End flap engagement assembly for erecting cartons and related systems and methods - Patents.com

Abstract

A method for at least partially erecting a carton includes loading a blank having a plurality of panels and a plurality of end flaps foldably connected to each of the plurality of panels into a blank feed assembly, positioning the blank on at least one conveyor assembly configured to move the blank in a downstream direction, operating the at least one conveyor assembly to move the blank in a downstream direction toward a carton erection assembly including an end flap engagement assembly positioned adjacent to the at least one conveyor assembly, and actuating the end flap engagement assembly such that a portion of the end flap engagement assembly contacts and moves at least one of the plurality of end flaps of the blank as the blank moves in the downstream direction.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 431,469, filed December 9, 2022.

[0002] [Incorporated by reference] The entire disclosure of U.S. Provisional Patent Application No. 63 / 431,469, filed December 9, 2022, is incorporated by reference herein for all purposes as if set forth in its entirety. [Background technology]

[0003] The present disclosure relates generally to systems and methods for forming cartons, and more particularly to systems and related methods for forming cartons that include at least one end flap engagement assembly for engaging one or more end flaps of a carton during the carton erection process. Summary of the Invention

[0004] According to one aspect, a method for at least partially assembling a carton includes loading a blank having a plurality of panels and a plurality of end flaps foldably connected to each of the plurality of panels into a blank feeding assembly; positioning the blank on at least one conveyor assembly configured to move the blank in a downstream direction; operating the at least one conveyor assembly to move the blank in the downstream direction toward a carton assembly having an end flap engagement assembly positioned adjacent to the at least one conveyor assembly; and actuating the end flap engagement assembly such that a portion of the end flap engagement assembly contacts and moves at least one of the plurality of end flaps of the blank as the blank moves in the downstream direction.

[0005] According to another aspect, the present disclosure generally relates to a carton forming system including: a blank feed assembly proximate an upstream end of the carton forming system for receiving at least one blank, each blank having a plurality of panels and a plurality of end flaps foldably connected to each of the plurality of panels; at least one conveyor assembly positioned downstream from the blank feed assembly in a machine direction of the carton forming system, the conveyor assembly including at least one conveyor member defining a rail for at least partially supporting the at least one blank and including a plurality of engaging lugs movable along the rail to at least partially move the at least one blank in the machine direction; and at least one end flap engaging assembly positioned adjacent to the at least one conveyor assembly, the end flap engaging assembly including a drive device, a connecting member operably coupled to the drive device, and a crank device operably coupled to the connecting member and supporting an end flap engaging member for contacting at least one of the plurality of end flaps of the blank.

[0006] According to another aspect, the present disclosure generally relates to an end flap engagement assembly for a carton forming system, the end flap engagement assembly including a drive device, a connecting member operably coupled to the drive device, and a crank device operably coupled to the connecting member and supporting an end flap engagement member for contacting at least one end flap of a blank.

[0007] Those skilled in the art will appreciate the above-mentioned advantages, as well as other advantages and benefits, of various additional embodiments upon reading the following detailed description of the embodiments with reference to the below-listed drawings. It is within the scope of this disclosure that the above-mentioned aspects be provided both individually and in various combinations.

[0008] According to common practice, the various features of the drawings described below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the present disclosure. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 2 is a plan view of a blank for forming a carton according to an exemplary embodiment of the present disclosure. [Figure 2] 1 is a perspective view of a system for at least partially forming a carton according to an exemplary embodiment of the present disclosure. [Figure 3] FIG. 3 is an enlarged perspective view of a blank feed assembly of the system of FIG. 2. [Figure 4] 3 is another enlarged perspective view of the blank feed assembly of the system of FIG. 2. [Figure 5] FIG. 3 is an enlarged perspective view of the conveyor assembly and end flap engagement assembly of the system of FIG. 2. [Figure 6] 3 is another perspective view of the conveyor assembly and end flap engagement assembly of the system of FIG. 2. [Figure 7A] FIG. 3 is a perspective view of a portion of the end flap engagement assembly of the system of FIG. 2. [Figure 7B] 3 is another perspective view of a portion of the end flap engagement assembly of the system of FIG. 2. [Figure 8] FIG. 3 is a perspective view of the operation of the system of FIG. 2. [Figure 9] FIG. 3 is a perspective view of the operation of the system of FIG. 2. DETAILED DESCRIPTION OF THE INVENTION

[0010] Corresponding parts are designated by corresponding reference numerals throughout the drawings.

