Automated method and automated system for packaging stacks of flexible articles

Abstract

The present invention discloses an automated method and an automated system for packaging stacks of flexible articles. The automated method comprises the following steps: loading the stacks of flexible articles into an upright box having a first open end and a second open end by a pair of end actuators, each open end having at least one wing-shaped portion, and the wing-shaped portion can move between an open configuration and a closed configuration; moving the wing-shaped portion of the first open end from the open configuration to the closed configuration by a first wing-shaped portion closing mechanism; pushing the stacks of flexible articles toward a first gap by a pushing mechanism, thereby forming a second gap between the second open end and the stacks of flexible articles; and moving the wing-shaped portion of the second open end from the open configuration to the closed configuration by a second wing-shaped portion closing mechanism; the first gap and the second gap are configured to prevent the wing-shaped portion from being blocked by the stacks of flexible articles while closing the wing-shaped portion.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to patent application No. PI2021003212 filed on June 10, 2021. The entire disclosure of the above application is incorporated herein by reference. Technical Field

[0003] The present application relates to methods and systems for packaging flexible articles. More particularly, the present application relates to methods and systems for automatically packaging a stack of flexible articles into an upright box without causing the flexible articles to bulge and damage the upright box. Background Art

[0004] In a glove production line, gloves as finished products are usually packaged into a packaging box during the product packaging process. Conventionally, this process is completed by manpower, whereby the gloves are manually stacked and inserted into the packaging box by workers. This packaging method requires a lot of labor intensity and will result in low glove packaging efficiency due to the possibility of misalignment or loss of direction of the gloves when they are loaded into the packaging box. Therefore, these gloves are bulky and bulging. In addition, the number of stacked gloves to be packaged into the packaging box may be variable. Since the height of the stacked gloves is higher than the height of the packaging box, a large number of stacked gloves are difficult to insert into the packaging box. Workers need to manually flatten the stacked gloves so that these stacked gloves can be fitted into the packaging box. This manual operation of flattening the stacked gloves is inefficient and unreliable, which will cause the stacked gloves to not be flattened. Unflattened stacked gloves will damage the packaging box during the product packaging process, resulting in a bulky and bulging packaging box. In addition to using manpower, many packaging machines have been developed to automatically load gloves into the packaging box. Most packaging machines load gloves into a packaging box by pushing the gloves into the box through one of the side openings of the packaging box. This pushing operation may cause the packaging box to experience damage, such as tearing due to the high friction between the gloves and any contact surfaces during the process of traveling into the packaging box. In addition, the gloves may also be misaligned or lose their direction when being pushed into the packaging box, which may affect the operation of closing the side wings of the packaging box. For this reason, the packaging box may appear bulky and bulging.

[0005] An exemplary technology of the packaging machine can refer to Chinese patent publication number CN202728596U, which discloses a device for loading finished gloves into a packaging box, the device comprising a glove transition box installed in a transition box bracket for accommodating finished gloves, wherein one end of the transition box bracket is provided with an outer guide tail, and the other end is provided with a transition box drive mechanism and a glove blocking drive mechanism. The transition box drive mechanism is configured to push the glove transition box into the packaging box, and the glove blocking drive mechanism is configured to block the gloves so that the gloves remain in the packaging box. The packaging machine involves an operation of pushing the gloves into the packaging box. When the gloves are pushed into the packaging box, the packaging box may be torn due to friction with any contact surface during the process of the gloves traveling into the packaging box. In addition, the gloves may be messy and bulky in the packaging box, which may make it difficult to close the wing-shaped portion of the packaging box. Therefore, the obtained packaging box is bulky and bulging.

[0006] Therefore, it is desirable to provide a method and system for automatically packaging a stack of flexible articles into an upright box without causing the flexible articles to bulge and damage the upright box. The present invention provides such a method and system for packaging a stack of flexible articles that solves the above problems. Summary of the invention

[0007] According to one aspect of the present application, an automated method for packaging stacks of flexible articles is provided, wherein the method comprises the following steps: loading the stacks of flexible articles into an upright box by a pair of end effectors, the upright box having a first open end and a second open end, wherein each open end has at least one wing-shaped portion, the wing-shaped portion being movable between an open configuration and a closed configuration, in which the wing-shaped portion does not cover the opening of the open end, and in which the wing-shaped portion covers the opening of the open end, thereby the stacks of flexible articles are loaded away from the first open end. The invention relates to a method for preparing an adhesive tape comprising: placing the adhesive tape in an offset position of the first open end portion, thereby leaving a first gap between the first open end portion and the stack of flexible articles; moving the wing-shaped portion of the first open end portion from the open configuration to the closed configuration by a first wing-shaped portion closing mechanism; pushing the stack of flexible articles toward the first gap by a pushing mechanism, thereby forming a second gap between the second open end portion and the stack of flexible articles; and moving the wing-shaped portion of the second open end portion from the open configuration to the closed configuration by a second wing-shaped portion closing mechanism, wherein the first gap and the second gap are configured to prevent the wing-shaped portion from being blocked by the stack of flexible articles while closing the wing-shaped portion.

