Box manufacturing device and box manufacturing method

Abstract

To provide a box manufacturing device capable of forming a box from a box material while suppressing a required space therefor.SOLUTION: A box manufacturing device includes a conveyance unit, an adhesive applying part, an upper die, an intermediate die, and a lower die. The conveyance unit forms a first transfer path for transferring the box material. The adhesive applying part is provided midway of the first transfer path and applies an adhesive agent to the box material. The upper die is provided movable vertically on the downstream side of the first transfer path and vertically presses the box material after the adhesive agent is applied. The intermediate die is formed into a frame shape, folds the box material when the box material pressed by the upper die passes therethrough, and bonds an adhesive application part of the box material to a bonding part. The lower die includes a recess defined by a bottom wall part and a side wall part rising from a circumference of the bottom wall part, and the upper die is fit to the recess.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a box mold manufacturing apparatus and a box mold manufacturing method. [Background technology]

[0002] Patent Document 1 discloses a box making device that includes a feeder that feeds box material to form a box shape in a conveying direction, a printer that prints on the folded box material, and a box assembling device that assembles the box material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2004-224383 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the box making device as described above, the supply device, the printer, and the box assembly device are arranged in one direction to transport the box material from the upstream device to the downstream device, which requires a large space to install the box making device, and the locations where the box making device can be installed are limited.

[0005] The present invention discloses a box mold manufacturing apparatus and a box mold manufacturing method that can form a box mold from a box material while reducing the required space. [Means for solving the problem]

[0006] A box-shaped manufacturing apparatus according to a first aspect of the present invention is a box-shaped manufacturing apparatus that forms a box shape with an opening at the top from a plate-shaped box material having a rectangular bottom portion having opposing first and second sides and opposing third and fourth sides, first and second side portions foldably connected to the first and second sides of the bottom portion, third and fourth side portions foldably connected to the third and fourth sides of the bottom portion, glue portions foldably connected to both ends of the third and fourth side portions, and a first top portion, a second top portion, a third top portion and a fourth top portion foldably connected to the first side portion, the second side portion, the third side portion and the fourth side portion, respectively, and the box-shaped manufacturing apparatus comprises a conveying unit, an adhesive application section, an upper mold, an intermediate mold, and a lower mold. The transport unit forms a first transport path for transporting the box material in a first direction with the first side first and the second side second, or with the third side first and the fourth side second. The adhesive applicator is provided in the middle of the first transport path and applies adhesive to a first attachment location at both ends of at least one of the first side surface portion and the first top surface portion to which the glue tab is attached, and a second attachment location at both ends of at least one of the second side surface portion and the second top surface portion to which the glue tab is attached. The upper mold is provided downstream of the first transport path so as to be movable up and down, and presses the box material from above after the adhesive has been applied. The intermediate mold passes through the box material pressed by the upper mold. The lower mold receives the box material pressed by the upper mold and passed through the intermediate mold. The lower surface of the upper mold is formed to be approximately the same size as the bottom surface portion and is configured to press the bottom surface portion from above. The intermediate mold is formed in a frame shape, and is configured to fold the third and fourth side portions relative to the bottom portion when the box material pressed against the upper mold passes therethrough, and then fold the first and second side portions relative to the bottom portion, at which time the glue tabs are attached to the first and second attachment locations. The lower mold has a recess defined by a bottom wall portion having substantially the same size as the bottom portion and a side wall portion rising from a periphery of the bottom wall portion, and is configured so that the upper mold fits into the recess.

[0007] A box-type manufacturing apparatus according to a second aspect of the present invention is the box-type manufacturing apparatus according to the first aspect, configured so that the upper and lower dies move away from the box type after the upper die is fitted into the recess of the lower die, and further comprising a pusher that pushes the box type in the first direction after the upper and lower dies have moved away from the box type, and a second conveying path along which the box type pushed by the pusher is conveyed.

[0008] A box-shaped manufacturing apparatus according to a third aspect of the present invention is a box-shaped manufacturing apparatus according to the first or second aspect, wherein the intermediate frame has a first inclined surface that guides the bending of the third and fourth side portions when the box material is pressed against the upper mold, and a second inclined surface that guides the bending of the first and second side portions when the box material is pressed against the upper mold, and at least a portion of the second inclined surface is positioned below the first inclined surface.

[0009] A box-shaped manufacturing apparatus according to a fourth aspect of the present invention is a box-shaped manufacturing apparatus according to any one of the first to third aspects, and further includes a holding section that holds a plurality of stacked box materials, a push-up section that pushes up the holding section from below, and a supply section that supplies the box material arranged at the top of the holding section to the conveying unit.

[0010] A box manufacturing method according to a fifth aspect of the present invention is a box manufacturing method for forming a box having an opening at the top from a plate-shaped box material having a rectangular bottom portion having opposing first and second sides and opposing third and fourth sides, a first side portion and a second side portion foldably connected to the first and second sides of the bottom portion, respectively, a third side portion and a fourth side portion foldably connected to the third and fourth sides of the bottom portion, respectively, a glue portion foldably connected to both ends of the third side portion and the fourth side portion, and a first top portion, a second top portion, a third top portion and a fourth top portion foldably connected to the first side portion, the second side portion, the third side portion and the fourth side portion, respectively, and the box manufacturing method comprises the following steps. conveying the box material in a first direction with the first side first and the second side second, or with the third side first and the fourth side second; applying adhesive to first attachment points at both ends of at least one of the first side surface portion and the first top surface portion to which the adhesive portion is attached, and to second attachment points at both ends of at least one of the second side surface portion and the second top surface portion to which the adhesive portion is attached; A step of pressing the box material from above with an upper mold after the adhesive is applied. In a process in which the box material is pressed by the upper mold, the third side portion and the fourth side portion are folded relative to the bottom portion, and then the first side portion and the second side portion are folded relative to the bottom portion, and at that time, the adhesive portion is attached to the first attachment portion and the second attachment portion. A step of fitting the folded box material into a recess defined by a bottom wall portion having substantially the same size as the bottom surface portion and a side wall portion rising from a peripheral edge of the bottom wall portion using the upper mold. Effect of the Invention

