Packaging machine feeding, separating and creasing mechanism

Abstract

To provide a packaging machine mechanism for feeding a sheet material into a packaging machine, separating the sheet material into lengths used to produce a packaging template, and forming notches and creases in the sheet material from which the packaging template is formed.SOLUTION: The machine 100 for forming the packing of the template according to the present invention includes a feeding system 108 that can feed multiple feeds of sheet material 104 into the machine 100 without repositioning the feeding system 108 or forming folds or bends in the sheet material 104. This machine 100 also includes a separation and cutting system with one or more cutting tables and an energized knife that cut a packaging template of the sheet material 104. The machine also includes a creasing roller that forms a crease in the sheet material 104. The machine also includes a system to reduce or eliminate the effects of irregularities in the sheet material 104.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. patent application Ser. No. 16 / 375,579, filed April 4, 2019, and entitled "Packaging Machine Infeed, Separation, and Creasing Mechanisms," which in turn claims the benefit of U.S. patent application Ser. No. 62 / 729,762, filed September 11, 2018, and entitled "Packaging Machine Infeed, Separation, and Creasing Mechanisms," Belgian patent application Ser. No. 2018 / 05697, filed October 10, 2018, and entitled "Packaging Machine Infeed, Separation, and Creasing Mechanisms," Belgian patent application Ser. No. 2018 / 05697, filed April 5, 2018, and entitled "Spring-Mounted Packaging Machine Infeed, Separation, and Creasing Mechanisms," This application claims priority to and the benefit of Belgian Patent Application No. 2018 / 05233, filed on April 5, 2018, entitled "Spring-Loaded Blades," and Belgian Patent Application No. 2018 / 05232, filed on April 5, 2018, entitled "Cutting Out False Creases," the disclosures of which are incorporated herein by reference in their entireties.

[0002]

[0002] Exemplary embodiments of the present disclosure relate to systems, methods, and apparatus for packaging items into boxes. More specifically, exemplary embodiments relate to a wrapper mechanism that feeds sheet material into a wrapper, separates the sheet material to lengths used to create packaging templates, and forms scores and creases in the sheet material to form the packaging templates therefrom. [Background technology]

[0003] The shipping and packaging industry often uses equipment that converts cardboard and other sheet materials into box templates. One advantage of such equipment is that it allows carriers to prepare boxes of the required size as needed, instead of having to maintain a stock of standard pre-made boxes of various sizes. Thus, carriers can predict the need for specific box sizes and eliminate the need to stock pre-made boxes of standard sizes. Instead, carriers can stock one or more baling fan-folded materials and use them to create various box sizes based on the need for the specific box size at each shipment. This allows carriers to reduce the storage space typically required for regularly used shipping supplies, as well as reduce waste and costs associated with the inherently inexact process of predicting box size needs when the items being shipped and their respective dimensions change from time to time.

[0004]

[0004] In addition to reducing the inefficiencies associated with storing pre-made boxes of multiple sizes, creating custom-sized boxes also reduces packaging and shipping costs. In the fulfillment industry, it is estimated that typically shipped items are packed in boxes that are approximately 65% ​​larger than the item being shipped. A box that is oversized for a particular item is more expensive than a custom-sized box for the item due to the cost of the excess materials used to create the larger box. When an item is packed into an oversized box, filler materials (e.g., styrofoam, foam peanuts, paper, air pillows, etc.) are often placed inside the box to prevent the item from moving inside and to prevent the box from denting when it is under pressure (e.g., when the box is taped shut or stacked). These filler materials reduce the costs associated with packing items into oversized boxes. This will further increase the strikes.

[0005]

[0005] Custom-sized boxes also reduce the shipping costs associated with transporting an item compared to shipping an item in an oversized box. A shipping vehicle filled with boxes 65% larger than the item being packaged is much less cost-effective than a shipping vehicle filled with custom-sized boxes for the item being packaged. In other words, a shipping vehicle filled with custom-sized packages can carry a significantly larger number of packages, thereby reducing the number of shipping vehicles required to transport the same number of items. Thus, in addition to or as an alternative to shipping charges based on package weight, shipping charges are often affected by the size of the packages being shipped. Thus, by reducing the size of the package of an item, the price of shipping the item can be reduced. Even when shipping charges are not calculated based on package size (e.g., based only on package weight), the use of custom-sized packages can reduce shipping costs because smaller custom-sized packages weigh less than oversized packages by using less packing and filling materials.

[0006]

[0006] While sheet material converting machines and related equipment can potentially alleviate the inconvenience associated with storing standard size shipping items and reduce the amount of space required to store such shipping items, previously available machines and related equipment have various drawbacks. For example, previous systems focused primarily on creating boxes and sealing the boxes once they are filled. Such systems require multiple separators and significant manual labor. For example, a typical box forming system includes a converter that cuts, scores, and / or creases the sheet material to form a box template. Once the template is formed, an operator removes the template from the converter and a manufacturer's joint is created in the template. The manufacturer's joint is where two opposing ends of the template are attached to one another. This may be accomplished manually and / or with additional machinery. For example, an operator may apply glue to one end of the template (e.g., with a glue gun) and fold the template to join the opposing ends together with the glue between them. Alternatively, an operator can at least partially fold the template and insert the template into a gluing machine that applies glue to one end of the template and bonds the two opposing ends together. In either case, significant operator participation is required. Furthermore, using a separate gluing machine can complicate the system and significantly increase the overall size of the system.

[0007]

[0007] Once the manufacturer's joints are created, the template can be partially erected and the bottom flaps of the template can be folded and secured to form the bottom of the box. Again, an operator must typically erect the box. The bottom flaps can be folded and secured by an operator manually or with the aid of additional machinery. An operator then transfers the items to be packaged into the box and folds and secures the top flaps. Summary of the Invention [Problem to be solved by the invention]

[0008]

[0008] Although some efforts have been made to create individual packaging machines that create packaging templates and erect and seal the packaging templates around the items to be packaged, there remains room for improvement in the field of packaging machines and related methods. [Means for solving the problem]

[0009]

[0009] Exemplary embodiments of the present disclosure relate to a system, method, and apparatus for packaging items into boxes. More specifically, the exemplary embodiments involve feeding sheet material into a packaging machine, packaging tape, and The present invention relates to a wrapping machine mechanism that separates the sheet material to lengths that are used to create the templates and that forms creases and cuts in the sheet material to form packaging templates therefrom.

[0010] For example, one embodiment of a packaging machine used to convert substantially rigid sheet material into a packaging template for assembly into a box or other package includes an infeed system that directs a first feed of sheet material and a second feed of sheet material into the packaging machine. The infeed system includes a first low friction surface and an associated first advancement mechanism. The first advancement mechanism is configured to engage and advance the first feed of sheet material along the first low friction surface and into the packaging machine. Also included is a second low friction surface and an associated second advancement mechanism. The second advancement mechanism is configured to engage and advance the second feed of sheet material along the second low friction surface and into the packaging machine. The first low friction surface and the second low friction surface form an acute angle that is configured to allow the sheet material to advance into the packaging machine without creating any folds or creases in the sheet material. The converting machine also includes one or more converting tools configured to perform one or more converting functions on the sheet material as it moves through the packaging machine, the one or more converting functions being selected from the group consisting of scoring, bending, folding, punching, cutting, and scoring to produce a packaging template.