[0008] According to the features of this aspect of the present application, loading the stack of flexible articles into an upright box may also include the following steps: extending a pair of end actuators toward each other in opposite directions so that the pair of end actuators are in close contact with each other; when the pair of end actuators are in close contact, loading the stack of flexible articles into a groove formed by the pair of end actuators by a loading device; holding each opposite end of the stack of flexible articles by a pair of end actuators; and retracting the two end actuators in two opposite directions when loading the stack of flexible articles into the upright box.

[0009] According to another feature of this aspect of the application, the first wing closing mechanism may be arranged in a horizontal position relative to the longitudinal axis of the upright box for closing the wings of the first open end.

[0010] According to another feature of this aspect of the present application, the automated method may also include the following steps: reorienting the upright box having a closed first end from a horizontal position to an upright position by a flipping mechanism so that the second open end faces upward to accept a wing closing operation performed by a second wing closing mechanism, which is arranged in a vertical position relative to the longitudinal axis of the upright box.

[0011] According to another feature of this aspect of the application, the pushing mechanism may include a plate-like member that can be extended and retracted along the opening of the second open end, the plate-like member being configured to engage with the stack of flexible articles in the upright box and push the stack of flexible articles toward the first gap.

[0012] According to another feature of this aspect of the application, the upright box can be transferred from one mechanism to another mechanism by one or more controlled arms configured to clamp and lift the upright box.

[0013] According to another feature of this aspect of the application, the controlled arm may include a gripping member that is movable within a predetermined direction and orientation for gripping, lifting and transferring the upright box.

[0014] According to another feature of this aspect of the present application, the first wing closing mechanism and the second wing closing mechanism may include a plurality of pushing members capable of extending and retracting in the plurality of pushing member positions for closing the wings, whereby the plurality of pushing members are arranged in an array along the path of the wing closing station.

[0015] According to another aspect of the present application, an automated system for packaging stacks of flexible articles is provided, wherein the system includes a pair of end effectors, the pair of end effectors being used to load the stacks of flexible articles into an upright box having a first open end and a second open end, wherein each open end has at least one wing-shaped portion, the wing-shaped portion being movable between an open configuration and a closed configuration, in which the wing-shaped portion does not cover the opening of the open end, and in which the wing-shaped portion covers the opening of the open end, whereby the stacks of flexible articles are loaded in an offset position away from the first open end, thereby A first gap is left between the first open end and the stack of flexible articles; a first wing-shaped portion closing mechanism, which is used to move the wing-shaped portion of the first open end from an open configuration to a closed configuration; a pushing mechanism, which is used to push the stack of flexible articles toward the first gap, thereby forming a second gap between the second open end and the stack of flexible articles; and a second wing-shaped portion closing mechanism, which is used to move the wing-shaped portion of the second open end from an open configuration to a closed configuration, wherein the first gap and the second gap are configured to prevent the wing-shaped portion from being blocked by the stack of flexible articles while closing the wing-shaped portion.

[0016] According to the features of this aspect of the present application, a pair of end effectors can be configured to extend toward each other in opposite directions so that the pair of end effectors are in close contact with each other to form a slot for receiving a stack of flexible articles.

[0017] According to another feature of this aspect of the present application, a pair of end actuators can also be configured to hold each opposite end of the stack of flexible articles and to retract the pair of end actuators in two opposite directions when the stack of flexible articles is loaded into the upright box.

[0018] According to another feature of this aspect of the application, the first wing closing mechanism may be arranged in a horizontal position relative to the longitudinal axis of the upright box for closing the wings of the first open end.

[0019] According to another feature of this aspect of the present application, the automated system may also include a flipping mechanism for redirecting an upright box having a closed first end from a horizontal position to an upright position so that the second open end faces upward to receive a wing closing operation performed by a second wing closing mechanism, which is arranged in a vertical position relative to the longitudinal axis of the upright box.