[0011] According to the present invention, a box mold manufacturing apparatus and a box mold manufacturing method are provided that can form a box mold from a box material while reducing the required space. [Brief description of the drawings]

[0012] [Figure 1] FIG. 2 is a development view of a box material according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a perspective view of a box assembled from the box members of FIG. 1. [Diagram 3] 1 is a side view of a box-shaped manufacturing apparatus according to an embodiment of the present invention; [Figure 4] FIG. [Diagram 5] FIG. [Figure 6] FIG. [Figure 7] FIG. [Figure 8] FIG. [Figure 9] FIG. [Figure 10] FIG. [Figure 11A] FIG. [Figure 11B] FIG. 4 is a front view of the first guide portion. [Figure 11C] FIG. 4 is a side view of the second guide portion. [Figure 12] FIG. [Figure 13] 1 is a flowchart showing the flow of a box-shaped manufacturing method. [Figure 14] FIG. 11 is a development view of a box material according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, a box manufacturing apparatus 2 according to an embodiment of the present invention and a box manufacturing method executed by the box manufacturing apparatus 2 will be described with reference to the drawings. FIG. 1 is a development view of a box material 1 handled by the box manufacturing apparatus 2. The box material 1 is assembled by the box manufacturing apparatus 2 as described later, and becomes a box type 1A with an open top as shown in FIG. 2. The broken lines in FIG. 1 and FIG. 2 indicate folding lines along which the box material 1 can be folded. FIG. 3 is a side view of the box manufacturing apparatus 2. Below, the box material 1 will be described, and then the configuration of the box manufacturing apparatus 2 and the box manufacturing method will be described. In the following description, for convenience of explanation, the description will be made according to the directions shown in the drawings. However, the present invention is not limited to these directions.

[0014] <1.Box material> As shown in Fig. 1, the box material 1 is formed of a single plate material. The box material 1 has a rectangular bottom surface portion 10 and first to fourth side surface portions 11 to 14 connected to the bottom surface portion 10. The bottom surface portion 10 has a first side 101 and a second side 102 that face each other, and a third side 103 and a fourth side 104 that face each other. The first side 101 and the second side 102 are short sides, and the third side 103 and the fourth side 104 are long sides. Hereinafter, in the box material 1, the direction along the first side 101 and the second side 102 will be referred to as the short side direction, and the direction along the third side 103 and the fourth side 104 will be referred to as the long side direction.

[0015] The first to fourth side portions 11 to 14 are connected to the first to fourth sides 101 to 104 of the bottom portion 10, respectively, in a manner that allows them to be folded. The widths of the short sides of the first and second side portions 11, 12 and the widths of the long sides of the third and fourth side portions 13, 14 are formed to increase with increasing distance from the bottom portion 10. In other words, the first to fourth side portions 11 to 14 are each trapezoidal. As a result, the area of ​​the box-shaped portion 1A in a plan view tapers from the upper opening toward the bottom portion 10 (see FIG. 2).

[0016] Fixed flaps 15, 16 are connected to both ends of the third side surface portion 13 in a foldable manner. The fixed flaps 15, 16 are bonded to the adjacent first and second side surface portions 11, 12 and the first and second top surface portions 110, 120, which will be described later, by an adhesive. Similarly, fixed flaps 17, 18 are connected to both ends of the fourth side surface portion 14 in a foldable manner. The fixed flaps 17, 18 are bonded to the adjacent first and second side surface portions 11, 12 and the first and second top surface portions 110, 120, which will be described later, by an adhesive. Each of the fixed flaps 15 to 18 is an example of a margin portion of the present invention.

[0017] The first to fourth top surface portions 110 to 140 are foldably connected to the longest sides of the first to fourth side surface portions 11 to 14, respectively. When the first to fourth top surface portions 110 to 140 of the box-shaped member 1A are folded along the folding lines so as to face the bottom surface portion 10, the upper opening can be closed.

[0018] In the box-shaped manufacturing apparatus 2 described later, adhesive is applied to the first attachment points 1100, 1101 and the second attachment points 1200, 1201. The first attachment points 1100, 1101 are both end portions in the short side direction of the first side surface portion 11 and the first top surface portion 110. The first attachment points 1100, 1101 may be both end portions in the short side direction of either one of the first side surface portion 11 and the first top surface portion 110. The second attachment points 1200, 1201 are both end portions in the short side direction of at least one of the second side surface portion 12 and the second top surface portion 120. The second attachment points 1200, 1201 may be both end portions in the short side direction of either one of the second side surface portion 12 and the second top surface portion 120. In this embodiment, a fastening flap 15 is adhered to the first attachment site 1100, a fastening flap 17 is adhered to the first attachment site 1101, a fastening flap 16 is adhered to the second attachment site 1200, and a fastening flap 18 is adhered to the second attachment site 1201, respectively.

[0019] The fixed flaps 15, 17 are formed so that when the first top surface portion 110 is folded against the first side surface portion 11 while being adhesively fixed to the first top surface portion 110 and the first side surface portion 11, the fixed flaps 15, 17 are formed so that when the first top surface portion 110 is folded against the first side surface portion 11, the fixed flaps 16, 18 are formed so that when the second top surface portion 120 is folded against the second side surface portion 12 while being adhesively fixed to the second top surface portion 120 and the second side surface portion 12, the fixed flaps 16, 18 are formed so that when the second top surface portion 120 is folded against ...

[0020] The box material 1 can be made of a material such as paper or resin.

[0021] <2.Box type manufacturing equipment> Next, the box-type manufacturing apparatus 2 will be described with reference to the drawings. Fig. 3 is a side view showing the overall configuration of the box-type manufacturing apparatus 2. As shown in Fig. 3, the box-type manufacturing apparatus 2 includes a supply unit 3, a transport unit 4, a coating unit 5, a molding unit 6, and a control unit 7. Each unit will be described below with reference to the directions shown in the drawing.