[0011] According to another embodiment, a packaging machine used to convert a generally rigid sheet material into a packaging template for assembly into a box or other package includes a separation system that separates the sheet material to lengths for use in creating the packaging template. The separation system includes a cutting table having a cutting edge, a first knife, and a second knife. The first knife has an attached end, a free end, and a first knife edge extending at least partially therebetween. The first knife edge is angled relative to the cutting edge of the cutting table to create a contact point between the first knife edge and the cutting edge of the cutting table as the first knife moves between a raised position and a lowered position. The second knife has an attached end, a free end, and a second knife edge extending at least partially therebetween. The second knife edge is angled relative to the cutting edge of the cutting table to create a contact point between the second knife edge and the cutting edge of the cutting table as the second knife moves between a raised position and a lowered position. The free ends of the first and second knives are positioned adjacent to one another near a center of the sheet material. The mounting ends of the first and second knives are positioned adjacent opposite sides of the sheet material.

[0012] According to another embodiment, a packaging machine used to convert a substantially rigid sheet material into a packaging template for assembly into a box or other package includes a creasing system for forming a transverse crease in the sheet material. The transverse crease is oriented transversely across the sheet material and traverses a length of the sheet material. The creasing system includes a support plate supporting the sheet material, a first creasing roller, and a second creasing roller. The first creasing roller is oriented transversely across the sheet material and traverses a length of the sheet material. The first creasing roller has a first creasing ridge extending radially therefrom. The first creasing roller is configured to be rotated to engage the first creasing ridge with the sheet material to form a crease in the sheet material. The second creasing roller is oriented transversely across the sheet material and traverses a length of the sheet material. The second creasing roller has a second creasing ridge extending radially therefrom. The second creasing roller is configured to be rotated to engage the second creasing ridge with the sheet material to form a crease in the sheet material. The first and second creasing rollers are disposed adjacent one another and are independently operable.

[0013] In another embodiment, a cutting unit for cutting a sheet material includes a cutting table having a first cutting edge and a blade having a second cutting edge. and a first actuator mounted between the cutting table and the blade for moving the blade relative to the cutting table during an up and down cutting movement. The first and second cutting edges are at an angle such that a contact point can be identified between the first cutting edge and the second cutting edge during the cutting movement. The pressure element is configured to exert a force on the blade to increase pressure between the first cutting edge and the second cutting edge at the contact point.

[0014] In another embodiment, there is provided a method of cutting sheet material using a cutting unit including a cutting table having a first cutting edge and a blade having a second cutting edge, the first cutting edge and the second cutting edge being at an angle, the method comprising the steps of moving the blade relative to the cutting table in an up and down (linear) cutting movement by a first actuator, and pressing the blade with a pressure element during the cutting movement to increase pressure between the first cutting edge and the second cutting edge at a contact point.

[0015] In another embodiment, an apparatus for producing a box template from a continuous length of sheet material includes a supply of sheet material, a cutting device, a controller, and a sensor. The supply is configured to supply the continuous length of sheet material to the cutting device. The cutting device is configured to cut the continuous length of sheet material into successive segments based on input from the controller to produce a box template. The sensor is configured to detect irregularities in the continuous length of sheet material and communicate locations of the irregularities to the controller. The controller is provided to activate a discharge cycle on the cutting device based on locations of waste segments in the continuous length of sheet material. The discharge cycle is configured to cut and discharge the waste segments from the continuous length.

[0016] In yet another embodiment, a method of generating a box template from a continuous length of sheet material is provided. The method includes feeding the continuous length of sheet material to a cutting device. The method also includes cutting the continuous length of sheet material into successive segments with the cutting device based on input from a controller to produce a box template. The method further includes detecting an irregularity at a location in the continuous length of sheet material with a sensor and transmitting the location to the controller. The method further includes activating a discharge cycle with the cutting device based on the location of the irregularity, cutting a waste segment from the continuous length, and discharging the waste segment from the cutting device.

[0017]

[0017] These and other objects and features of the present disclosure will become more fully apparent from the following description and the accompanying drawings, or may be learned by the practice of the disclosure as set forth hereinafter.

[0018]

[0018] To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be made by reference to specific embodiments thereof which are illustrated in the accompanying drawings. It will be understood that these drawings are merely illustrative embodiments of the invention and therefore should not be considered as limiting the scope of the invention. The invention will be described and explained with further specificity and detail through the use of the accompanying drawings, in which: [Brief description of the drawings]

[0019] [Figure 1]

[0019] FIG. 1 illustrates an example box template. [Diagram 2]

[0020] FIG. 1 illustrates an example packaging machine used to package items. [Diagram 3]

[0021] FIG. 3 is a cross-sectional view of an infeed system of the packaging machine of FIG. 2. [Figure 4] FIG. 3 is a cross-sectional view of an infeed system of the packaging machine of FIG. 2. [Diagram 5] FIG. 3 is a cross-sectional view of an infeed system of the packaging machine of FIG. 2. [Figure 6]

[0022] FIG. 3 is an elevational view of the separation mechanism of the packaging machine of FIG. 2. [Figure 7] FIG. 3 is a plan view of a separation mechanism of the packaging machine of FIG. 2. [Figure 8]

[0023] FIG. 3 shows a dual roller creasing mechanism of the packaging machine of FIG. 2. [Figure 9]

[0024] FIG. 2 is a side view of an example cutting unit according to an embodiment of the present disclosure. [Figure 10]

[0025] FIG. 10 is a plan view of the cutting unit of FIG. 9. [Figure 11]

[0026] FIG. 1 illustrates an example apparatus including a cutting unit, a feed section, and a controller according to an embodiment of the present disclosure. [Figure 12]

[0027] FIG. 1 is a schematic diagram of an example apparatus for forming a box template according to an embodiment of the present disclosure. [Figure 13]

[0028] FIG. 13 is a plan view of the device of FIG. 12. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020]

[0029] The embodiments described herein relate generally to systems, methods, and apparatus for packaging items into boxes. More specifically, the embodiments described relate to a wrapper mechanism that feeds sheet material to a wrapper, separates the sheet material to lengths used to create packaging templates, and forms cuts and creases in the sheet material to form packaging templates therefrom.

[0021]

[0030] Although the present disclosure will be described in detail with reference to a specific configuration, this description is illustrative and should not be construed as limiting the scope of the present disclosure. Various modifications may be made to the illustrated configuration without departing from the spirit and scope of the present invention as defined by the claims. For better understanding, the same components are designated by the same reference numerals throughout the various accompanying drawings.

[0022]

[0031] Throughout the specification and claims, components are described as being in a particular orientation or relative position. Such descriptions are used for convenience only and are not intended to limit the invention. For example, a component may be described as being above or below another component. However, it will be understood that machines, systems, and mechanisms may be oriented in other ways in some embodiments. As a result, a component described as being above another component may be located below or to the side of the other component in some embodiments. In some cases, a component described as being "above" or "below" another component may be understood to be located on one side or another of the sheet material being converted into a packaging template.