[0020] According to another feature of this aspect of the application, the pushing mechanism may include a plate-like member that can be extended and retracted along the opening of the second open end, the plate-like member being configured to engage with the stack of flexible articles in the upright box and push the stack of flexible articles toward the first gap.

[0021] According to another feature of this aspect of the application, the automated system may also include one or more controlled arms configured to transfer the upright box from one mechanism to another.

[0022] According to another feature of this aspect of the application, the controlled arm may include a gripping member that is movable within a predetermined direction and orientation for gripping, lifting and transferring the upright box.

[0023] According to another feature of this aspect of the present application, the first wing closing mechanism and the second wing closing mechanism may include a plurality of pushing members, which can extend and retract in the positions of the plurality of pushing members for closing the wings, whereby the plurality of pushing members are arranged in an array along the path of the wing closing station.

[0024] Those skilled in the art will readily appreciate that the present application is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent in the present application.The embodiments described herein are not intended as limitations on the scope of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] To facilitate understanding of the present application, preferred embodiments are shown in the accompanying drawings. When considered in conjunction with the following description, the present application, its structure and operation, and its advantages will be easily understood and appreciated by examining these preferred embodiments.

[0026] Figure 1 It is a three-dimensional diagram of the packaging system.

[0027] Figure 2 It is a top view of the packaging system.

[0028] Figure 3 is a side view of the packaging system.

[0029] Figures 4a to 4c is a diagram showing a pair of end effectors in a loading station of a packaging system.

[0030] Figure 5 is a diagram showing a stack of flexible articles positioned in a biased position within an upright box of the interlocking fold type.

[0031] Figure 6is a diagram showing a process of loading a stack of flexible articles by a robot arm in a loading station of a packaging system.

[0032] Figure 7 is a diagram illustrating a first wing closure mechanism and a second wing closure mechanism of a packaging system.

[0033] Figure 8 1 is a diagram showing a process of closing the wings of an upright box in a first wing closing mechanism and a second wing closing mechanism of a packaging system.

[0034] Fig. 9 : is a diagram showing an upright box of a butterfly folding type.

[0035] Fig.10 is a flow chart illustrating the process flow for loading a stack of flexible articles into an upright box.

[0036] Fig.11 is a flow chart showing the process flow for closing the wings of a vertical box. DETAILED DESCRIPTION

[0037] The present application will now be described in more detail by way of examples with reference to the accompanying drawings.

[0038] Figures 1 to 3 A packaging system is shown for automatically packaging a stack of flexible articles 200 into an upright box 100. The upright box 100 mentioned herein preferably refers to a box erected from a box blank. The box blank can be a flat sheet of a plate that has been cut, scored and slotted. The box blank can be made of any suitable material, such as paper, plastic or a combination of the two. The box blank can be erected manually or automatically by a machine to form an upright box 100. The upright box 100 has a first open end 101 and a second open end 102, wherein each open end 101, 102 includes at least one wing 103, 104, 105, 106, 107, 108, which can be moved between an open configuration, in which the wing 103, 104, 105, 106, 107, 108 does not cover the opening of the open end 101, 102, and a closed configuration, in which the wing 103, 104, 105, 106, 107, 108 covers the opening of the open end 101, 102. As an example, the flexible article 200 is preferably a glove, which includes but is not limited to surgical gloves, latex gloves, nitrile gloves, neoprene gloves, polyvinyl chloride gloves, or any combination thereof.

[0039] The packaging system generally includes: a pair of end effectors 1, which are configured to load a stack of flexible articles 200 into an upright box 100; a first wing-shaped portion closing mechanism 4, which is configured to seal a first open end 101 by moving wings 103, 104, 105 from an open configuration to a closed configuration; and a second wing-shaped portion closing mechanism 6, which is configured to seal a second open end 102 by moving wings 106, 107, 108 from an open configuration to a closed configuration. A collection station 7 is also provided, which is configured to receive the sealed upright box 100. The collection station 7 preferably includes a surface inclined at a predetermined angle so that the sealed upright box 100 can slide on the surface. In addition, the packaging system also includes one or more control arms 3, 5, which are configured to transfer the upright box 100 from one mechanism to another. A conveyor track 2 is provided to transfer the erected boxes 100 from the erection station to the loading station and the wing closing station.

