers of cones 130, one above the other, the cones 130 in each layer being disposed in side-by-side relationship. For this purpose, the spacer members 131 are provided with alternate, relatively large holes for receiving the bottom end of spools 132 and relatively small holes for receiving the upper ends of spools 132. Thus, the spools 132 are staggered with respect to each other in a vertical direction.

It will be understood by those skilled in the art that the dimensions of container 11 are such that the topmost layer of cones 130 will project slightly above the upper edge of panels 21, 22, 23 and 24. Thus, a portion of the uppermost layer projects outwardly beyond the score lines 40, 41, 42 and 43. Therefore, if the container 11 is to be closed, the cones 130 must be compressed within the container 11. Normally, the compression is for a distance of approximately 2 inches and is for the purpose of urging the ends of the spools 132 tightly into seated positions in the spacer members 131.

After the cones 130 have been packed in the container 11, the door 50 is closed so as to be coplanar with the remaining portion of panel 22. The top flaps 59 and 69 are folded, along top flap score lines 55 and 65, over the top of the top layer of cones 130, the fiaps 59 and 69 being folded inwardly toward each other so that their edges 56 and 66 abut. Then, a tape is passed over the abutting portions of the flaps 59 and 69 so as to retain them together. It will be understood that, in many instances the fiaps 59 and 69 are not, and need not be, long enough to have their edges 56 and 66 abut.. In such instances, the flaps 59 and 69 need not be secured together or to anything. Thereafter, the flaps 79 and 89 are folded along top flap score lines 75 and 85, over the flaps 59 and 69 and likewise held in a closed condition with their edges 76 and 86 abutting relationship by means of a tape 133. If desired, the flaps 59 and 69 may be glued or strapped to the flaps 79 and 89 to form the close-d top of the container 11.

The tape 133 may, if desired, be commenced at score line 40 and extend along the central portions of intermediate flaps 57 and 58 and thence across the edges of flaps 79 and 89 and then along the central portions of flaps 68 and 67 to terminate at score line 41, thereby securing the flap members 29, 31, 33 and 35 in relative positions for compression. By such an arrangement the container 11 when closed will tend to lock the end portions of the tape 133 between the inner intermediate flaps 57, 67 and their associated panels 20 and 21.

It will be understood that when the top flaps are closed to form a top, as aforesaid, the intermediate flaps are essentially in their upright extended positions so that the top formed by the top flaps 59, 69, 79 and 89 is spaced from the upper edges of the panels namely edges 40, 41, 42 and 43. The width of two of the intermediate flaps such as flaps 77 and 78 is greater than the height above the edges 40, 41, 42 and 43 that the cones 130 extend. Therefore, no compressive force need be exerted by the closing of the top. The container 11 is now essentially in the condition illustrated in FIG. 6.

Next, the container 11 with its top closed is fed beneath the ram mechanism shown in FIG. 2. The fingers 101 of the ram mechanism extend essentially outwardly as the top of container 11 is positioned beneath the platen 92. Thereafter, the cylinder 91 is actuated to extend the piston 90 and hence bring the platen 92 down upon the top of the container 11. This urges the closed top formed by the flaps 59, 69, 79 and 89 downwardly flat on top of all cones 130 in the uppermost layer. As the top is moved downwardly, it causes the intermediate flaps to jack knife outwardly and be progressively closed toward each other, pivoting about the scorelines 54, 64, 74 and 84 and also pivoting about the scorelines or edges 40, 41, 42 and 43, as well as pivoting about the scorelines 55, 65, 7 5 and 85.

Thereafter, the piston 90 moves downwardly a distance sufficient to seat the container top on the edges 40, 41, 42 and 43, as illustrated in FIGS. 3 and 7. At this time, the inner and outer intermediate flaps of each panel, such as flaps 77 and 73, are brought flat against each other and extend essentially outwardly in a horizontal position. Next, since the actuator 130 has engaged the switch 121, during the last increment of the downward movement of the piston 90, the cylinder 113 is actuated to extend the piston rod 114 and thereby pivot all fingers 101 simultaneously downwardly to vertical positions. The fingers acting upon the outer intermediate flaps 58, 63, 78 and 88 simultaneously, urge these intermediate flaps from the position shown in FIGS. 3 and 7 to the positions shown in FIGS. 4 and 8.