[0023]

[0032] As used herein, the terms "box template" and "blank" are used interchangeably and refer to a substantially flat material that can be folded into a box-like shape. The box template can be made from a stock of sheet material (e.g., cardboard, corrugated board, cardboard, etc.). In some cases, the sheet material is a fan-folded material that is folded back and forth on itself to form a bail. The box template can have notches, cutouts, dividers, and / or creases that allow the box template to be bent and / or folded into a box. Furthermore, the box template can be made of any suitable material commonly known to those skilled in the art. For example, cardboard or corrugated board may be used as the box template material. The suitable material can also have any thickness and weight that allows it to be bent and / or folded into a box-like shape.

[0024]

[0033] FIG. 1 illustrates one example embodiment of a packaging template 10. The packaging template 10 includes cuts (shown in solid lines) and folds (shown in dashed lines). As used herein, a fold can be an indentation in the sheet material that facilitates folding the packaging template 10 at the location of the indentation. Alternatively, a fold can be a partial cut or score that cuts the sheet material only partially through its entire thickness, such that a weakening of the sheet material occurs at the location of the partial cut or score. It has become.

[0025]

[0034] The packaging template 10 includes four central panels A, B, C, and D. Each of the four central panels is adapted to form a wall of a box. In the configuration of FIG. 1, panel B forms the bottom wall of the box, panels A and C form the upright walls of the box, and panel D forms the top wall of the box. FIG. 1 also shows how the length l, width b, and height h of the box result from the dimensions of the packaging template 10. Each panel A, B, C, and D has two side flaps, which are indicated by A', B', C', and D', respectively. These side flaps are adapted to form the two side walls of the box. Additionally, in this embodiment, a glue tab A'' extends from panel A. The glue tab A'' serves to connect panel A to panel D when forming the box.

[0026]

[0035] In FIG. 1, a wedge of material is cut between adjacent side flaps. This may be advantageous in some cases in folding the side flaps. Nevertheless, in other embodiments, box templates may be formed in which adjacent side flaps are separated from one another by a single cut rather than multiple cuts to remove the wedge of material. For example, the side flaps of the box template 10 may be formed by a straight cut across the box template 10 starting at an edge of the blank and extending toward the central axis of the box template for a length equal to the length of the side flap.

[0027]

[0036] It will also be understood that the side flaps A', B', C', and D' may be sized to fully or partially form the side panel. When the side panel is only partially formed, it typically has an opening in the middle so that the box is not fully closed. This may be advantageous in some circumstances. When the side panel is fully formed, the side flaps may be adjacent or overlapping. Various combinations thereof are also possible. It will also be understood how the box template 10 may be created to form a box with predetermined dimensions.

[0028]

[0037] Reference is made throughout this description to a box template 10. However, it will be understood that the box template 10 is merely one example of a box template that may be provided in the embodiments disclosed herein. Thus, the particular configuration of the box template (e.g., number and proportion of panels / flaps, cut / fold placement, etc.) is not limited to that shown in FIG.

[0029]

[0038] Attention is now directed to Figure 2, which illustrates an example packaging machine 100 used to create and erect a packaging template around an article to be packaged. In the illustrated embodiment, articles for packaging are delivered to the packaging machine 100 via a conveyor 102. Dimensions of the article may be obtained while the article is placed on the conveyor 102 or prior to it.

[0030]

[0039] In either case, the articles are advanced into a packaging machine 100 on a conveyor 102. The packaging machine 100 creates a custom-sized box template for the articles from a sheet of material 104. The packaging machine 100 also folds and secures the box template around the articles. The articles to be packaged are then advanced out of the packaging machine 100 on another conveyor 106.

[0031] Feeding mechanism

[0040] One common challenge with packaging machines is feeding the sheet material into the machine. For example, the infeed mechanism of some packaging machines creates folds or creases in the sheet material as it is fed into the packaging machine. The folds or creases can cause problems as the sheet material progresses through the packaging machine. As an example, the folds or creases can cause problems when the packaging material is wrapped. The folds or creases may also cause the packaging machine to create desired creases and / or cuts in the sheet material in undesirable locations in the sheet material.

[0032]

[0041] In the illustrated embodiment, the packaging machine 100 includes an infeed mechanism 108 that is designed to feed multiple streams or feeds of sheet material into the converter 100 without creating undesirable folds or creases in the sheet material. Additionally, the infeed mechanism 108 does not require a cassette changer that moves up and down to feed sheet material from different streams of sheet material into the packaging machine 100.

[0033]

[0042] The infeed mechanism 108 is shown in Figures 3-5. In some embodiments, such as that shown in Figure 3, the infeed mechanism 108 includes a first track 110 that guides a first feed 112 of sheet material 104 to a first end of the packaging machine 100 and a second track 114 that guides a second feed 116 of sheet material 144 to the first end of the packaging machine 100. The first track 110 and the second track 114 can each include a substantially flat surface along which the respective feeds of sheet material may be advanced. Additionally, the first track 110 and the second track 114 can include guides 118, 120 that help the first and second feeds 112, 116 of sheet material 104 lie substantially flat on the flat surfaces of the respective tracks 110, 114. In some embodiments, the guides 118 , 120 include one or more wheels that are capable of pivoting and that engage the first and second feeds 112 , 116 of the sheet material 104 .

[0034]

[0043] As best seen in Figures 4 and 5, the infeed system 108 also includes a first low friction surface 122 and an associated first advanced mechanism 124. The first low friction surface 122 is generally aligned with the flat surface of the track 110. The first advancement mechanism 124 is positioned and configured to engage and advance the first feed 112 of the sheet material 104 along the first low friction surface 122. More specifically, the first advancement mechanism 124 may comprise one or more feed rollers, pulleys, and / or belts that may rotate and engage the first feed 112. The first advancement mechanism 124 may be spaced from the first low friction surface 122 by a distance that is equal to or less than the thickness of the first feed 112. The first low friction surface 122 acts as a support plate for the first feed 112. By engaging the first advancement mechanism 124 with the first feed 112 , the first feed 112 is advanced along the first low friction surface 122 and into the packaging machine 100 .

[0035]

[0044] The infeed system 108 also includes a second low friction surface 126 and an associated second advancement mechanism 128. The second low friction surface 126 is generally aligned with the flat surface of the track 114. The second advancement mechanism 128 is positioned and configured to engage and advance the second feed 116 of the sheet material 104 along the second low friction surface 126. More specifically, the second advancement mechanism 128 may comprise one or more rollers, pulleys, and / or belts that may rotate and engage the second feed 116. The second advancement mechanism 128 may be spaced apart from the second low friction surface 126 by a distance that is equal to or less than the thickness of the second feed 116. The second low friction surface 126 acts as a support plate for the second feed 116. By engaging the second advancement mechanism 128 with the second feed 116 , the second feed 116 is advanced along the second low friction surface 126 and into the packaging machine 100 .