[0040] Reference Figure 4a to Figure 4b , showing a pair of end effectors 1 in a loading station. Figure 4a The pair of end effectors 1 in close contact are shown. In an exemplary embodiment, the first end effector 1a and the second end effector 1b are initially arranged opposite to each other. When the loading operation is in progress, the first end effector 1a and the second end effector 1b extend toward each other in opposite directions so that the first end effector and the second end effector contact each other for holding the stack of flexible articles 200. Preferably, one end of each end effector 1a, 1b is provided with a bracket, whereby a groove 8 is formed when the two brackets of the end effectors 1a, 1b contact each other, and the groove is configured to be connected to the stack of flexible articles 200 by the user or as shown in FIG. Figure 6 The stack of flexible articles 200 loaded by the machine shown in the figure is preferably in the form of a robot arm 23. The robot arm 23 may include a pair of grippers 24, which are configured to hold the stack of flexible articles 200 and automatically load the stack of flexible articles onto the slot 8.

[0041] Reference Figure 4bEach end effector 1a, 1b further comprises a plate-like member 9a, 9b configured to engage with one end of a stack of flexible articles 200 when the stack of flexible articles 200 is loaded into the slot 8. Preferably, each plate-like member 9a, 9b is connected to an elongated rod 10a, 10b pivotally connected to the other end of the end effector 1a, 1b. Each elongated rod 10a, 10b is movable between a direction toward a corresponding support of the elongated rod and a direction away from a corresponding support of the elongated rod relative to a pivot point at the other end of the end effector 1a, 1b. After the stack of flexible articles 200 is loaded into the slot 8, each plate-like member 9a, 9b is actuated to pivot toward the corresponding support of the plate-like member so as to keep each end of the flexible article 200 in the end effector 1a, 1b. Preferably, a sensing unit may be provided to automatically actuate the plate-like members 9a, 9b to move toward the corresponding support. The sensing unit may be installed at a portion of the loading station for checking the loading condition in the slot 8. As an example, if the slot 8 is loaded with a stack of flexible articles 200, the sensing unit may transmit a signal to a processing unit of the packaging system to actuate the plate-like members 9a, 9b to hold the ends of the stack of flexible articles 200. The actuation of the plate-like members 9a, 9b may also be facilitated by a user by pressing a physical control button or a virtual control button.

[0042] Reference Figure 4cThe packaging system further includes a compression mechanism 12 configured to compress the stack of flexible articles 200 when the stack of flexible articles 200 is loaded into the slot 8 and held by the pair of end effectors 1a, 1b, to ensure that the stack of flexible articles 200 fully enters the slot 8 during the loading operation. Without such a compression operation, some flexible articles 200 may hang loosely on the edge of the slot 8, which may cause the pair of end effectors 1a, 1b to be stuck during the process of traveling into the upright box 100. In addition, the packaging system includes a pair of plate-like members 22, each of which is arranged at one side of the slot 8, and each of which is configured to form a vertical channel for the compression mechanism 12 during the compression operation to prevent the stack of flexible articles 200 from escaping from the slot 8 and to ensure that the stack of flexible articles 200 is fully in the slot 8. The pair of plate-like members 22 are initially placed in a horizontal position. After the stack of flexible articles 200 is loaded into the slot 8, the pair of plate-like members 22 is actuated to move to a vertical position, thereby forming a vertical passage around the slot 8. In addition, the compression mechanism 12 is configured to discharge air from the stack of flexible articles 200. Preferably, the compression mechanism 9 includes a body that can rotate between predetermined directions, the body having a pushing member that can extend and retract in a vertical direction relative to the longitudinal surface of the stack of flexible articles 200. The compression mechanism 12 can also be configured to compress the stack of flexible articles 200 until a predetermined thickness so that the stack of flexible articles 200 can be fitted into the upright box 100.