[0011] The present disclosure generally relates to systems including end flap engagement assemblies for forming cartons or other containers, trays, or other structures for holding articles, such as beverage containers. Such beverage containers can be made from materials suitable in compositions for packaging particular food or beverage items, including, but not limited to, aluminum and / or other metals, glass, plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and nylon, and the like, or any combination thereof.

[0012] Cartons according to the present disclosure can accommodate articles of any shape. For purposes of illustration, and not for purposes of limiting the scope of the present disclosure, the following detailed description describes beverage containers (e.g., glass beverage bottles) as disposed within carton embodiments. As used herein, the terms "inside," "internal," "outside," "exterior," "lower," "bottom," "upper," and "top" refer to orientations determined with respect to a fully erected carton and an upright carton.

[0013] 2 generally illustrates an exemplary embodiment of a method and system 100 for at least partially forming a carton from a blank 20 (FIG. 1). In the illustrated embodiment, the system 100 includes at least one end flap engagement assembly 145 (FIG. 5) for engaging one or more cartons formed from at least a partially folded configuration of the blank 20 and for engaging one or more end flaps of the blank 20 during the process of at least partially forming, e.g., assembling or otherwise reconfiguring, the carton.

[0014] 1, there is shown a plan view of the exterior 22 of a blank, generally designated 20, suitable for use with system 100 to form cartons according to various exemplary embodiments of the present disclosure. The resulting carton can be used to house multiple items, such as containers, e.g., metal fluid-filled containers such as aluminum cans, or plastic / glass / composite fluid-filled containers such as bottles, and the carton formed from blank 20 can be sized to house multiple items in various matrix and / or tiered arrangements as desired.

[0015] The carton blank 20 can have a longitudinal axis L1 and a transverse axis L2. In the illustrated embodiment, the blank 20 and the carton formed therefrom can include multiple panels, including a top panel 15 foldably connected to a first side panel 17 at a first horizontal fold line 19. A bottom panel 21 can be foldably connected to the first side panel 17 at a second horizontal fold line 23. A second side panel 25 can be foldably connected to the bottom panel 21 at a third horizontal fold line 27. In the illustrated embodiment, the blank 20 includes an attachment flap 29 foldably connected to the top panel 15 at a fourth horizontal fold line 31. Any of the top panel 15, bottom panel 21, first side panel 17, second side panel 25, and attachment flap 29 can be differently shaped, positioned, configured, or omitted without departing from this disclosure.

[0016] The blank 20 and the carton formed therefrom may also include a plurality of end flaps foldably connected to respective panels of the plurality of panels. In the illustrated embodiment, the top panel 15 may be foldably connected to a first top end flap 33 and a second top end flap 35. The first side panel 17 may be foldably connected to a first side end flap 37 and a second side end flap 39. The bottom panel 21 may be foldably connected to a first bottom end flap 41 and a second bottom end flap 43. The second side panel 25 may be foldably connected to a first side end flap 45 and a second side end flap 47. When the carton is erected, top end flap 33, bottom end flap 41, and first side end flaps 37 and 45 can close a first end of the carton, and top end flap 35, bottom end flap 43, and second side end flaps 39 and 47 can close a second end of the carton. According to alternative embodiments of the present disclosure, different flap configurations can be used to at least partially close the ends of the carton.