[0022] <3. Supply unit> 4 is a top view of the supply unit 3. The supply unit 3 is a unit for supplying the prepared plate-shaped box material 1 to the downstream conveying unit 4, and is disposed at the most upstream position in the box manufacturing apparatus 2. The supply unit 3 includes a pair of guide plates 30, 30 disposed at a distance in the left-right direction, a holding portion 31, a support portion 32, and a push-up portion 33. The holding portion 31, the support portion 32, and the push-up portion 33 are disposed between the pair of guide plates 30, 30. The pair of guide plates 30, 30 are fixed to a frame material constituting the box manufacturing apparatus 2, and the distance in the left-right direction is slightly longer than the length of the box material 1 in the short side direction.

[0023] [Holding part] The holding section 31 is a flat member that holds multiple stacked box materials 1. In this embodiment, the multiple box materials 1 are stacked on the upper surface of the holding section 31 such that, in a top view, the first top surface 110 is located at the front (or downstream) side, the second top surface 120 is located at the rear (or upstream) side, the third top surface 130 is located at the right side, and the fourth top surface 140 is located at the left side. The holding section 31 is pushed up from the bottom together with the stacked box materials 1 by a push-up section 33, which will be described later. The multiple box materials 1 are set on the holding section 31, for example, when the holding section 31 is at the lowest position in its vertical movable range.

[0024] [Support and push-up section] The support column 32 is a columnar member extending in the vertical direction. The push-up section 33 is connected to the support column 32 so as to be slidable in the vertical direction. The support column 32 and the push-up section 33 may be a known air cylinder, hydraulic cylinder, rotary actuator, or the like. The push-up section 33 is fixed to the holding section 31, and slides the holding section 31 in the vertical direction along the support column 32. In other words, the support column 32 and the push-up section 33 constitute a drive mechanism for the holding section 31. The drive mechanism including the support column 32 and the push-up section 33 is electrically connected to the control unit 7 described later, and the operation is controlled by the control unit 7.

[0025] [Detection unit] The supply unit 3 further includes a detection unit 34 for detecting the box material 1. The detection unit 34 in this embodiment includes a detection module 340 fixed near the upper end of the left guide plate 30, and a detection module 341 fixed near the upper end of the right guide plate 30. The detection modules 340 and 341 are aligned with each other so as to be at approximately the same position in the up-down and front-rear directions. When the detection unit 34 detects a box material 1 placed on the holding portion 31 while the holding portion 31 is being pushed up, the detection unit 34 transmits a detection signal to the control unit 7 described later. In other words, the box material 1 detected by the detection unit 34 is the box material 1 placed at the top at that time.

[0026] The detection unit 34 can be composed of a known ultrasonic sensor, radar sensor, optical sensor, etc. In other words, the detection module 340 and the detection module 341 may be a pulse transmitter and a pulse receiver, a pulse transceiver, or a light emitting element and a light receiving element. Preferably, the detection module 340 and the detection module 341 are fixed to the outside of the guide plate 30. In this case, the guide plate 30 may be formed with a through hole through which the pulse or light passes so as not to interfere with detection by the detection unit 34.

[0027] [Supply Department] The supply unit 3 further includes a supply section 35. The supply section 35 is configured to pick up the box material 1 arranged at the top of the holding section 31 and supply it to the conveying unit 4. The supply section 35 according to this embodiment has two suction pads 350. The suction pad 350 suctions the first top surface portion 110 or the first side surface portion 11 of the box material 1 from above and delivers it to the first conveying section 41 of the conveying unit 4 described later. More specifically, the suction pad 350 is configured to be movable in the front-rear direction, and can retreat to the vicinity of the first top surface portion 110 to suction the box material 1 arranged in the holding section 31, or advance while suctioning the box material 1, and stop suction. The drive mechanism (not shown) of the suction pad 350 can be composed of a known air cylinder, hydraulic cylinder, rotary actuator, etc. The operation of the supply section 35 is controlled by the control unit 7 described later.

[0028] <4.Transport unit> Fig. 5 is a top view of the transport unit 4, and Figs. 6 to 7 are side views showing a schematic configuration of the transport unit 4. For ease of explanation, other elements are omitted from Figs. 5 to 7 as appropriate. The transport unit 4 includes a first transport section 41 and a second transport section 42, and the first transport section 41 and the second transport section 42 form a first transport path along which the box material 1 is transported. The box material 1 is transported in the direction of arrow A1 (first direction) with the first side 101 side being the leading (front) and the second side 102 side being the trailing.

[0029] [First conveyor section] The first conveying section 41 includes a first shaft 411 and a second shaft 412 extending in the left-right direction, and a third shaft 413 and a fourth shaft 414 disposed below the first shaft 411 and the second shaft 412 and extending in the left-right direction. The first shaft 411 and the second shaft 412 are disposed at intervals from each other in the front-rear direction, and the third shaft 413 and the fourth shaft 414 are disposed at intervals from each other in the front-rear direction, similar to the first shaft 411 and the second shaft 412. Two upper pulleys 415 are fixed to each of the first shaft 411 and the second shaft 412 at intervals in the left-right direction. An endless rubber belt 410 is wound around each of the two upper pulleys 415 fixed at the same position in the left-right direction. In addition, two lower pulleys 416 are fixed to each of the third shaft 413 and the fourth shaft 414 at intervals in the left-right direction. An endless rubber belt 417 is wound around each of the two lower pulleys 416 fixed at the same position in the left-right direction. The endless rubber belt 417 according to this embodiment is a toothed belt having teeth on the inside, and the lower pulley 416 has an outer circumferential surface formed to mesh with the teeth of the endless rubber belt 417.

[0030] In the first conveying section 41, at least one of the first to fourth shafts 411 to 414 may be a drive shaft rotated by a motor (not shown). When the endless rubber belts 410 and 417 are rotated in the directions shown in Fig. 6 by the first to fourth shafts 411 to 414, respectively, the box material 1 supplied from the supplying section 35 is wound between the endless rubber belts 410 and 417 and conveyed in the direction of arrow A1. When the third top surface portion 130 and the fourth top surface portion 140 of the box material 1 reach the vicinity of a fifth shaft 421 of the second conveying section 42 described later by the conveying of the first conveying section 41, conveying by the second conveying section 42 begins.