[0043] Reference Figure 4b , the upright box 100 is transferred from the erection station by the conveying track 2. Preferably, the conveying track 2 is arranged perpendicular to the paired end actuators 1a, 1b. The conveying track 2 includes a plurality of groups of peripheral edges 11 extending in the vertical direction, each group of peripheral edges having four peripheral edges 11 extending in the vertical direction, and the peripheral edges are configured to keep the upright box 100 in the upright position of the box. Each group of peripheral edges in the vertically extending peripheral edges 11 is guided to simultaneously be in a direction parallel to the paired end actuators 1a, 1b to form a travel path for the paired end actuators 1a, 1b, so that the second end actuator 1b can extend across the upright box 100 through the first open end 101 and the second open end 102, thereby being in close contact with the first end actuator 1a. Then, the pair of end effectors 1a, 1b holding each opposite end of the stack of flexible articles 200 are actuated to travel on the conveying track 2 into the upright box 100 for loading the stack of flexible articles 200 into the upright box 100. In a preferred embodiment, as Figure 5As shown in , a stack of flexible articles 200 is loaded into the upright box 100 in a biased position away from the first open end 101, thereby leaving a first gap between the first open end 101 and the stack of flexible articles 200. Preferably, when the stack of flexible articles 200 is loaded into the upright box 100, both end effectors 1a, 1b are retracted in two opposite directions. In one embodiment of the present application, each end effector 1a, 1b further includes a stopper 25a, 25b, which is configured to hold the stack of flexible articles 200 by extending inwardly to the stack of flexible articles 200 when the end effectors 1a, 1b are retracted away from the upright box 100. Preferably, the stops 25a, 25b may be made of a soft and flexible material, such as Teflon or nylon, and the stops 25a, 25b are designed so that the two stops 25a, 25b will retract in a direction away from the stack of flexible articles 200 as the stops hold the stack in place. Advantageously, the loading operation prevents the stack of flexible articles 200 and the upright case 100 from frictionally contacting any surface during the progress of the stack of flexible articles 200 into the upright case 100, and also prevents the stack of flexible articles 200 and the upright case 100 from being torn during the loading operation.

[0044] In one embodiment of the present application, the loading operation is performed so that when the stack of flexible articles 200 is held by the pair of end effectors 1a, 1b, the stack of flexible articles 200 can be loaded into the upright box 100 while maintaining substantially the same distance between the two end effectors 1a, 1b to prevent the flexible articles 200 from bulging when loaded into the upright box 100. In this particular embodiment, the pair of end effectors 1a, 1b may have a sensing unit that ensures that the two end effectors 1a, 1b are spaced apart by the same distance during the forward travel into the upright box 100. As an example, the sensing unit may be an infrared sensor that detects the distance between the two end effectors 1a, 1b. After the pair of end effectors 1a, 1b have been retracted to a predetermined distance, the stoppers 25a, 25b will also be retracted in two opposite directions away from the stack of flexible articles 200.

[0045] Reference Figure 7 and Figure 8, showing a wing closing station. The packaging system further comprises a first wing closing mechanism 4 and a second wing closing mechanism 6, which are configured to respectively close the wings 103, 104, 105 of the first open end 101 of the upright box 100 and the wings 106, 107, 108 of the second open end 102. Preferably, the first open end 101 of the upright box 100 is guided toward the first wing closing mechanism 4 for first receiving the wing closing operation. Advantageously, the first gap between the first open end 101 and the stack of flexible articles 200 ensures a smooth wing closing operation because the first gap prevents the wings 103, 104, 105 from being blocked by the stack of flexible articles 200 while closing them. Preferably, the first wing closing mechanism 4 is arranged in a horizontal position relative to the longitudinal axis of the upright box 100 at the wing closing station for closing at least one wing 103, 104, 105 of the first open end 101. Preferably, the second wing closing mechanism 6 is arranged in a vertical position relative to the longitudinal axis of the upright box 100 at the wing closing station for closing at least one wing 106, 107, 108 of the second open end 102.

[0046] In a particular embodiment, each open end 101, 102 of the upright box 100 has more than one wing, including two inner wings 104, 107 and two outer wings 103, 105, 106, 108. Both the first wing closure mechanism 4 and the second wing closure mechanism 6 include a plurality of push members 14, 15, 18, 19, which are extendable and retractable in their positions for closing the wings 103, 104, 105, 106, 107, 108, whereby the plurality of push members 14, 15, 18, 19 are arranged in an array along the path of the wing closure station. As an example, the first push member 14 of the first wing-shaped closing mechanism 4 and the first push member 18 of the second wing-shaped closing mechanism 6 may include two elongated rods connected in the form of a scissor assembly, wherein the distance between the two distal ends of the elongated rods is at least the width of the open ends 101, 102, in particular the distance between the two inner wings 104, 107. The first push members 14, 18 are configured to be along the longitudinal axis of the upright box 100, which is parallel to the first open end 101 and the second open end 102, for engaging with the inner wings 104, 107 and simultaneously moving the inner wings 104, 107 from the open configuration to the closed configuration. The first push member 14 of the first wing-shaped closing mechanism 4 and the first push member 18 of the second wing-shaped closing mechanism 6 may also include one or more push plates having a flat surface for moving the first outer wing 103 of the open end 101 of the upright box 100 and the first outer wing 106 of the open end 102 from the open configuration to the closed configuration. In addition, the second pushing member 15 of the first wing-shaped closing mechanism 4 and the second pushing member 19 of the second wing-shaped closing mechanism 6, which are preferably arranged beside the first pushing members 14, 18, may include one or more pushing plates with a flat surface for moving the second outer wing-shaped portion 105 of the open end portion 101 and the second outer wing-shaped portion 108 of the open end portion 102 from the open configuration to the closed configuration to completely cover the opening of the first open end portion 101 and the opening of the second open end portion 102 of the upright box 100. In addition, the first outer wings 103, 106 also include an inwardly folded wing 109 at the end of the first outer wing, which may be formed by the folding member 13 of the first wing-shaped closing mechanism 4 and the folding member 17 of the second wing-shaped closing mechanism 6, whereby the inwardly folded wing 109 is configured to slide into the upright box 100 when the first outer wings 103, 106 are pushed to the closed configuration.