[0017] In one embodiment, the top and bottom end flaps 33, 41, and first side end flaps 37, 45 extend along a first peripheral region of the blank 20 and are foldably connected to their respective panels 15, 21, 17, and 25 at respective portions of a first longitudinal fold line 62 that extends along the length of the blank 20. In the illustrated embodiment, the top and bottom end flaps 35, 43, and second side end flaps 39, 47 extend along a second peripheral region of the blank 20 and are foldably connected to their respective panels 15, 21, 17, and 25 at respective portions of a second longitudinal fold line 64 that also extends along the length of the blank 20. The longitudinal fold lines 62, 64 may, for example, be substantially straight or may be offset at one or more locations depending on the thickness of the blank or other factors.

[0018] It will be understood that the blank 20 and the carton formed therefrom can have different configurations without departing from this disclosure. The blank 20 and the carton formed therefrom can also include one or more additional or alternative features to suit a particular application, such as a handle feature, a dispenser feature, an item protection feature, etc. As described herein, an intermediate folded configuration between the blank 20 and the carton formed therefrom may be designated as the blank 20.

[0019] 2, method and system 100 may include a machine frame F that supports the various assemblies and components thereof described herein. Machine frame F may include one or more of bases, legs, struts, tie bars, platforms, etc. in various arrangements to provide a support structure for the assemblies and components described herein. For example, machine frame F may support such components above a base surface such as the ground or floor and may provide access at one or more locations for a human operator, for example, to inspect, maintain, and / or otherwise operate system 100.

[0020] 3 and 4, the system 100 may include a blank feed assembly 103 adjacent the upstream end of the system 100 and having a magazine 105 defining an interior space for receiving one or more folded or collapsed cartons / blanks 20 (FIG. 8). As shown, the magazine 105 may be shaped and arranged to support a plurality of cartons / blanks 20 in a horizontally stacked arrangement. It will be appreciated that the magazine 105 may include one or more features, such as a pusher, hopper, other actuator, etc., for advancing the cartons / blanks 20 forward through the magazine 105.

[0021] A pick-and-place blank feeding device 106, e.g., a pick-and-place blank feeder, may be provided located downstream of the magazine 105, e.g., in the downstream or machine direction M along which the cartons / blanks 20 move during operation of the system 100 as described herein. In the illustrated embodiment, a pair of carton-engaging arms 107 may be pivotally / rotatably mounted to respective overhead supports 108, e.g., rods, bars, shafts, mounting blocks, etc. Each carton-engaging arm 107 may include a respective vacuum cup 109 mounted to a distal end portion thereof, as shown. In this regard, during operation of the system 100, the carton-engaging arms 107 may be actuated to position each vacuum cup 109 to engage a blank 20 / carton in the magazine 105, and a vacuum may be applied to the vacuum cups 109 (e.g., via hoses or other fluid lines) such that the vacuum cups 109 are configured to acquire the cartons / blanks 20 by pressure differential, such as suction.

[0022] Thus, as described further herein, the carton-engaging arm 107 can rotate or pivot about / with the overhead support 108 to move each blank 20 / carton generally in the machine direction M from the blank feed assembly 103 onto a downstream conveyor assembly 111. In the illustrated embodiment, a stop member 110 or other limiter can be supported upstream of the carton-engaging arm 107 to minimize, inhibit, and / or prevent rearward movement of the carton-engaging arm 107 beyond a preselected position at which the stop member 110 is positioned. It will be understood that in some embodiments, a portion of the conveyor assembly 111 can extend along the blank feed assembly 103.

[0023] 2-6, the conveyor assembly 111 may include a pair of first conveyor members 113 mounted to the machine frame F in spaced-apart and generally parallel relationship relative to the machine direction M. Each conveyor member 113 includes an upper surface defining a respective rail 115 for supporting the cartons / blanks 20 received from the blank feed assembly 103, as shown. Also shown, one or more sprockets 117 may be rotatably mounted to each conveyor member 113 via, for example, a shaft, bearing, spindle, rod, or the like. A pair of respective endless belts or chains 125 may be at least partially wrapped around or otherwise positioned in generally curved engagement with the sprockets 117 such that, upon rotation of the sprockets 117, the chains 125 move along respective generally closed paths, as described further herein.