[0031] [Second conveyor section] The second conveying section 42 includes a fifth shaft 421 and a sixth shaft 422 extending in the left-right direction. The fifth shaft 421 and the sixth shaft 422 are arranged at intervals from each other in the front-rear direction. The fifth shaft 421 is arranged between the first shaft 411 and the second shaft 412 in the front-rear direction. Two pulleys 420 are fixed to the fifth shaft 421 and the sixth shaft 422 at intervals in the left-right direction. An endless rubber belt 423 is wound around each of the two pulleys 420 fixed at the same position in the left-right direction. The endless rubber belt 423 according to this embodiment is a toothed belt having teeth on the inside, and the pulley 420 has an outer circumferential surface formed to mesh with the teeth of the endless rubber belt 423. One of the fifth shaft 421 and the sixth shaft 422 can be a drive shaft rotated by a motor (not shown). When the endless rubber belt 423 rotates in the direction of the arrow shown in FIG. 7, the box material 1 is conveyed in the direction of the arrow A1, as will be described later.

[0032] The endless rubber belts 423 each have a hook portion 4230 protruding from the outer circumferential surface. The hook portion 4230 rotates together with the endless rubber belt 423, and when the third top surface portion 130 and the fourth top surface portion 140 of the box material 1 reach below the fifth shaft 421, the hook portion 4230 hooks onto the third top surface portion 130 and the fourth top surface portion 140, and pushes the third top surface portion 130 and the fourth top surface portion 140 from the rear to the front, thereby transporting the box material 1. At this time, the box material 1 is supported from below by a support plate 424 fixed to a frame material constituting the box-shaped manufacturing apparatus 2.

[0033] After the application of adhesive by the application unit 5 described later is completed, the second conveying section 42 conveys the box material 1 to the molding unit 6 downstream of the first conveying path. When the box material 1 reaches a pair of support parts 60, 60 of the molding unit 6 following the first conveying path, the hook part 4230 leaves the box material 1. The second conveying section 42 then pauses until the next box material 1 is supplied. In this embodiment, the hook part 4230 is formed in two at a position that divides the endless rubber belt 423 in half, so that when one hook part 4230 reaches the support part 60, the other hook part 4230 reaches above the fifth shaft 421. As a result, the other hook part 4230 is hooked onto the next box material 1.

[0034] <5. Coating unit> The coating unit 5 is provided midway along the first conveying path. While the box material 1 is being conveyed by the second conveying section 42, the coating unit 5 applies adhesive to the first attachment points 1100, 1101 and the second attachment points 1200, 1201. FIG. 8 is a top view of the conveying unit 4 including the coating unit 5. The coating unit 5 is an example of an adhesive applicator of the present invention. The coating unit 5 will be described below.

[0035] The application unit 5 according to this embodiment includes a pair of nozzles 50, 50. The pair of nozzles 50, 50 are disposed between the fifth shaft 421 and the sixth shaft 422 of the second conveying section 42 in the front-rear direction, and are disposed at a distance from each other in the left-right direction. This distance in the left-right direction is approximately the same as the distance between the first attachment points 1100 and 1101 and the distance between the second attachment points 1200 and 1201. The pair of nozzles 50, 50 are connected to a tank 52 by a tube 51, and are configured to spray the adhesive in the tank 52 toward the first attachment points 1100, 1101 and the second attachment points 1200, 1201.

[0036] Each of the pair of nozzles 50, 50 according to this embodiment includes a drive mechanism and a distance detection sensor (not shown). When the first attachment points 1100, 1101 are disposed at positions facing the pair of nozzles 50, 50, the distance detection sensor detects the vertical distance from the first attachment points 1100, 1101 and transmits a detection signal to a control unit 7 (described later). The drive mechanism controls the vertical positions of the pair of nozzles 50, 50 according to a command from the control unit 7 based on the detection signal from the distance detection sensor. When the pair of nozzles 50, 50 are disposed at appropriate positions, adhesive is sprayed from the pair of nozzles 50, 50. As the distance detection sensor, a known ultrasonic sensor, radar sensor, or the like can be used.

[0037] Thereafter, when the box material 1 is further transported in the direction of the arrow A1, the second attachment points 1200, 1201 are positioned opposite the pair of nozzles 50, 50. The application unit 5 performs the same operation as when it sprayed adhesive onto the first attachment points 1100, 1101, and sprays adhesive onto the second attachment points 1200, 1201. The timing at which the first attachment points 1100, 1101 and the second attachment points 1200, 1201 arrive below the pair of nozzles 50, 50 can be monitored by the control unit 7.

[0038] The type of adhesive is not particularly limited, but in this embodiment, a hot melt adhesive is used as the adhesive.

[0039] <6. Molding unit> The molding unit 6 assembles the box material 1 while bonding the fixed flaps 15-18 to the corresponding bonding locations to form the box mold 1A. FIG. 9 is a front view of the molding unit 6 as seen from the front side. However, for the sake of convenience, the frame material of the box mold manufacturing device 2 and the like are omitted as appropriate in FIG. 9. As shown in FIG. 9, the molding unit 6 includes a pair of left and right support parts 60, 60, an upper mold 61, an intermediate frame 62, a lower mold 63, and a support plate 64. Of these members, the upper mold 61 and the lower mold 63 are configured to be slidable in the up and down direction. Each member will be described below.

[0040] [Support part] The pair of left and right support parts 60, 60 support the box material 1 from both the left and right sides when it reaches the molding unit 6. More specifically, the pair of left and right support parts 60, 60 support the third top surface part 130, the third side surface part 13, the fourth top surface part 140 and the fourth side surface part 14 from below. In this state, the box material 1 is aligned so that the bottom surface part 10 faces the lower surfaces 6110A-D of an upper mold 61 described later.

[0041] [Upper mold] 10 is a bottom view of the upper die 61. The upper die 61 according to this embodiment has a flat base 610 and pressing parts 611A-D protruding from the bottom surface of the base 610. The base 610 has a rectangular shape when viewed from above, and is fixed to a drive mechanism (not shown) so as to be horizontal in the box-type manufacturing apparatus 2. Thus, the upper die 61 is configured to slide up and down within a predetermined range of motion while maintaining the horizontal position.