[0036]

[0045] In some embodiments, the first and second advancement mechanisms 124, 128 are actuated independently of one another. For example, the first advancement mechanism 124 can be actuated to advance the first feed 112 into the converting machine 100, or the second advancement mechanism 128 can be actuated to advance the second feed 114 into the converting machine 100. In such embodiments, sheets from only one of the first feed 112 and the second feed 114 may be fed into the converting machine 100. The material 104 is advanced into the converting machine 100 one at a time, allowing the desired type of sheet material 104 (e.g., size, thickness, color, strength, etc.) to be selected and advanced into the packaging machine 100 as needed.

[0037]

[0046] As can be seen in FIG. 5 , the first low-friction surface 122 and the second friction surface 126 form an acute angle θ with respect to one another. In an exemplary embodiment, the apex of the angle θ is formed by the second ends of the first and second low-friction surfaces 122, 126. The first ends of the first and second low-friction surfaces 122, 126 are disposed closer to a first end of the packaging machine 100 where the sheet material 104 enters the converting machine 100, and their second ends are disposed closer to an opposite second end of the converting machine 100. The angle θ is small enough to allow the sheet material 104 to advance into the converting machine 100 without creating any folds or creases in the sheet material 104. For example, in some embodiments, the angle θ is less than about 15°, 12.5°, 10°, 7.5°, 5°, 3°, or 2°. The relatively small angle θ orients the sheet material 104 such that as the sheet material 104 advances into the track 130 of the packaging machine 100, the sheet material 104 does not bend so much as to create undesirable folds or creases in the sheet material 104. Additionally, the relatively small angle θ allows either feed 112, 114 of the sheet material 104 to be advanced into the packaging machine 100 without requiring adjustment, repositioning, or reorientation of the infeed mechanism 108.

[0038]

[0047] The first and second low friction surfaces 122, 126 form an angle θ, although the particular configuration of how the angle θ is formed may vary from embodiment to embodiment. For example, in the illustrated embodiment, the second low friction surface 126 is approximately parallel to the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100, while the first low friction surface 122 is angled upward from the second low friction surface 126 (and the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100). In other words, the first end of the first low friction surface 122 is spaced further from the second low friction surface 126 than the second end of the first low friction surface 122.

[0039]

[0048] However, in other embodiments, the first low friction surface 122 may be approximately parallel to the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100, and the second low friction surface 126 may be angled downward from the first low friction surface 122 (and the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100). In still other embodiments, the first and second low friction surfaces 122, 126 may both be angled relative to the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100. For example, the first low friction surface 122 may be angled upward from the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100, and the second low friction surface may be angled downward from the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100.

[0040]

[0049] In some examples, the first and second low friction surfaces 122, 126 can be angled away from the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100 by equal and opposite amounts (e.g., +2.5° and −2.5°). In other examples, the first and second low friction surfaces 122, 126 may be angled away from the horizontal and / or feed direction of the sheet material 104 through the packaging machine 100 by different amounts (e.g., +3.5° and −1.5°).

[0041]

[0050] In yet other embodiments, the first and second low friction surfaces 122, 126 can be oriented approximately parallel to one another. In such cases, the first and second low friction surfaces 122, 126 can be spaced apart a small enough distance to allow the sheet material to be advanced into the packaging machine without creating any folds or creases in the sheet material and with limited or no repositioning of the infeed system. In some cases, the first and second low friction surfaces 122, 126 can be spaced apart from one another by approximately 4 inches. The distance may be less than about 1 inch, about 3 inches, about 2.5 inches, about 2 inches, about 1.5 inches, about 1 inch, about 0.75 inches, about 0.5 inches, about 0.25 inches, about 0.1 inches, or less.

[0042]

[0051] It will be appreciated that other aspects of the first and second low friction surfaces 122, 126 may vary from embodiment to embodiment. For example, in the illustrated embodiment, the first and second low friction surfaces 122, 126 are formed of separate components that are connected together or positioned adjacent to one another. However, in other embodiments, a single component may be formed with the first and second low friction surfaces 122, 126 disposed on opposite sides thereof.

[0043]

[0052] Regardless of the particular orientation of the first and second low-friction surfaces 122, 126, the first and second advancement mechanisms 124, 128 may be oriented to engage the first and second feeds 112, 114 to advance the first and second feeds 112, 114 along the first and second low-friction surfaces 122, 126, respectively. For example, as shown in Figures 4 and 5, the orientation of the first advancement mechanism 124 generally corresponds to the orientation of the first low-friction surface 122, and the orientation of the second advancement mechanism 128 generally corresponds to the orientation of the second low-friction surface 126.

[0044]

[0053] Additionally, as can be seen in each of the figures, the first advancement mechanism 124 is disposed above the first low friction surface 122. Additionally, the second low friction surface 126 is disposed below the first low friction surface 122. As a result, the second low friction surface 126 and the first advancement mechanism 124 are disposed on either side of the first low friction surface 122. Similarly, the second advancement mechanism 128 is disposed below the second low friction surface 126. As a result, the second advancement mechanism 128 and the first low friction surface 122 are disposed on either side of the second low friction surface 126.

[0045] separation mechanism

[0054] Once the sheet material 104 is advanced into the packaging machine 100, it must be cut or separated into lengths that can be used to form individual packaging templates. Typically, a rotary knife is used to cut the sheet material. One advantage of a rotary knife is its reliability. However, a disadvantage of a rotary knife is that the cutting speed is relatively slow because the rotary knife must move across the sheet material to make the cut. Because the cutting speed of a rotary knife is relatively slow, the throughput of a packaging machine incorporating it is lower than desired.

[0046]

[0055] 6 and 7 show elevation and plan views of a separation mechanism 140 that can be used to separate the sheet material 104 to lengths for packaging templates. The separation mechanism 140 includes a knife that cuts the sheet material 104 by an up-down cutting movement. As used herein, "up-down cutting movement" is not limited to movement in a vertical plane. Rather, in general, "up-down cutting movement" refers to a knife moving toward and away from the sheet material 104 to create a cut in the sheet material 104. Thus, movement of the knife through diagonal and / or horizontal planes can be considered an up-down cutting movement as long as the knife is moving toward and away from the sheet material 104 being cut. The up-down cutting movement of the knife is also referred to herein as moving the knife between an inoperative position and an operative position.

[0047]

[0056] The up-down cutting movement is advantageous because it is easily controllable. Another advantage is that one up-down cutting movement can be very short and takes less time compared to a rotary knife. Furthermore, the up-down cutting movement is performed relative to a cutting table, which is an element that acts as a support for the sheet material while the knife cuts it. As a result, the sheet material does not move undesirably during the cutting movement of the knife. The cutting table also acts as a counter knife for the knives. This means that the cutting table can exert a counter force to the force that the knife exerts on the sheet material. As a result, the sheet material does not move with the downward movement of the knife.

[0048]

[0057] 6 in more detail, the separating mechanism 140 is shown in an elevational view. As can be seen, the separating mechanism 140 includes a cutting table 142. The cutting table 142 has an upper surface that supports the sheet material 104 after it has advanced past the infeed mechanism 108. The cutting table 142 also includes a cutting edge 144, which helps to facilitate cutting of the sheet material 104, as will be described in more detail below.