[0024] Also shown, a series of upstanding carton engagement lugs 127 are coupled at spaced intervals along the length of each chain 125 such that the lugs 127 project upwardly above each conveyor member 113 along the top of the closed path of the chain 125, where the engagement lugs 127 are configured to move synchronously with the chain 125. As described further herein, when the chain 125 is driven to move around the sprocket 117, the lugs 127 are brought into engagement with a trailing edge portion of each carton / blank 20, causing the underside of the blank / carton 20 to move, e.g., frictionally slide, along the rail 115.

[0025] In the illustrated embodiment, a center plate 128 is supported on the machine frame F and may be positioned between and in a generally parallel relationship with the rails 115 to at least partially support a central portion of the cartons / blanks 20, such as larger cartons / blanks 20. It will be understood that the center plate 128 may be omitted from the system 100 without departing from this disclosure.

[0026] A pair of carton braces 129 may be attached to the machine frame F, for example, using posts or other mounting members, and may include one or more spaced apart downward extensions 133 that provide a stop or upper limit for the movement of the cartons / blanks 20 traveling along the conveyor assembly 111. In this regard, the carton braces 129 may be positioned above the conveyor members 113 to maintain / stabilize the vertical position of the cartons / blanks 20 traveling along the system 100.

[0027] Conveyor assembly 111 may also include a pair of second conveyor members 135 positioned downstream of first conveyor member 113 and a second pair of endless belts or chains 125 at least partially wrapped around or otherwise generally curvedly engaged one or more sprockets rotatably mounted to conveyor members 135, such that rotation of the sprockets causes chains 125 to move along respective second generally closed paths, as described further herein. In the illustrated embodiment, the sprockets may include sprockets 137, 139, and 141, as well as sprocket 121 associated with first conveyor member 131, although different arrangements of sprockets or rotatable members may be provided without departing from this disclosure. It will be understood that one or more carton-engaging lugs may be coupled to chains 125 associated with each second conveyor member 135, for example, in the manner described above with respect to first conveyor member 113, for engaging cartons downstream of first conveyor member 113.

[0028] Although conveyor assembly 111 is shown as having a pair of adjacent / overlapping conveyor members and associated chains, it will be understood that conveyor assembly 111 may be provided in different arrangements without departing from this disclosure.

[0029] The carton assembly 143 can be positioned at least partially along the conveyor assembly 111 and can include a pair of parallel and spaced apart end flap engagement assemblies 145 that are at least partially driven by a portion of the drive assembly 231 (FIG. 2), as further described herein.

[0030] 7A and 7B, each end flap engagement assembly 145 may include a drive device 147, a connecting member 149 extending from the drive device 147 and operably coupled to the drive device 147 to facilitate movement thereof, and a crank device 151 operably coupled to the connecting member 149 to facilitate contact between the end flap engagement member 152 and at least one end flap of the carton / blank 20.

[0031] The drive device 147 may include a rotating member 153 that is rotatably mounted to a portion of the system 100, for example, via a shaft or other structure about which the rotating member 153 rotates freely or with which the rotating member 153 rotates. The rotating member 153 and / or associated shaft may be supported on a mounting block 155 that is attached to the frame F or another portion of the system 100. One or more bushings / bearings or other members may be positioned between the mounting block 155 and the rotating member 153 to facilitate relative movement of the components.

[0032] Rotating member 153 may include a generally circular, disk-shaped body 157 that defines and / or is coupled to a protrusion 159 that extends outwardly from rotating member 153 in a direction generally parallel to the axis of rotation about which body 157 rotates, as shown. As described further herein, protrusion 159 is positioned spaced apart from the axis of rotation of body 157 of rotating member 153.

[0033] In the illustrated embodiment, the adapter 161 can at least partially surround a periphery of the body 157 of the rotating member 153 and can define a recessed track 163 at least partially therealong for at least partially receiving a belt or other moving portion of the drive assembly 231. The adapter 161 can be fixedly attached to the body 157 of the rotating member 153, as shown, such that action of one or more components of the drive assembly 231 to rotate the adapter 161 can similarly rotate the rotating member 153. In some embodiments, the system 100 can lack the adapter 161, and a recessed track can be defined along a portion of the body 157 of the rotating member 153 for engaging one or more portions of the drive assembly 231.