[0042] The pressing portions 611A-D are aligned with the four corners of the base 610, respectively, and have lower surfaces 6110A-D that press the bottom portion 10 from above. The lower surfaces 6110A-D of the pressing portions 611A-D form an imaginary rectangle having substantially the same size as the bottom portion 10 as a whole, and are configured to press the bottom portion 10 from above. The pressing portions 611A-D further have inclined surfaces 6111A-D facing in the left-right direction, and inclined surfaces 6112A-D facing in the front-rear direction, respectively. The inclined surfaces 6111A and 6111C correspond to the fourth side surface portion 14 of the box material 1, and the inclined surfaces 6111B and 6111D correspond to the third side surface portion 13 of the box material 1. The inclined surfaces 6112A and 6112B correspond to the first side surface portion 11 of the box material 1, and the inclined surfaces 6112C and 6112D correspond to the second side surface portion 12 of the box material 1.

[0043] [Intermediate frame (intermediate type)] 11A is a top view of intermediate frame 62. Intermediate frame 62 has frame portion 620 in the shape of a rectangular frame, and first guide portions 621A-D and second guide portions 622A-D attached to frame portion 620. First guide portions 621A and C are members that guide the folding of fourth side surface portion 14, and first guide portions 621B and D are members that guide the folding of third side surface portion 13. Second guide portions 622A and B are members that guide the folding of first side surface portion 11, and second guide portions 622C and D are members that guide the folding of second side surface portion 12.

[0044] 11B is a front view of the first guide portions 621A and 621B, or the first guide portions 621C and 621D, as viewed from the front side. The first guide portions 621A-D have fixed portions 6210A-D, inclined portions 6211A-D, and inner wall portions 6212A-D, respectively. The fixed portions 6120A-D are portions fixed to the frame-shaped portion 620. The inner wall portions 6212A-D are plate-shaped portions extending in the vertical direction, and are fixed in an offset state to the inner wall of the frame-shaped portion 620. The distance between the inner wall portions 6212A and 6212B, or the inner wall portions 6212C and 6212D is slightly longer than the length of the first side 101 or the second side 102 of the bottom surface portion 10 of the box material 1.

[0045] The inclined portions 6211A-D have surfaces inclined with respect to the horizontal direction. As a result, the inclined portions 6211A-D form a first inclined surface for guiding the third side surface portion 13 and the fourth side surface portion 14 to be folded relative to the bottom surface portion 10 when the upper mold 61 presses the bottom surface portion 10. The upper ends of the inclined portions 6211A-D are located at the uppermost positions in the intermediate frame 62. Therefore, when the box material 1 descends together with the upper mold 61, the first inclined surface comes into contact with the box material 1 in the intermediate frame 62 first. As a result, in the box material 1, the third side surface portion 13 and the fourth side surface portion 14 are folded relative to the bottom surface portion 10 first.

[0046] 11C is a side view of the second guide portions 622A and 622C, or the second guide portions 622B and 622D, as viewed from the left side. The second guide portions 622A-D have fixing portions 6220A-D, inclined portions 6221A-D, and inner wall portions 6222A-D, respectively. The fixing portions 6220A-D are portions fixed to the upper surface of the frame-shaped portion 620. The inner wall portions 6222A-D are plate-shaped portions extending in the vertical direction, and are fixed in an offset state to the inner wall of the frame-shaped portion 620. The distance between the inner wall portions 6222A and 6222C, or the inner wall portions 6222B and 6222D is slightly longer than the length of the third side 103 or the fourth side 104 of the bottom surface portion 10 of the box material 1.

[0047] The inclined portions 6221A-D are continuous with the fixing portions 6220A-D and the inner wall portions 6222A-D, respectively, and have surfaces inclined with respect to the horizontal direction. As a result, the inclined portions 6221A-D form a second inclined surface for guiding the first side surface portion 11 and the second side surface portion 12 to be folded relative to the bottom surface portion 10 when the upper mold 61 presses the bottom surface portion 10. The upper ends of the inclined portions 6221A-D are located at approximately the same position as the upper end of the frame-shaped portion 620, and are located lower than the upper ends of the inclined portions 6211A-D. Therefore, when the box material 1 descends together with the upper mold 61, the second inclined surface comes into contact with the box material 1 after the first inclined surface starts to come into contact with the box material 1. As a result, in the box material 1, the third side surface portion 13 and the fourth side surface portion 14 are folded relative to the bottom surface portion 10, and then the first side surface portion 11 and the second side surface portion 12 are folded relative to the bottom surface portion 10. At this time, the fixing flaps 15 to 18 are folded so that the fixing flap 15 faces the first attachment point 1100, the fixing flap 17 faces the first attachment point 1101, the fixing flap 16 faces the second attachment point 1200, and the fixing flap 18 faces the second attachment point 1201.

[0048] [Lower mold] 12 is a top view of the lower mold 63. The lower mold 63 according to this embodiment has a flat base 630 and formwork portions 631A-D protruding from the top surface of the base 630. The base 630 has a rectangular shape when viewed from above, and is fixed to a drive mechanism (not shown) so as to be horizontal in the box-type manufacturing apparatus 2. Thus, the lower mold 63 is configured to slide up and down within a predetermined range of motion while maintaining the horizontal position.

[0049] The formwork portions 631A-D are aligned with the four corners of the base portion 630, and have bottom portions 6310A-D, first wall portions 6311A-D rising from the periphery of the bottom portions 6310A-D, and second wall portions 6312A-D. The bottom portions 6310A-D form a rectangular bottom wall portion having approximately the same size as the bottom surface portion 10 as a whole.

[0050] The first wall portions 6311A and 6311C are inclined with respect to the bottom portions 6310A and 6310C, and have inclined surfaces corresponding to the inclined surfaces 6111A and 6111C of the upper mold 61, respectively. The first wall portions 6311B and 6311D are inclined with respect to the bottom portions 6310B and 6310D, and have inclined surfaces corresponding to the inclined surfaces 6111B and 6111D of the upper mold 61, respectively. The second wall portions 6312A and 6312B are inclined with respect to the bottom portions 6310A and 6310B, and have inclined surfaces corresponding to the inclined surfaces 6112A and 612B of the upper mold 61, respectively. The second wall portions 6312C and 6312D are inclined with respect to the bottom portions 6310C and 6310D, and have inclined surfaces corresponding to the inclined surfaces 6112C and 612C of the upper mold 61, respectively. The first walls 6311A to 6311D and the second walls 6312A to 6312D form a side wall having a shape generally the same as the tapered shape formed by the first to fourth side surface portions 11 to 14 of the box mold 1A as a whole.