[0049]

[0058] The separating mechanism 140 also includes first and second knives 146, 148. The first knife 146 has an attached end 150, a free end 152, and a first knife edge 154 extending at least partially therebetween. Similarly, the second knife 148 has an attached end 156, a free end 158, and a second knife edge 160 extending at least partially therebetween. The free ends 152, 158 of the first and second knives 146, 148 are disposed adjacent to one another above the sheet material 104. For example, in some embodiments, the free ends 152, 158 of the first and second knives 146, 148 are spaced apart by less than 1 inch, 0.75 inches, 0.5 inches, 0.25 inches, or 0.1 inches. Further, in some embodiments, the free ends 152, 158 are disposed approximately above the center of the sheet material 104. The attached ends 150, 156 of the first and second knives 146, 148 are positioned adjacent opposite sides of the sheet material 104.

[0050]

[0059] The mounting ends 150, 156 of the first and second knives 146, 148 are connected to tracks 162, 164, respectively. The connections between the mounting ends 150, 156 and the tracks 162, 164 are movable to allow the first and second knives 146, 148 to be raised, lowered or moved towards and away from the sheet material 104. Additionally, the first and second knives 146, 148 are associated with one or more actuators 166 (e.g., motors, springs, cylinders, etc.) to move the knives 146, 148 between the raised and lowered positions. In some embodiments, the one or more actuators 166 associated with the knives 146, 148 simultaneously move the first and second knives 146, 148 between the inactivated and activated positions. In other embodiments, the one or more actuators 166 may be enabled to independently move the first and second knives 146, 148 between the inactivated and activated positions.

[0051]

[0060] The cutting edge 144 of the cutting table 142 and the first and second knives 146, 148 can be configured to cooperate to cut the sheet material 104. For example, the first and second knives 146, 148 can be sized, shaped, positioned, and / or oriented relative to the cutting edge 144 to enable the cutting edge 144 and the first and second knife edges 154, 160 to efficiently cut the sheet material 104 when the first and second knives 146, 148 move from a non-operative position to an operative position.

[0052]

[0061] By way of example, the first and second knife edges 154, 160 may each be angled relative to the cutting edge 144 of the cutting table 142 to create a point of contact between the first knife edge 154 and the cutting edge 144 and between the second knife edge 160 and the cutting edge 144. More specifically, the cutting edge 144 of the cutting table 142 lies in a plane and the first and second knife edges 154, 160 are angled toward the plane of the cutting edge 144. In some embodiments, the first knife edge 154 is angled relative to the cutting edge 144 of the cutting table 142 such that the mounting end 150 of the first knife 146 is disposed on a first side of the plane and the free end 152 of the first knife 146 is disposed on a second side of the plane. Similarly, the second knife edge 160 can be angled relative to the cutting edge 144 of the cutting table 142 such that the mounting end 156 of the second knife 148 is disposed on the first side of the plane and the free end 158 is disposed on the second side of the plane.

[0053]

[0062] In some embodiments, the separation mechanism 140 includes a biasing member associated with each of the first and second knives 146, 148 that biases or maintains the first and second knives 146, 148 against the cutting edge 144; for example, FIG. 7 shows a top view of the first knife 146. As can be seen, the mounting end 150 of the first knife 146 can be mounted (pivotally or at an angle) such that the first knife 146 is angled toward the cutting edge 144. Additionally, the biasing member 168 applies a force to the first knife 144 to ensure that the first knife 146 contacts the cutting edge 144 with sufficient force such that the first knife 146 and the cutting edge 144 can cut the sheet material 104. Additionally, the biasing member 168 ensures that the single moving contact point between the first knife edge 154 and the cutting edge 144 is consistent even when the edge is not perfectly straight. As a result, the biasing member 168 reduces the need for costly dimensional tolerances on the components. The second knife 148 can include a similar biasing member. The biasing member can include a spring, a cylinder, a motor, or the like.

[0054]

[0063] In addition to the first and second knives 146, 148 being angled toward the cutting edge 144 (e.g., the free ends 152, 158 are disposed closer to the cutting edge 144 than the attached ends 150, 156), the first and second knives may also taper from the attached ends 150, 156 toward the free ends 152, 158 such that the first and second knife edges 154, 160 are angled in two directions relative to the cutting edge 144 of the cutting table 142. For example, the first knife edge 154 has a first end adjacent the attached end 150 and a second end adjacent the free end 152, the second end being disposed vertically higher than the first end. In other words, the first knife 146 has a non-cutting edge opposite the first knife edge 154, and the second end of the first knife edge 154 is disposed closer to the non-cutting edge than the first end of the first knife edge 154. Similarly, second knife edge 160 has a first end adjacent to mounting end 156 and a second end adjacent to free end 158, the second end being disposed vertically higher (or closer to the non-cutting edge) than the first end.

[0055]

[0064] As a result of the angled configuration of the first and second knives 146, 148, the contact points between the first knife edge 154 and the cutting edge 144 and between the second knife edge 160 and the cutting edge 144 move across the cutting edge 144 as the first and second knives move between the inoperative and operative positions. Because the first and second knife edges 154, 160 are configured essentially as mirror images of one another, when the contact point between the first knife edge 154 and the cutting edge 144 moves across the cutting edge 144 in a first direction, the contact point between the second knife edge 160 and the cutting edge 144 moves across the cutting edge 144 in a second direction that is opposite to the first direction. Nevertheless, it will be appreciated that the first and second knives may not be mirror images of one another. In such cases, the contact points may move in the same direction as the first and second knives move between the inoperative and operative positions.

[0056] Creasing mechanism

[0065] As the sheet material 104 advances through the conversion machine 100, various cuts and folds are made to transform the sheet material into a packaging template, such as packaging template 10 shown in FIG. A crease is formed in the sheet material 104. One of the challenges in making a packaging template such as packaging template 10 is forming the transverse creases between panels A, B, C, and D. Typically, a creasing tool is moved laterally across the sheet material to form the creases. Similar to the rotary knife described above, moving the creasing tool laterally across the sheet material can be relatively slow, thereby reducing the throughput of the packaging machine. Additionally, moving the creasing tool laterally requires that the sheet material be stationary when forming the creases, or else the creases will be formed at an angle, or the creasing tool must be able to move both horizontally and vertically to crease the transverse creases.

[0057]

[0066] FIG. 8 illustrates a creasing system 180 that can be used to form transverse creases in the sheet material 104 in a consistent and rapid manner. The creasing system 180 includes a support plate 182 that supports the sheet material 104 as it moves through the packaging machine 100. The creasing system 180 also includes a first creasing roller 184 that is oriented across and across the length of the sheet material 104. The first creasing roller 184 has a body 186 with a predetermined diameter. In the illustrated embodiment, the body 186 is cylindrical, although the body 186 may have other shapes. A first creasing ridge 188 extends radially from the cylindrical body 186. The first creasing ridge 188 may be integrally formed with the cylindrical body 186, or may include an insert attached to the body 186, or may include an insert received within and extending from a recess in the body 186.