[0034] The connecting member 149 may include a first end portion 165, a central portion 167 extending from the first end portion 165, and a second end portion 169 extending from the central portion 167, as shown.

[0035] First end portion 165 of connecting member 149 can have a generally circular or otherwise closed configuration to at least partially receive or otherwise couple to protrusion 159 of rotating member 153, as shown. Connecting member 149 can be coupled to protrusion 159 and rotating member 153 via a bushing / bearing 171, as shown, via a clip, clamp, or other fastening structure, and / or via a press fit or friction fit between protrusion 159 and first end portion 165.

[0036] The central portion 167 of the connecting member 149 can have the form of a generally elongated pair of members and can include one or more cross bars therealong, e.g., for reinforcement. The central portion 167 of the connecting member 149 can be selectively sized to position the first end portion 165 and the second end portion 169 at a desired location along the system 100.

[0037] The second end portion 169 of the connecting member 149 can have a generally circular or otherwise closed configuration for at least partially receiving a portion of the crank device 151 therethrough, as shown. The connecting member 149 can be coupled to the crank device 151 via a bushing / bearing 173 as shown, via a clip, clamp, or other fastening structure, and / or via a press fit or friction fit between a protrusion and the second end portion 169.

[0038] The portion of the crank arrangement 151 that extends at least partially through the second end portion 169 of the connecting member 149 may be part of a pivot arm or crank arm 175. In the illustrated embodiment, the arm 175 may include a body 177 for at least partially receiving an axle 179.

[0039] As shown, the body 177 of the crank arm 175 can include an opening through which the axle 179 passes, and the opening can align with a corresponding opening in the mounting block 183 such that the axle 179 passes through the mounting block 183 and the body 177 of the crank arm 175. In some embodiments, the axle 179 can be fixedly coupled to the crank arm 175.

[0040] As described herein, the crank arm 175 may be pivotally mounted on the system 100 relative to the mounting block 183 such that a portion of the crank arm 175 is movable through a U-shaped channel 181 defined in the mounting block 183 during operation of the respective end flap engagement assembly 145.

[0041] The end flap engagement member 152 can be coupled proximate to the distal end of the shaft 179 as shown and can have a generally tapered configuration, for example, an at least partially curved teardrop shape as shown, although the end flap engagement member 152 can have a different configuration without departing from this disclosure.

[0042] 2-7B , each end flap engagement assembly 145 can be positioned upstream of a respective end flap redirection member 207 of the carton assembly 143 and is operable to selectively position an end flap of the carton / blank 20 relative to the end flap redirection member 207, as described further herein. Each end flap redirection member 207 is positioned facing the rotatable end flap engagement assembly 145, as shown, and has a body with a generally curved or blunt forward nose portion intersecting a sloped upper surface. The sloped upper surface of the end flap redirection member 207 can include one or more angled, beveled, stepped, etc. surfaces for slidably engaging a portion of the blank / carton 20, as described further herein.

[0043] Each end flap redirection member 207 may be positioned adjacent and below a respective carton forming frame 217 having a sloped upper surface 219 for slidably engaging a portion of the blank 20, as described further herein. The upper surface 219 of the carton forming frame 217 is sloped upwardly from a generally horizontal lower portion 221 such that an airflow discharge area 223 is defined therebetween. In this regard, the lower portion 221 of each carton forming frame 217 may be provided with an opening in fluid communication with a respective conduit, e.g., a tube, hose, channel, etc., that is fluidly coupled to a respective air blower 229 (FIG. 6).

[0044] Blower 229 may be a fluid transmission mechanism operable to direct moving air through conduit 227, out opening 227, and into airflow discharge area 223 to facilitate assembly of cartons / blanks 20, as described further herein. In this regard, blower 229 may be, for example, a fan, pump, or other fluid transmission mechanism driven by an engine, motor, or other actuator to selectively provide airflow to airflow discharge area 223.