[0051] As a result of the above, the bottom wall and the side wall define a tapered recess 632 that is recessed downward as a whole. The recess 632 passes through the intermediate frame 62 together with the upper die 61, and is configured to receive the box material 1 from below after the first to fourth side surface portions 11 to 14 and the fixing flaps 15 to 18 have been folded. In other words, the upper die 61 fits into the recess 632 with the box material 1 sandwiched therebetween.

[0052] When the box material 1 is sandwiched between the lower mold 63 and the upper mold 61, the fixing flap 15 is fixed to the first attachment position 1100, the fixing flap 17 to the first attachment position 1101, the fixing flap 16 to the second attachment position 1200, and the fixing flap 18 to the second attachment position 1201. In this way, the box mold 1A is formed.

[0053] [Support plate] In this embodiment, the lower mold 63 is used in combination with a support plate 64. The support plate 64 is a plate extending in the front-rear direction, and its position in the up-down direction is fixed in the box mold manufacturing device 2. The support plate 64 is disposed on the upper surface of the base 630 between the mold parts 631A and 631B of the lower mold 63 and between the mold parts 631C and 631D. The thickness of the support plate 64 is equal to or less than the thickness of the bottom parts 6310A-D of the mold parts 631A-D. Therefore, even if the support plate 64 is present in the lower mold 63, the upper mold 61 is not prevented from fitting into the recess 632, and the support plate 64 does not interfere with the bottom part 10. The support plate 64 supports the box mold 1A released from the upper mold 61 and the lower mold 63 so that it does not fall after the upper mold 61 rises and the lower mold 63 descends and they are separated from the box mold 1A. That is, the box mold 1A is formed by the upper mold 61 and the lower mold 63, and when the upper mold 61 and the lower mold 63 are respectively retracted from the box mold 1A, the box mold 1A is left on the support plate 64.

[0054] [Pusher] The molding unit 6 further includes a pusher 65. The pusher 65 is fixed to a drive mechanism (not shown) and is movable in the front-rear direction above the support plate 64. When the box mold 1A is left on the support plate 64, the pusher 65 slides from rear to front, pushing the box mold 1A from the second side surface portion 12 or the second top surface portion 120 side of the box mold 1A in the direction of arrow A1, and transporting it to the outside of the box mold manufacturing apparatus 2. In other words, the support plate 64 is an example of the second transport path of the present invention.

[0055] <7. Control unit> The control unit 7 is a part that monitors and controls the operation of the box-shaped manufacturing apparatus 2, and includes a processor, a non-volatile memory, a volatile memory, and the like. The control unit 7 is connected to each of the units 3 to 6 via wired or wireless data communication, and can cause each of the units 3 to 6 to operate in cooperation with each other to efficiently manufacture the box mold 1A. The control unit 7 may be disposed anywhere in the box-shaped manufacturing apparatus 2. The control unit 7 may also be configured to be physically separated from each of the units 3 to 6. The control unit 7 may include an operating member that accepts user operations, and a display. The operation of the control unit 7 will be described later together with the box mold manufacturing method.

[0056] <8. Box-shaped manufacturing method> Next, a method for manufacturing the box mold 1A using the box mold manufacturing device 2 will be described. FIG. 13 is a flow chart showing the flow of the method for manufacturing the box mold 1A. The manufacturing method shown in FIG. 13 starts from a state in which a plurality of stacked box materials 1 are set in the holding section 31. At this time, the holding section 31 of the supply unit 3 is positioned sufficiently downward, and the plurality of box materials 1 are set with the first side 101 facing forward and the second side 102 facing backward, as shown in FIG. 4. In this state, when the control unit 7 receives an instruction from the user to start the process, the manufacturing of the box mold 1A starts.

[0057] First, the control unit 7 controls the drive mechanism composed of the support part 32 and the push-up part 33 to push up the holding part 31 together with the box material 1 (step S1). In addition, the control unit 7 causes the detection unit 34 to detect the box material 1 while the holding part 31 is rising.

[0058] When the detection unit 34 detects the uppermost box material 1, the control unit 7 stops driving the support parts 32 and the push-up part 33, and keeps the holding part 31 waiting in that position (step S2).

[0059] Next, the control unit 7 drives the first conveying section 41 and the second conveying section 42 (step S3). More specifically, the endless rubber belt 410 and the endless rubber belt 417 of the first conveying section 41 start to rotate, and the endless rubber belt 423 of the second conveying section 42 starts to rotate.

[0060] Next, the control unit 7 causes the supply section 35 to pick up and supply the box material 1 (step S4). More specifically, the suction pad 350 moves onto the first top surface section 110 and adsorbs the box material 1. After adsorbing the box material 1, the suction pad 350 moves the box material 1 to the first conveying section 41, and then stops adsorption and returns to the initial position.

[0061] Next, the first conveyor 41 conveys the box material 1 to the second conveyor 42 (step S5). Note that the control unit 7 controls the timing so that the hook portion 4230 of the endless rubber belt 423 of the second conveyor 42 is located near the upper side of the fifth shaft 421 at this time.

[0062] Next, transport by the second transport section 42 and application of adhesive by the application unit 5 are performed (step S6). The control unit 7 controls the timing at which the application unit 5 applies adhesive to the first attachment points 1100, 1101 and the timing at which the application unit 5 applies adhesive to the second attachment points 1200, 1201, based on, for example, the timing at which the second transport section 42 starts transporting. After the application of adhesive by the application unit 5, the box material 1 reaches the molding unit 6.