The fingers 101 in their vertical positions, as illustrated in FIGS. 4 and 8, hold the intermediate flaps fiat against their associated panels and the operator passes a metal strap 134 around the lower portion of all fingers, drawing the strap 134 tight in position covering the mid portion of all outer intermediate flaps 58, 68, 78 and 88. The fingers 101 are then withdrawn by the retraction of piston rod 90 thereby sliding from beneath strap 134 and leaving the container 11 in a closed compressed condition as illustrated in FIG. 10.

When the piston rod 90 approaches its uppermost position, the actuator 120 engages the switch 123 which, in turn, actuates the cylinder 113 to retract the piston rod 114 and thereby tilt the fingers 101 to their essentially horizontal or outwardly extending positions. The ram mechanism, therefore, is in a position to receive the next container 11 to be compressed and sealed.

It will be recognized by those skilled in the art that While the present container 11 is particularly useful for forming a compressed package of textile yarns, the container 11 has other and varied uses in that a container of one length, ie a relatively long container may be produced by simply leaving the intermediate flaps 57, 67, 77, 87, 58, 68, 78 and 88 extended in the plane of their respective panels and forming a top by folding the top flaps 59, 69, 79 and 89 inwardly. Also, a relatively short container may be formed by folding the intermediate flaps 57, 67, 77, 87, 58, 68, 78 and 88 against the outer surfaces of panels 26, 21, 22 and 23 as illustrated in FIG. 10.

Furthermore, the inventive concept is not limited to fibre board containers, such as the illustrated container 11, or to the application of force or pressure in a specific direction since it will be understood that other containers having laterally deformable flexible portions may readily be compressed utilizing the teaching herein, the flexible portions being held in various Ways after compression so as to retain the compressible material therein in a compressed condition.

It will be obvious to those skilled in the art that many variations may be made in the embodiments here chosen for the purpose of illustrating the present invention without parting from the scope thereof as defined by the appended claim.

I claim:

In a method of packaging compressible material in a compressed condition in a container having a pair of opposed side panels, a front panel and a rear panel connected together to form a tumbler member closed at one end, said container including top flaps at the other end of said tubular member, a plurality of pairs of intermediate flaps of approximately the same width, each pair of intermediate flaps being joined to each other along a common edge and disposed between each top flap and its associated panel, one of said intermediate flaps being joined to the upper edge of its associated panel along a panel score line, the other of said intermediate flaps being connected along a top flap score line to an edge of its associated top flap, said top flaps being foldable along the flap score lines over the upper end of said container for forming the top of said container, the improvement which comprises inserting said compressible material within said container to a level above the panel score lines of said panels and to a height no greater than the distance to said top flap score lines when said intermediate flaps are extended in the planes of their associated panels, closing said top flaps along said top flap score lines over the upper end of said compressible material, securing at least some of said top flaps in their closed condition, applying a force downwardly on said top to compress said compressible material within said container while simultaneously urging the common edge of said intermediate flaps outwardly of the direction of the applied force for causing said intermediate flaps to pivot along said common edge toward each other, the intermediate flaps adjacent said panels pivoting outwardly about said panel score lines, the intermediate flaps adjacent said top flaps pivoting outwardly about said top flap score lines, continuing the application of said force on said top until said flap score lines are respectively brought into approximate coincidence with said panel score lines, thereafter folding said intermediate flaps along the panel score lines and top flap score lines into positions outwardly adjacent said panels and thereafter securing said intermediate flaps in their positions adjacent said panels.

References Cited UNITED STATES PATENTS 2,641,318 6/1953 Brady 53376 X 2,682,137 6/1954 Cox 5324 2,763,973 9/1956 Atkins 5324 2,883,042 4/1959 Richer 2067 2,887,834 5/1959 Guyer 5337 X 3,020,832 2/1962 Sholin -233 3,062,131 11/1962 Mankki 100 233 3,112,027 11/1963 Field 2067 3,117,873 1/1964 Bartels et al 5322 X TRAVIS S. MCGEHEE, Primary Examiner.

FRANK E. BAILEY, Examiner.

R. L. FARRIS, A. E. FOURNIER, Assistant Examiners.

Images