[0045] At least some of the above-described components of system 100 described above may be driven by rotatable shafts, axles, etc., which may be driven to rotate by drive assembly 231. In the illustrated embodiment, drive assembly 231 may include a series of interconnected shafts, gearboxes, and associated couplings, and in one embodiment may be operatively coupled to the various assemblies of system 100 described herein by a transmission assembly. In this regard, upon rotation of an input shaft, for example, by a motor (such as a servo motor), an engine, etc., drive assembly 231 may operate to provide torque or rotational motion to the various shafts, axles, gears, pulleys, sprockets, etc. of the transmission assembly to operate system 100. It should be understood that in some embodiments, a separate motor, engine, actuator (e.g., pneumatic or hydraulic actuator), etc. may be employed to drive one or more components of system 100.

[0046] 2-7B, and with further reference to Figures 8 and 9, operation of the system 100 for assembling cartons / blanks 20, according to one exemplary embodiment of the present disclosure, can include loading / receiving at least one carton / blank 20 into the blank feed assembly 103 and disposing a vacuum source in fluid communication with the vacuum cup 109 of the blank feeder 106 to engage the vacuum cup 109 with a leading carton 20 in the magazine 105. It will be appreciated that such disposition of the leading carton 20 can be accomplished by an actuator and / or a human operator.

[0047] Actuation of the drive assembly 231 can rotate or pivot the overhead support 108 of the blank feeder 106 to move the attached carton engagement arm 107 at least partially forward in the machine direction M and orient the carton / blank 20 in a generally upward or downward direction as positioned on the conveyor assembly 111. In particular, the folded carton 20 can be provided in a folded configuration supported on the rails 115 of the respective conveyor members 113 and respective portions of the central support plate 128. In such position, the end flaps 33, 35, 37, 39, 41, 43, 45, 47 can be positioned in an outermost position relative to the central support plate 128.

[0048] Continued operation of the drive assembly 231 rotates the sprockets 117, 119, 121, 123 to engage the respective chains 125, causing the upper portions of the chains 125 to move in the machine direction M. One or more of the lugs 127 carried by each chain 125 can engage the trailing edge of the carton / blank 20 to slidably advance the carton / blank 20 along the rails 115 and central support plate 128.

[0049] The drive assembly 231 also actuates the end flap engagement assembly 145. In particular, one or more belts associated with the drive assembly 231 / transmission assembly 239 and positioned within a recessed track 163 of the adapter 161 on the rotating member 153 can rotate the rotating member 153, for example, in the direction of arrow A1.

[0050] As the rotating member 153 rotates, the protrusion 159 extending from its body 157 can be carried along an eccentric path, for example, along a circular path spaced radially outward from the geometric center / axis of rotation of the body 157 of the rotating member 153, to carry the first end portion 165 of the connecting member 149 along such eccentric path.

[0051] The above-mentioned movement of the first end portion 165 of the connecting member 149 is transmitted along its central portion 167 to the second end portion 169, thereby causing movement of the crank arm 175 that is at least partially received therethrough.

[0052] In the illustrated embodiment, the connecting member 149 is disposed between the drive device 147 and the crank device 151 such that driven movement of the second end portion 169 of the connecting member 149 generally causes vertical reciprocating movement of the crank arm 175 about an axis 179 in the direction indicated by the double arrow V as shown.

[0053] The aforementioned generally upward and downward movement of crank arm 175 causes shaft 179 and its associated end flap engagement member 152 to move along a rotational path generally indicated by double arrow A2.

[0054] In this regard, actuation / driving of the end flap engagement assemblies 145 by respective portions of the drive assembly 231 may cause the respective end flap engagement members 152 to tilt upwardly, thereby engaging and, for example, impacting, striking, deflecting or otherwise moving upwardly the respective top end flaps 33, 35 (broadly, the "first end flaps").