[0047] The packaging system further comprises a flipping mechanism arranged between the first wing-shaped portion closing mechanism 4 and the second wing-shaped portion closing mechanism 6, the flipping mechanism being configured to redirect the upright box 100 having the closed first open end 101 from a horizontal position to an upright position, so that the second open end 102 faces upwards to receive the wing-shaped portion closing operation performed by the second wing-shaped portion closing mechanism 6, the second wing-shaped portion closing mechanism being arranged in a vertical position relative to the longitudinal axis of the upright box 100. Preferably, the flipping mechanism comprises a platform 20, the platform being configured to allow the upright box 100 to rest on the platform in the horizontal position of the box. The platform 20 can be actuated by an actuator 21 to be lifted upward from an initial horizontal position to an upright position, which causes the upright box 100 resting on the platform 20 to flip with the platform. In addition, the packaging system further comprises a pushing mechanism 16, which is arranged in a vertical position at the wing-shaped portion closing station relative to the longitudinal axis of the upright box 100, and which is installed behind the flip mechanism and in front of the second wing-shaped portion closing mechanism 6. The pushing mechanism 16 is configured to push the stack of flexible articles 200 toward the first gap, thereby forming a second gap between the second open end 102 and the stack of flexible articles 200. Advantageously, this pushing operation by the pushing mechanism 16 is to expel trapped air from the stack of flexible articles. In addition, the second gap ensures a smooth wing-shaped portion closing operation because the second gap prevents the wings 106, 107, 108 of the second open end 102 from being blocked by the stack of flexible articles 200 while closing the wings 106, 107, 108. Preferably, pushing mechanism 16 includes a plate-like member that is extendable and retractable in the vertical direction along the opening of second open end 102, the plate-like member being configured to engage with the stack of flexible articles 200 within upright box 100 and push the stack of flexible articles 200 toward the first gap to form the second gap.

[0048] The packaging system also includes one or more controlled arms 3, 5, which are used to transfer the upright box 100 loaded with stacked pieces of flexible articles 200 from one mechanism to another. As an example, the first controlled arm 3 is configured to clamp and lift the upright box 100 from the conveying track 2, and guide the first open end 101 of the upright box 100 to the first wing-shaped portion closing mechanism 4 to receive the wing-shaped portion closing operation performed by each pushing member 14, 15. In addition, the first controlled arm 3 is configured to place the upright box 100 with the closed first open end 101 on the flip mechanism. The second controlled arm 5 is configured to transfer the redirected upright box 100 to the second wing-shaped portion closing mechanism 6 to receive the wing-shaped portion closing operation performed by each pushing member 18, 19. Preferably, the control arms 3, 5 can include a gripping member that can move in a predetermined direction and orientation for clamping, lifting and transferring the upright box 100. The second controlled arm 5 is also configured to transfer the upright boxes 100 obtained from the second wing closing mechanism 6 to the collection station 7 .

[0049] As an example, the upright box 100 described herein is of an interlocking folding type, such as Figure 5 It should be understood that the design of the upright box 100 can be easily replaced with other designs, such as but not limited to Fig. 9 The pushing members 14, 15 of the first wing-shaped closing mechanism 4 and the pushing members 18, 19 of the second wing-shaped closing mechanism 6 in the wing-shaped closing station 7 can be redesigned accordingly to form the wings 103, 104, 105, 106, 107, 108 of the upright box 100 of the closed butterfly folding type. Preferably, the upright box 100 described herein can be glued or not.