[0063] Next, the molding unit 6 molds the box mold 1A (step S7). The control unit 7 lowers the upper mold 61 and raises the lower mold 63 at an appropriate timing, for example, based on the timing when the second conveyor 42 starts conveying. When the upper mold 61 is lowered, it presses the bottom surface portion 10 of the box material 1 supported by the supports 60, 60, and passes through the inside of the inner walls 6212A-D and the inner walls 6222A-D of the intermediate frame 62 together with the box material 1. At this time, the third and fourth side surface portions 13 and 14, including the fixing flaps 15-18 of the box material 1, are folded against the bottom surface portion 10, and then the first and second side surface portions 11 and 12 are folded against the bottom surface portion 10. At this time, the fixing flaps 15 to 18 are folded inside the first side surface portion 11 and the second side surface portion 12, and are attached to the first and second attachment points 1100, 1101, 1200, 1201. Next, the upper die 61 descends and the lower die 63 ascends, sandwiching the folded box material 1 therebetween and fitting it into the recess 632. This causes the fixing flaps 15, 17 to the first side surface portion 11 and the first top surface portion 110, and the fixing flaps 16, 18 to the second side surface portion 12 and the second top surface portion 120 to be bonded and fixed. In other words, step S7 includes a sub-step of pressing the box material 1 with the upper mold 61, a sub-step of folding the third and fourth side portions 13 and 14 against the bottom portion 10, and then folding the first and second side portions 11 and 12, while attaching the fixing flaps 15-18 to the first and second attachment locations 1100, 1101, 1200, 1201, and a sub-step of fitting the box material 1 into the recess 632 with the upper mold 61.

[0064] Next, the upper mold 61 and the lower mold 63 are retracted (step S8). The control unit 7 controls the timing of lifting the upper mold 61 and the timing of lowering the lower mold 63 based on, for example, the timing of lowering the upper mold 61 in step S6. The upper mold 61 and the lower mold 63 move away from each other in the vertical direction and return to their initial positions.

[0065] Next, the box mold 1A is transported (step S9). The control unit 7 advances the pusher 65 based on, for example, the timing at which the upper mold 61 and the lower mold 63 are retracted in step S7. The pusher 65 pushes the box mold 1A on the support plate 64 aside, thereby transporting the box mold 1A, for example, to equipment disposed downstream of the box mold manufacturing apparatus 2. The equipment disposed downstream of the box mold manufacturing apparatus 2 can be, for example, a line for storing contents in the box mold 1A, or another device.

[0066] After the box material 1 is picked up and supplied in step S4, the control unit 7 raises the holding portion 31 until the detection unit 34 detects the uppermost box material 1 again. As a result, the supply unit 3 is placed in a standby state for the next box material 1 to be transported.

[0067] Through the above steps S1 to S9, the box mold 1A is continuously molded from the box material 1.

[0068] <9. Features> The box-shaped manufacturing apparatus 2 configured as above provides the following effects. (1) In the supply unit 3, the holding section 31 that holds the multiple box materials 1 is configured to slide up and down, thereby saving space in the front-rear direction. Also, in the molding unit 6, the upper mold 61 and the lower mold 63 are configured to slide up and down to mold the box mold 1A, which also saves space in the front-rear direction. As a result, the entire box manufacturing apparatus 2 can be designed compactly, and it becomes easy to continuously carry out the process of storing the contents in the molded box mold 1A and then sealing the box mold 1A. In other words, the box manufacturing apparatus 2 is suitable for introduction into a product shipping base having a product warehouse, etc.

[0069] (2) The endless rubber belt 423 has the hook portion 4230 formed thereon, so that the box material 1 can be transported more reliably. Furthermore, the endless rubber belt 423 has two hook portions 4230 formed at a position that divides the belt in half. Therefore, when one hook portion 4230 reaches the molding unit 6, the other hook portion 4230 is ready to wait for the next box material 1 near the fifth shaft 421, so that the molding of the box mold 1A can be performed efficiently.

[0070] <10. Variations> Although one embodiment of the present invention has been described above, the present invention is not limited to this embodiment, and various modifications are possible without departing from the spirit of the present invention. The following modified examples can be combined as appropriate.

[0071] (1) The box material is not limited to that of the above embodiment. For example, as shown in FIG. 14, the box material may be a box material 1B including a bottom surface portion 10B having a first side 104B, a second side 103B, a third side 101B, and a fourth side 102B. In the box material 1B, the fixing flaps 15B and 17B are connected to the third side surface portion 11B, and the fixing flaps 16B and 18B are connected to the fourth side surface portion 12B. The third top surface portion 110B and the fourth top surface portion 120B are connected to the third side surface portion 11B and the fourth side surface portion 12B in a foldable manner, respectively. In this case, the first attachment points 1100B and 1101B can be arranged on at least one of the first side surface portion 14B and the first top surface portion 140B, and the second attachment points 1200B and 1201B can be arranged on at least one of the second side surface portion 13B and the second top surface portion 130B. The conveying unit 4 can convey the box material 1B with the third side 101B first and the fourth side 102B second, and the coating unit 5 can coat the first and second bonding locations 1100B and 1200B first and then coat the first and second bonding locations 1101B and 1201B. The configuration of the intermediate frame 62 can be modified to have a first inclined surface for folding the third and fourth side surface portions 11B and 12B, and a second inclined surface for folding the first and second side surface portions 14B and 13B, with at least a portion of the second inclined surface being positioned below the first inclined surface.

[0072] (2) In the box material 1 of the above embodiment, any one of the sides 102 to 104 may be the first side, instead of the side 101. Furthermore, the transport unit 4 may transport any side of the bottom surface portion 10 first, and the configuration of the molding unit 6 may be modified accordingly. The box-shaped manufacturing device 2 may include a rotation mechanism or the like that appropriately positions the box material 1 with respect to the upper mold 61 before transferring the box material 1 after the adhesive is applied to the molding unit 6. Furthermore, the box material 1 does not have to form a tapered box mold 1A, and the shapes of the first to fourth side surface portions 11 to 14 and the shapes of the first to fourth top surface portions 110 to 140 are not particularly limited. The same applies to the box material 1B.

[0073] (3) The drive mechanism of the holding part 31 may be a motor-driven mechanism. The drive mechanism of the supply part 35, the drive mechanism of the coating unit 5, the drive mechanism of the upper mold 61, the drive mechanism of the lower mold 63, and the drive mechanism of the pusher 65 are also not particularly limited.