[0055] In this regard, as the carton / blank 20 continues to advance in the machine direction M, the top end flaps 33, 35 are biased upward by their respective end flap engagement assemblies 145 to engage their respective end flap redirection members 207 at their respective nose portions and / or upper sloped portions and are guided toward the sloped upper surfaces 219 of their respective carton forming frames 217.

[0056] Meanwhile, the bottom end flaps 41, 43 are positioned to closely engage or support the upper surface of the respective second conveyor members 135. As the carton / blank 20 continues to advance in the machine direction M, the sliding engagement of the top end flaps 33, 35 with the upper angled surfaces 219 of the respective carton forming frames 217 causes the carton 20 to at least partially open, e.g., causing the top and bottom panels to move further and further apart from one another. Such opening / assembly of the carton 20 is facilitated by airflows generated by the respective air blowers 229 and exiting the respective airflow discharge areas 223 toward the interior of the carton / blank 20.

[0057] Following at least partial assembly of a carton from the blanks 20 described above, the carton may be moved to another system or to a further downstream portion of the system 100, for example, loading of containers, forming closed ends of the carton 20, transportation, storage, etc.

[0058] In view of the above, the end flap engagement assembly 145 provides a component of the system 100 that facilitates the use of an existing drive assembly / transmission assembly, e.g., one that is common to at least one of the blank feed assembly 103, the conveyor assembly 111, and / or the carton assembly 143, so as to eliminate the need for a separate actuator, e.g., pneumatic, hydraulic, etc., to drive the end flap engagement assembly 145 separately from such other components of the system 100.

[0059] Generally, the blanks of the present disclosure may be constructed from paperboard having a thickness such that they are heavier and more rigid than regular paper. The blanks may also be constructed from other materials, such as cardboard, or any other material having suitable properties to enable the structure to function at least generally as described above. The blanks may be coated, for example, with a clay coating. Product, advertising, and other information or images may then be printed on the clay coating. The blanks may then be coated with a varnish to protect the information printed on the blanks. The blanks may also be coated, for example, with a moisture barrier on one or both sides of the blank. The blanks may also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.

[0060] The foregoing description of the present disclosure illustrates and describes various embodiments. Because various changes can be made in the above configurations without departing from the scope of the present disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted in an illustrative and not a limiting sense. Moreover, the scope of the present disclosure encompasses various modifications, combinations, variations, etc. of the above-described embodiments. In addition, while the present disclosure shows and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the present disclosure as expressed herein, commensurate with the above teachings, and / or within the skill or knowledge of the relevant art. Furthermore, some features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure.

Claims

1. 1. A method for at least partially erecting a carton, comprising: loading a blank into a blank feed assembly, the blank comprising a plurality of panels and a plurality of end flaps foldably connected to each of the plurality of panels; positioning the blank on at least one conveyor assembly configured to move the blank in a downstream direction; operating the at least one conveyor assembly to move the blanks in the downstream direction toward a carton erection assembly including an end flap engagement assembly positioned adjacent the at least one conveyor assembly; actuating the end flap engagement assembly such that a portion of the end flap engagement assembly contacts and moves at least one end flap of the plurality of end flaps of the blank as the blank moves in the downstream direction; A method comprising:

2. 2. The method of claim 1, further comprising the step of slidably moving the at least one end flap of the plurality of end flaps of the blank onto an inclined upper surface of at least one carton forming frame of the carton assembly positioned downstream of the end flap engagement assembly.

3. 3. The method of claim 2, wherein the at least one carton-forming frame includes a lower portion such that an airflow discharge area is at least partially defined between the lower portion and the sloped upper surface in fluid communication with a blower device for facilitating the formation of a carton from the blank.

4. 4. The method of claim 3, wherein the drive device comprises a rotating member having a body with a protrusion extending outwardly from the rotating member, the protrusion being coupled to a connecting member.

5. 5. The method of claim 4, wherein the protrusion is spaced from an axis of rotation of the rotating member, the method including rotating the rotating member such that the protrusion moves along an eccentric path.

6. 6. The method of claim 5, wherein the protrusion is coupled to a first end portion of the connecting member, the connecting member further comprising a second end portion coupled to a crank arm of a crank arrangement.