[0058]

[0067] The first creasing roller 184 is configured to rotate about its axis to engage the first creasing ridges 188 with the sheet material 104 to form creases in the sheet material 104. The support plate 182 provides a counter pressure to the first creasing roller 184 to enable the first creasing ridges 188 to form creases in the sheet material 104.

[0059]

[0068] The distance between the support plate 182 and the outer surface of the cylindrical body 186 can be about the same as or greater than the thickness of the sheet material 104. As a result, when the first creasing roller 184 is rotated such that the first creasing ridges 188 face away from the sheet material 104 (as shown in FIG. 8 ), the sheet material 104 can move between the first creasing roller 184 and the support plate 182 without any creases being formed in the sheet material 104.

[0060]

[0069] In contrast, when the first creasing ridge 188 has its outer radial surface facing toward the support plate 182, the distance therebetween is less than the thickness of the sheet material 104. As a result, the sheet material 104 may be positioned between the first creasing roller 184 and the support plate 182 without being significantly affected until the first creasing roller 184 is rotated such that the first creasing ridge 188 is facing toward the support plate 182. When the first creasing roller 184 is rotated such that the first creasing ridge 188 is facing toward the support plate 182, the first creasing ridge 188 engages the sheet material 104 and the sheet material 104 is compressed between the first creasing ridge 188 and the support plate 182, thereby forming a crease in the sheet material 104.

[0061]

[0070] In some embodiments, the creasing system 180 also includes a second creasing roller 190, which can be generally similar to the first creasing roller 184. For example, the second creasing roller can include a body 192 and a second creasing ridge 194. The second creasing ridge 194 can be integrally formed with the body 192, or can include an insert attached to the body 192, or can be recessed within the body 192. 8, the second creasing roller 190 may be configured to rotate a second creasing ridge 194 into engagement with the sheet material 104 to form a crease in the sheet material 104. In yet other embodiments, the creasing system 180 may include three or more creasing rollers.

[0062]

[0071] In embodiments including two or more creasing rollers 184, 190, at least the first and second creasing rollers 184, 190 can be positioned adjacent to one another. For example, the first and second creasing rollers 184, 190 may be spaced apart (in the feed direction of the sheet material) by less than 24 inches, less than 18 inches, less than 12 inches, less than 6 inches, etc. The relatively close spacing of the first and second creasing rollers 184, 190 may limit the size of the creasing system 180 while allowing the creases to be formed close together in the sheet material 104.

[0063]

[0072] The first and second creasing rollers 184, 190 (or additional creasing rollers) can operate in a variety of manners. For example, the first and second creasing rollers 184, 190 can operate independently of one another. By way of example, the first creasing roller 184 can rotate to form a crease in the sheet material 104 while the second creasing roller 190 remains disengaged from the sheet material 104, or vice versa. Alternatively, the first and second creasing rollers 184, 190 can be configured to simultaneously engage the sheet material 104 to simultaneously form multiple creases in the sheet material 104. In yet other embodiments, the first and second creasing rollers 184, 190 can be configured to alternately engage the sheet material 104 to form creases in the sheet material 104. By alternating between the first creasing roller 184 and the second creasing roller 190, the speed at which transverse creases can be formed in the sheet material 104 can be significantly increased.

[0064]

[0073] In some embodiments, the creasing system 180 or packaging machine 100 includes a feed mechanism 196 configured to feed the sheet material 104 through the packaging machine 100. The creasing system 180 can be configured to form creases in the sheet material 104 while the sheet material 104 is moving through the packaging machine 100. In other words, the sheet material 104 does not have to stop moving through the packaging machine 100 to allow the transverse creases to be formed. Rather, the creasing rollers can rotate into engagement with the sheet material 104 to form creases in the sheet material 104 while the sheet material 104 continues to move (by the feed mechanism 196) through the packaging machine 100.

[0065] cutting mechanism

[0074] In addition to creating creases in the sheet material 104 as described above, cuts can be made in the sheet material 104 to create box templates, such as box template 10. For example, cuts may be made in the sheet material 104 to separate adjacent flaps from one another. Figures 9 and 10 show elevation and plan views, respectively, of a cutting unit 200 that can be used to create cuts in the sheet material 104.

[0066]

[0075] In the illustrated embodiment, the cutting unit 200 includes a blade 202 and a cutting table 204. The blade 202 may be a guillotine-type blade. For example, the blade 202 may perform an up and down movement 206, also known as a drop movement. The configuration of the blade 202 may be relatively simple. For example, the blade 202 may be a straight guillotine blade. The blade 202 may be one or more segments including, for example, a mounting segment 208 and a cutting segment 210. It may include a number part.

[0067]

[0076] The blade 202 can be manufactured from metal or stainless steel. Alternatively, the blade can be made from a ceramic material or another hard and sharp material.

[0077] The cutting table 204 can act as a counter blade to the blade 202, which helps in good operation of the cutting unit. The cutting table 204 can be straight along the cutting edge 212, which allows the blade 202 to slide with its cutting edge 214 along the cutting edge 212 of the cutting table 204. The blade 202 can be arranged at an angle α to this end relative to the cutting table. The angle α introduces a contact point between the cutting edge 212 of the cutting table 204 and the cutting edge 214 of the blade 202. This cutting point can be identified and formed by a contact point between the first cutting edge 212 and the second cutting edge 214. The contact point is only visible when the cutting edges 212, 214 meet. This occurs during each cutting movement 206. This means that the blade 202 and the cutting table 204 are arranged or placed such that an angle α is formed between the first cutting edge 212 and the second cutting edge 214. An effective cut is made in the sheet material 104 at the location of the contact point. Another name for the contact point is the cut point. This effective cut can be explained with reference to FIG.

[0068]

[0078] FIG. 9 shows the blade 202 in a position above the cutting table 204. This is why there is no contact point yet in FIG. 9. The blade 202 and the cutting table 204 are too far apart so that the cutting edges 212, 214 do not meet. When the blade 202 in FIG. 9 is moved downwards by the actuator 216, the contact point occurs at a given moment during the cutting movement. In FIG. 9, this contact point occurs on the right hand side of the blade 202. Alternatively, in another embodiment, this could occur on the left hand side of the blade. For example, this is possible by having the blade tilted from the other side. This contact point, or cutting point, moves during each movement 206 of the blade 202. This means that the position of the contact point moves over the cutting edge 212 of the cutting table 204 over a given distance during the cutting movement 206. In FIG. 9, this displacement of the contact point goes from right to left. This displacement of the contact point is a function of the position of the blade 202. If the blade 202 is a straight blade, then this displacement is directly proportional to the position of the blade 202 .

[0069]

[0079] The cutting table 204 may be flat along an upper side 218, so that the sheet material 104 can run on the flat upper side 218. The upper side 218 may be smooth so that the sheet material 104 can advance without much resistance. Alternatively, the cutting table 204 may take the form of a blade with a sharp edge, provided at a distance from a sliding surface (not shown). The sliding surface performs the function of supporting the sheet material 104 in the same way as the flat upper side 218 of the cutting table 204 of FIG. 9. The blade with the sharp edge acts as a counter blade for the blade. Here, the sharp edge of the blade acts as the cutting edge 212. The blade is controlled by an actuator 216. The actuator 216 ensures that the blade 202 can perform an up and down cutting movement 206 relative to the cutting table 204. The cutting movement 206 may be a linear movement. For example, the actuator may be a pneumatic or electromechanical actuator. The movement of the actuator 216 may be linear in the up and down direction 206 .