[0074] (4) The supply unit 3, the first transport section 41, the support plate 64, and the pusher 65 may be omitted. In addition, the hook portion 4230 may also be omitted.

[0075] (5) The configuration of each unit 3 to 6 can be changed as appropriate. For example, the first conveying section 41 and the second conveying section 42 may be any as long as they can convey the box material 1 in one direction. Furthermore, the upper mold 61, the intermediate frame 62, and the lower mold 63 are not limited to those in the above embodiment. In the intermediate frame 62, at least a part of the second inclined surface may be disposed below the first inclined surface. Furthermore, the intermediate frame 62 may be configured to be slidable in the up-down direction relative to the upper mold 61, and the support plate 64 may be configured to be slidable in the front-rear direction relative to the lower mold 63. Furthermore, for example, the pressing sections 611A to 611D of the upper mold 61, the first guide sections 621A to 621D and the second guide sections 622A to 622D of the intermediate frame 62, and the mold sections 631A to 631D of the lower mold 63 may each be integrally formed.

[0076] (6) The order in which steps S1 to S9 are performed and the specific control method may be changed as appropriate. For example, step S3 may be performed after step S4 or before step S2. [Explanation of symbols]

[0077] 1, 1B: Box material 1A: Box type 10: Bottom part 11:First side part 12:Second side part 13:Third side part 14: 4th side part 2:Box type manufacturing equipment 3: Supply unit 31: Holding part 33: Push-up part 4: Transport unit 5: Nozzle unit 6: Molding unit 7: Control unit

Claims

1. A box manufacturing device which forms a box having an opening at the top from a plate-like box material having a rectangular bottom portion having opposing first and second sides and opposing third and fourth sides, a first side portion and a second side portion foldably connected to the first and second sides of the bottom portion, respectively, a third side portion and a fourth side portion foldably connected to the third and fourth sides of the bottom portion, respectively, a glue portion foldably connected to both ends of the third side portion and the fourth side portion, respectively, and a first top portion, a second top portion, a third top portion and a fourth top portion foldably connected to the first side portion, the second side portion, the third side portion and the fourth side portion, respectively a conveying unit that forms a first conveying path for conveying the box material in a first direction with the first side side first and the second side side second, or with the third side side first and the fourth side side second; an adhesive application unit that is provided in the middle of the first transport path and that applies adhesive to first attachment locations at both ends of at least one of the first side surface portion and the first top surface portion to which the adhesive portion is attached, and to second attachment locations at both ends of at least one of the second side surface portion and the second top surface portion to which the adhesive portion is attached; an upper mold that is provided on a downstream side of the first conveying path so as to be movable up and down and that presses the box material from above after the adhesive has been applied; an intermediate die through which the box material pressed by the upper die passes; a lower die that receives the box material that has been pressed by the upper die and passed through the intermediate die; Equipped with The lower surface of the upper mold is formed to be substantially the same size as the bottom surface portion and is configured to press the bottom surface portion from above, the intermediate mold is formed in a frame shape, and is configured to fold the third side portion and the fourth side portion relative to the bottom portion when the box material pressed against the upper mold passes through, and then fold the first side portion and the second side portion relative to the bottom portion, and at that time, affix the adhesive margin portion to the first attachment portion and the second attachment portion, the lower mold has a recess defined by a bottom wall portion having substantially the same size as the bottom surface portion and a side wall portion rising from a peripheral edge of the bottom wall portion, and is configured so that the upper mold is fitted into the recess; The box material that has passed through the intermediate die and been bent is fitted into the recess by the upper die to form the box shape. Box type manufacturing equipment.

2. After the upper die is fitted into the recess of the lower die, the upper die and the lower die are separated from the box die, a pusher that pushes the box mold in the first direction after the upper mold and the lower mold are separated from the box mold; a second conveying path along which the box-shaped object pushed by the pusher is conveyed; The box mold manufacturing apparatus of claim 1 further comprising:

3. The intermediate frame is a first inclined surface that guides bending of the third side surface portion and the fourth side surface portion when the box material is pressed against the upper mold; a second inclined surface that guides the bending of the first side surface portion and the second side surface portion when the box material is pressed against the upper mold; having The box-shaped manufacturing apparatus according to claim 1 or 2, wherein at least a portion of the second inclined surface is disposed below the first inclined surface.

4. A holding portion for holding a plurality of the stacked box materials; A push-up portion that pushes up the holding portion from below; a supply section that supplies the box material arranged at the top of the holding section to the transport unit; The box-shaped manufacturing apparatus of claim 1 or 2, further comprising:

5. A method for manufacturing a box having an opening at the top, comprising the steps of: forming a box having an opening at the top from a plate-shaped box material having a rectangular bottom portion having opposing first and second sides and opposing third and fourth sides; a first side portion and a second side portion foldably connected to the first and second sides of the bottom portion, respectively; a third side portion and a fourth side portion foldably connected to the third and fourth sides of the bottom portion, respectively; a glue portion foldably connected to both ends of the third side portion and the fourth side portion, respectively; and a first top portion, a second top portion, a third top portion and a fourth top portion foldably connected to the first side portion, the second side portion, the third side portion and the fourth side portion, respectively; conveying the box material in a first direction with the first side first and the second side second, or with the third side first and the fourth side second; applying an adhesive to first attachment points at both ends of at least one of the first side surface portion and the first top surface portion to which the adhesive portion is attached, and to second attachment points at both ends of at least one of the second side surface portion and the second top surface portion to which the adhesive portion is attached; pressing the box material from above with an upper mold after the adhesive has been applied; a step of folding the third side portion and the fourth side portion relative to the bottom portion during a process in which the box material is pressed by the upper mold, and then folding the first side portion and the second side portion relative to the bottom portion, and at that time, attaching the adhesive portion to the first attachment portion and the second attachment portion; a step of fitting the folded box material into a recess defined by a bottom wall portion having substantially the same size as the bottom surface portion and a side wall portion rising from a peripheral edge of the bottom wall portion using the upper mold; The box manufacturing method includes:

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