7. 7. The method of claim 6, wherein the crank device comprises a crank arm pivotally mounted to a carton forming system and a shaft coupled to the crank arm, and an end flap engagement member coupled to the shaft.

8. 8. The method of claim 7, wherein the axle is at least partially received through and fixedly coupled to the crank arm, the method including the step of moving the crank arm such that the end flap engagement member pivots into engagement with the at least one end flap of the plurality of end flaps of the blank.

9. 1. A carton forming system comprising: a blank feed assembly adjacent the upstream end of the carton forming system for receiving at least one blank having a plurality of panels and a plurality of end flaps foldably connected to each of the plurality of panels; at least one conveyor assembly positioned downstream from the blank feed assembly in a machine direction of the carton forming system, the at least one conveyor assembly including at least one conveyor member defining a rail for at least partially supporting the at least one blank, and a plurality of engaging lugs movable along the rail to move the at least one blank at least partially in the machine direction; at least one end flap engagement assembly positioned adjacent to the at least one conveyor assembly, the end flap engagement assembly including a drive device, a connecting member operably coupled to the drive device, and a crank device operably coupled to the connecting member and supporting an end flap engagement member for contacting at least one end flap of the plurality of end flaps of the blank; A carton forming system comprising:

10. 10. The carton forming system of claim 9, further comprising a carton assembly comprising the at least one end flap engaging assembly and at least one carton forming frame positioned downstream from the end flap engaging assembly, the at least one carton forming frame defining a sloped upper surface for slidably receiving the at least one end flap of the plurality of end flaps of the blank.

11. 11. The carton forming system of claim 10, wherein the at least one carton forming frame includes a lower portion such that an airflow discharge area is at least partially defined between the lower portion and the sloped upper surface, the airflow discharge area being in fluid communication with a blower device to facilitate formation of a carton from the blank.

12. 12. The carton forming system of claim 11, wherein the drive device comprises a rotating member having a body with a protrusion extending outwardly from the rotating member, the protrusion being coupled to the connecting member.

13. 13. The carton forming system of claim 12, wherein the protrusion is spaced from an axis of rotation of the rotatable member such that the protrusion is configured to move along an eccentric path upon rotation of the rotatable member.

14. 14. The carton forming system of claim 13, wherein the protrusion is coupled to a first end portion of the connecting member, the connecting member further comprising a second end portion coupled to a crank arm of the crank device.

15. 15. The carton forming system of claim 14, wherein the crank device comprises a crank arm pivotally mounted to the carton forming system and a shaft coupled to the crank arm, the end flap engagement member being coupled to the shaft.

16. 16. The carton forming system of claim 15, wherein the axle is at least partially received through and fixedly coupled to the crank arm such that the end flap engagement member pivots upon movement of the crank arm.

17. 1. An end flap engagement assembly for a carton forming system, comprising: A drive unit; a connecting member operably coupled to the drive device; a crank device operably coupled to the connecting member and supporting an end flap engaging member for contacting at least one end flap of the blank; 1. An end flap engagement assembly comprising:

18. 18. The end flap engagement assembly of claim 17, wherein the driver comprises a rotating member having a body with a protrusion extending outwardly from the rotating member, the protrusion being coupled to the connecting member.

19. 20. The end flap engagement assembly of claim 18, wherein the protrusion is spaced from an axis of rotation of the rotating member such that the protrusion is configured to move along an eccentric path upon rotation of the rotating member.

20. 20. The end flap engagement assembly of claim 19, wherein the protrusion is coupled to a first end portion of the connecting member, the connecting member further comprising a second end portion coupled to a crank arm of the crank device.

21. 21. The end flap engagement assembly of claim 20, wherein the crank device comprises a crank arm pivotally mounted to the carton forming system and a shaft coupled to the crank arm, and the end flap engagement member is coupled to the shaft.

22. 22. The end flap engagement assembly of claim 21, wherein the shaft is at least partially received through and fixedly coupled to the crank arm such that the end flap engagement member pivots upon movement of the crank arm.

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