[0070]

[0080] FIG. 10 shows a pressure element 220 provided for exerting a force F on the blade 202. More specifically, this force is directed such that the pressure between the first cutting edge 212 and the second cutting edge 214 can increase. As a result, the distance 222 between the blade 202 and the cutting table 204 decreases. FIG. 10 further shows that the pressure element 220 is located at a distance from the hinge element 224. Thereby, this pressure is increased by causing the hinge element 224 to exert a counter force against the force F, causing a torque F'. This The torque F' ensures contact between the first cutting edge 212 and the second cutting edge 214 at a contact point coincident with the cut point. More specifically, as the blade 202 is pressed against the cutting table 204, it increases the pressure against the contact point between the cutting table 204 and the blade 202.

[0071]

[0081] The hinge element 224 can be hinged to an upward axis 226, whereby the blade 202 can rotate so that the blade 202 is closer to or farther from the cutting table 204. In other words, the distance 222 between the blade 202 and the cutting table 204 is adjustable. This can be important for good operation of the cutting unit. When the blade 202 executes a downward movement 206 approaching the cutting table 204, the cutting table 204 acts more effectively as a counter blade.

[0072]

[0082] In an alternative embodiment not shown, the pressure element may be embodied as a torque spring in the hinge element 224. As a further alternative, the pressure element may be embodied as a pneumatic cylinder or spring.

[0073]

[0083] In use, the blade 202 moves relative to the counter blade 212, whereby the sheet material 104 is cut at a position where the cutting edge 214 contacts the cutting edge 212 of the cutting table 204. The blade 202 can be at an angle α such that the cutting edges 212, 214 of the blade 202 and the cutting table 204 are in contact only over a minimum area, which contact area is related to the cut point. The effect of the pressure element 220 is related to this contact area. Due to the cutting movement 206, the blade 202 is subjected to undesirable effects such as vibrations or bending. This contact area can be ensured by having the pressure element 220 press against the blade 202.

[0074]

[0084] From the foregoing, it will be understood that the cutting mechanism shown in Figures 9 and 10 may be similar or identical to the separation mechanism 140 of Figures 6 and 7, or vice versa. For example, the configurations of the blades, cutting tables, operations, functions, etc. from each embodiment may be similar or identical to one another. Similarly, aspects illustrated or described in connection with one embodiment may be incorporated into other embodiments.

[0075]

[0085] Figure 11 shows a schematic plan view of a converting assembly 230 that may be incorporated into the packaging machine 100 to convert the sheet material 104 into a box template. The converting assembly 230 of Figure 11 has an inlet 232 shown at the top of the figure and an outlet 234 shown at the bottom of the figure. At the inlet 232, the sheet material 104 is fed as a continuous length. At the outlet 234, the resulting box template exits the converting assembly 230.

[0076]

[0086] The converting assembly 230 is configured to separate a continuous length of sheet material 104 entering the converting assembly 230 via the entrance 232, with each segment being provided to create a box template. The converting assembly 230 is further configured to provide cuts to each segment, for example to create side flaps in the box template and to provide creases (for example to define panels thereof). It is clear that the continuous length can be fed through the entrance 232 in a continuous manner, i.e. the rate at which the sheet material 104 enters is approximately constant, or in a discontinuous manner, i.e. the rate at which the sheet material 104 enters is not constant. When the sheet material 104 is fed in a discontinuous manner, the sheet material 104 can be stopped, for example periodically. These stops of the sheet material 104 can be synchronized with one or more cutting units 236. The cutting units 236 can then create cuts in the sheet material 104 while the sheet material 104 is stationary. This keeps the cutting unit 236 in a fixed position as seen in the direction 238 of movement of the conversion assembly 230. When the sheet material 104 is continuously fed, the cutting unit 236 can be arranged on a slide that allows the cutting unit 236 to move synchronously with the sheet material 104 in the direction of movement 238 during cutting. With such a slide, it is possible to make multiple cuts at different longitudinal positions of the sheet material 104 as well as to cut the sheet material 104 while stationary. Since the relative positions of the cutting unit 236 and the sheet material 104 are related, combinations of the above are also possible and can work with one or more cutting units 236.

[0077]

[0087] The conversion assembly 230 may also include the following components: longitudinal blades 240, longitudinal creasing wheels 242, transverse creasing rollers 244 (which may be similar or identical to the creasing system 180 described above), and a cutting unit 236. It will be clear that the sequence of these different components may be changed in different ways without adversely affecting the essential operation of the machine. The cutting unit 236 may here for example be provided at the inlet 232 in order to cut the continuous length of sheet material 104 into segments, after which the different segments are further processed individually. The discharge 244 may be arranged downstream of the cutting unit 236 provided to cut the continuous length of sheet material 104 into segments. This will be explained further below.

[0078]

[0088] The longitudinal blade 240 may be formed as a disk having a periphery formed as a blade for cutting the sheet material 104. The disk may be disposed on a shaft extending laterally across the sheet material 104. The disk may be displaceable in a transverse direction. The disk may be displaceable in a transverse direction by an actuator, and the transverse position of the disk may be adjustable by the controller 246. This allows different segments of the sheet material 104 to be cut to different widths. This allows the conversion assembly 230 to be used to produce box templates of alternating different widths. Alternatively, the longitudinal blade 240 may be disposed on several transverse shafts.

[0079]

[0089] Similar to the longitudinal blades 240, the longitudinal creasing wheels 242 can be positioned on the transverse shafts. The longitudinal creasing wheels 242 can also be positioned in the transverse direction via actuators, the position of which is controlled by the controller 246. This allows the longitudinal creases in successive segments to be formed at different transverse positions. Successive box templates can thereby have different fold lines.

[0080]

[0090] As seen in the direction of movement, the two transverse creasing rollers 244 may be arranged adjacent to each other. The transverse creasing rollers 244 may be of substantially identical form and may be individually controllable by the controller 246. Each transverse creasing roller 244 may be of a cylindrical body with a predetermined diameter. The cylindrical body is provided with a protrusion extending substantially over its entire length, in order to create an indentation in the sheet material 104 when it passes under the creasing roller 244 and when the cylindrical body rotates. A counter pressure element, which may be in the form of a plate, is provided for this purpose below the creasing roller 244. Here, the distance between the plate and the cylindrical surface is greater than or equal to the thickness of the sheet material 104, and the distance between the plate and the top of the protrusion on the cylindrical surface when the protrusion is in its position closest to the plate is less than the thickness of the sheet material 104. Thus, the sheet material 104 can pass under the creasing roller 244 without being significantly affected by it until the protrusions rotate to create a depression in the cardboard.