[0050] In another aspect of the present application, a packaging system can be used to perform a series of steps to package a stack of flexible articles 200 into an upright box 100. Fig.10, shows the process flow of loading a stack of flexible articles 20 into an upright box 100. In step 301, the stack of flexible articles 200 is first loaded into the slot 8 formed by the pair of end effectors 1a, 1b in close contact by a user or a machine. In step 302, after the loading operation is completed, each plate-like member 9a, 9b of the pair of end effectors 1a, 1b is actuated to hold each opposite end of the stack of flexible articles 200 in the slot 8. In step 303, the pair of end effectors 1a, 1b travel into the upright box 100 to load the stack of flexible articles 200 into the upright box 100 in a biased position away from the first open end 101 of the upright box 100. In step 304, when the stack of flexible articles 200 is loaded into the upright box 100, the two end effectors 1a, 1b are retracted in opposite directions.

[0051] Reference Fig.11 , shows the process flow of closing the wings 103, 104, 105, 106, 107, 108 of the upright box 100. In step 401, the first controlled arm 3 lifts the upright box 100 from the conveying track 2 and moves the first open end 101 of the upright box 100 to the first wing closing mechanism 4 to receive the wing closing operation performed by the pushing members 14, 15. As shown in step 402, when the first open end 101 is closed, the first controlled arm 3 additionally places the upright box 100 on the flip mechanism to redirect the upright box 100 from the horizontal position of the box to the upright position. In step 403, the pushing mechanism 16 is actuated to push the stack of flexible articles 200 toward the first gap through the opening of the second open end 102. In step 404 , the second controlled arm 5 moves the reoriented upright box 100 to the second wing closing mechanism 6 to receive the wing closing operation by the pushing members 18 , 19 .

[0052] The present disclosure includes the contents contained in the appended claims, as well as the contents of the foregoing description. Although the present invention has been described in its preferred form to a certain extent, it should be understood that the present disclosure of the preferred form is made by way of example only, and many changes may be made in the details of construction and the combination and arrangement of parts without departing from the scope of the present application.

Claims

1. An automated method for packaging a stack of flexible articles (200), wherein: The automated method comprises the following steps: The stack of flexible articles (200) is loaded into an upright box (100) by a pair of end effectors (1a, 1b), wherein the upright box (100) has a first open end (101) and a second open end (102), wherein each of the first open end (101) and the second open end (102) has at least one wing-shaped portion, and the wing-shaped portion is movable between an open configuration and a closed configuration, in which the wing-shaped portion does not cover the opening of the first open end (101) and the opening of the second open end (102), and in the closed configuration, the wing-shaped portion covers the opening of the first open end (101) and the opening of the second open end (102), whereby the stack of flexible articles (200) is loaded in a biased position away from the first open end (101), thereby leaving a first gap between the first open end (101) and the stack of flexible articles (200); moving the wing of the first open end (101) from the open configuration to the closed configuration by a first wing closing mechanism (4); Pushing the stack of flexible articles (200) toward the first gap by a pushing mechanism (16), thereby forming a second gap between the second open end (102) and the stack of flexible articles (200); and moving the wing of the second open end (102) from the open configuration to the closed configuration by a second wing closing mechanism (6); wherein the first gap and the second gap are configured to prevent the wing-shaped portion from being blocked by the stacked pieces of the flexible article (200) while closing the wing-shaped portion. Loading the stack of flexible articles (200) into the upright box (100) further comprises the following steps: extending the pair of end effectors (1a, 1b) toward each other in opposite directions so that the pair of end effectors (1a, 1b) are in close contact with each other; when the pair of end effectors (1a, 1b) are in close contact, loading the stack of flexible articles (200) into a groove (8) formed by the pair of end effectors (1a, 1b) by a loading device; holding each opposite end of the stack of flexible articles (200) by the pair of end effectors (1a, 1b); and retracting the pair of end effectors (1a, 1b) in two opposite directions when loading the stack of flexible articles (200) into the upright box (100).

2. The automated method according to claim 1, wherein: The first wing closing mechanism (4) is arranged in a horizontal position relative to the longitudinal axis of the upright box (100) for closing the wing of the first open end (101).

3. The automated method according to claim 2, further comprising the steps of: The upright box (100) having a closed first open end (101) is reoriented from a horizontal position to an upright position by a flipping mechanism so that the second open end (102) faces upward to receive a wing closure operation by the second wing closure mechanism (6), which is arranged in a vertical position relative to the longitudinal axis of the upright box (100).

4. The automated method according to any one of claims 1 to 3, wherein: The pushing mechanism (16) includes a plate-like member that is extendable and retractable along the opening of the second open end (102), the plate-like member being configured to engage with a stack of flexible articles (200) within the upright box (100) and push the stack of flexible articles (200) toward the first gap.

5. The automated method according to any one of claims 1 to 3, wherein: The upright box (100) is transferred from one mechanism to another by one or more controlled arms (3, 5), and one or more controlled arms (3, 5) are configured to clamp and lift the upright box (100).

6. The automated method according to claim 5, wherein: The controlled arms (3, 5) include gripping members that are movable in predetermined directions and orientations for gripping, lifting and transferring the upright box (100).

7. The automated method according to any one of claims 1 to 3, wherein: The first wing closing mechanism (4) and the second wing closing mechanism (6) include a plurality of pushing members (14, 15, 18, 19), which are capable of extending and retracting in the positions of the plurality of pushing members (14, 15, 18, 19) for closing the wings, whereby the plurality of pushing members (14, 15, 18, 19) are arranged in an array along the path of the wing closing station.

8. An automated system for packaging a stack of flexible articles, wherein: The automation system comprises: A pair of end effectors (1a, 1b) for loading a stack of the flexible articles (200) into an upright box (100), the upright box (100) having a first open end (101) and a second open end (102), wherein each of the first open end (101) and the second open end (102) has at least one wing portion that is movable between an open configuration and a closed configuration, in which the wing portion is movable between an open configuration and a closed configuration. The wing-shaped portion does not cover the opening of the first open end (101) and the opening of the second open end (102), and in the closed configuration, the wing-shaped portion covers the opening of the first open end (101) and the opening of the second open end (102), whereby the stack of the flexible articles (200) is loaded in a biased position away from the first open end (101), thereby leaving a first gap between the first open end (101) and the stack of the flexible articles (200); a first wing closure mechanism (4), the first wing closure mechanism (4) being used to move the wing of the first open end (101) from the open configuration to the closed configuration; a pushing mechanism (16) for pushing the stack of flexible articles (200) toward the first gap, thereby forming a second gap between the second open end (102) and the stack of flexible articles (200); and a second wing closure mechanism (6) for moving the wing of the second open end (102) from the open configuration to the closed configuration; wherein the first gap and the second gap are configured to prevent the wing-shaped portion from being blocked by the stacked pieces of the flexible article (200) while closing the wing-shaped portion. The pair of end effectors (1a, 1b) are configured to extend toward each other in opposite directions so that the pair of end effectors (1a, 1b) are in close contact with each other to form a groove (8) for receiving stacked pieces of the flexible article (200).

9. The automation system according to claim 8, wherein: The pair of end effectors (1a, 1b) are also configured to hold each opposite end of the stack of flexible articles (200) and to retract the pair of end effectors (1a, 1b) in two opposite directions when the stack of flexible articles (200) is loaded into the upright box (100).

10. The automation system according to claim 8 or 9, wherein: The first wing closing mechanism (4) is arranged in a horizontal position relative to the longitudinal axis of the upright box (100) for closing the wing of the first open end (101).

11. The automated system according to claim 10 further comprises a flipping mechanism for redirecting the upright box (100) having a closed first open end (101) from a horizontal position to an upright position so that the second open end (102) faces upward to accept a wing closing operation performed by the second wing closing mechanism (6), the second wing closing mechanism (6) being arranged in a vertical position relative to the longitudinal axis of the upright box (100).

12. The automation system according to claim 8 or 9, wherein: The pushing mechanism (16) includes a plate-like member that is extendable and retractable along the opening of the second open end (102), the plate-like member being configured to engage with a stack of flexible articles (200) within the upright box (100) and push the stack of flexible articles (200) toward the first gap.

13. The automated system according to claim 8 or 9, further comprising one or more controlled arms (3, 5) configured to transfer the upright box (100) from one mechanism to another.

14. The automated system of claim 13, wherein: The controlled arms (3, 5) include gripping members that are movable in predetermined directions and orientations for gripping, lifting and transferring the upright box (100).

15. The automated system according to claim 8 or 9, wherein: The first wing closing mechanism (4) and the second wing closing mechanism (6) include a plurality of pushing members (14, 15, 18, 19), which are capable of extending and retracting in the positions of the plurality of pushing members (14, 15, 18, 19) for closing the wings, whereby the plurality of pushing members (14, 15, 18, 19) are arranged in an array along the path of the wing closing station.

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