[0081]

[0091] It will also be understood how the transverse creasing rollers 244 can be controlled to form transverse creases at predetermined locations in the sheet material 104. Because of the provision of the crease rollers 244, two transverse creases can be provided close to each other in the cardboard without the need to slow down the feed of the sheet material 104 through the conversion assembly 230. It will be appreciated that when two transverse creases must be provided close to each other in the sheet material 104 and only one transverse crease roller 244 is provided, the feed of the sheet material 104 must be stopped to allow the one transverse crease roller 244 time to perform a complete rotation so that it can once again rotate the protrusions onto the sheet material 104. The two transverse crease rollers 244 provide a solution to this slow down and allow the feed to be higher.

[0082]

[0092] In some embodiments, as seen in the direction of movement, the conversion assembly includes a plurality of cutting units 236a, 236a', 236b, 236b', 236c, 236c', which may be arranged two by two adjacent to each other. The plurality of cutting units 236a, 236a', 236b, 236b', 236c, 236c' may be connected to a controller 246. Thus, good cooperation of the different cutting units may be ensured. As a result, the multiple cutting units 236a, 236a', 236b, 236b', 236c, 236c' can make several cuts in the sheet material 104 substantially simultaneously by having the multiple cutting units 236a, 236a', 236b, 236b', 236c, 236c' perform their cutting movements 206 substantially simultaneously. The sheet material 104 can be advanced when the multiple cutting units 236a, 236a', 236b, 236b', 236c, 236c' are in the position shown in Figure 9, which is the position when no cutting movements are being performed.

[0083] Removing false creases

[0093] When multiple box templates have to be formed, a machine, system, or apparatus as described herein may be used to make the box templates. A supply of sheet material may supply the sheet material used to form the box templates. Typically, the sheet material is supplied continuously or nearly continuously. To this end, the sheet material may be supplied on a roll. Alternatively, a continuous length of the sheet material may be supplied, which is folded in a zigzag fashion such that the continuous length is formed by a series of straight layers of the sheet material. From the supply, the sheet material may be fed into a cutting device, where the sheet material is cut into a plurality of segments, each of which is further processed to form a box template.

[0084]

[0094] Irregularities in a continuous length of sheet material can potentially adversely affect the quality of the box template and / or the boxes formed therefrom. When a continuous length is folded in a zigzag fashion and fed as a succession of layers of sheet material in a stack, each fold in the stack forms a so-called false crease in the sheet material. A false crease is a crease that is present in the sheet material but that has not been positioned to aid in the folding during folding of the sheet material or box template to form a box. Tests have shown that a false crease in an unlucky position in the box template can disrupt the entire box folding process at that position on the box template. This can cause problems in further processing of the box template. By detecting the irregularity and transmitting the position of the irregularity to a controller that controls the cutting device, an ejection cycle can be activated. The ejection cycle can cut a waste segment from the continuous length and eject it. This ejection cycle ensures that the irregularity does not get mixed up in the box template, or at least does not end up in a predefined problem zone of the box template. This is explained further below.

[0085]

[0095] Another irregularity may relate to a series of two lengths of sheet material. is not supplied in an infinitely long form. A continuous length of sheet material is supplied on a roll or in a stack. In practice, the end of the roll or the end of the stack can be connected to the beginning of a new roll or a new stack. At the point of this connection, the continuous length of sheet material has other properties that may be undesirable for the box template. At least these other properties can cause problems in certain problem zones in the box template, whereby the box template can no longer be folded in an optimal manner. By activating the ejection cycle, various types of irregularities can be cut from the sheet material and ejected.

[0086]

[0096] FIG. 12 shows a schematic side view of a cutting device 250, which may be similar or identical to other devices disclosed herein. FIG. 12 shows only one transverse creasing roller 252 of the cutting device 250, and a controller 254. The transverse creasing rollers 252a and 252b each include a protrusion 256. The transverse creasing rollers 252a and 252b are further each disposed above a pressure plate 258, as described above. As an alternative to the embodiment of FIG. 12, a separate pressure plate 258 may be provided for each creasing roller 252a and 252b. As a further alternative, a counter roller (not shown) may be provided instead of the pressure plate 258. The counter roller may then be driven synchronously with the creasing roller so that the sheet material can move past the rollers. The advantage of the transverse creasing rollers 252a, 252b in combination with a counter roller is that the counter roller performs the same forward movement as the transverse creasing rollers under the sheet material when the projection 258 passes in the sheet material. Thereby, the resistance to the forward movement is not increased. When a pressure plate 258 is provided, the sliding resistance at the location under the sheet material may temporarily increase when the projection 256 presses against the pressure plate 258. In the case of the counter roller, the pressure between the rollers and on the sheet material increases, but no resistance to the forward movement occurs.

[0087]

[0097] FIG. 12 further illustrates a supply 260 that supplies a continuous length of sheet material. In the embodiment of FIG. 12, the continuous length of sheet material is formed into a stack 262. In the stack 262, a number of straight sheets or layers of sheet material are connected to each other in a zigzag fashion to form a continuous length. An advantage of a stack of sheet material is that it can be transported more efficiently than a roll, since the stack occupies a beam-like space and can therefore be positioned and handled more easily and efficiently. A further advantage is that the sheets in the stack are straight in all directions and therefore do not have any curves. An alternative to a stack is a roll of sheet material. However, rolls are more difficult to handle and less efficient to store. In the case of a roll, the sheet material still has curves that are necessary to form a roll. Furthermore, not all types of sheet material can be supplied in rolls. A further advantage is the production of the sheet material at the supply location.

[0088]

[0098] A drawback of stack 262 is that the sheet material is folded up to 180 degrees between adjacent sheets in a continuous length. This creates a crease where the cardboard will tend to fold easily whenever it is used in future. When this crease is lost in the box template at a location where folding is not desired in further processing of the sheet material, this crease is called a false crease. In some circumstances, the false crease can create problems in forming the box.

[0089]

[0099] For completeness, Figure 12 shows an unwinding aid 264 for unwinding the stack 262 in principle. The unwinding aid 264 is provided to rotate 266 so that a continuous length of sheet material is fed by the rotation to an inlet 268 of the cutting device 250. The unwinding aid 264 can take a variety of different forms, for example a statically curved guide plate. Includes form.

[0090]

[0100] FIG. 12 shows a cross-sectional view of a stack 262 between the end of the stack 262 and the beginning of a further stack (not shown). 262. Such joints 270 may also be problematic in further processing of the cardboard. In some embodiments, joints 270 and fold lines between adjacent sheets of stack 262 are considered irregularities.

[0091]

[0101] FIG. 12 further illustrates a sensor 272 for detecting irregularities. The sensor 272 includes: 12 as a non-contact sensor. In some embodiments, the sensor may be a camera. It will be apparent that a contact sensor may also be provided to detect irregularities. Thus, the present disclosure is not limited to non-contact sensors. In FIG. 12, the sensor is located between the feed 260 and the cutting device 250. Alternatively, the sensor 272 may be located at the inlet 268 of the cutting device 250. As a further alternative, the sensor 272 may be integrated into the feed 260.

[0092]

[0102] The sensor 272 is operatively connected to the controller 254. The controller 254 receives input from the sensor 272 when the sensor 272 detects an irregularity in the sheet material. The controller 254 can also control the feed rate of the sheet material at the inlet of the cutting device 250. Since the location of the sensor 272 is known and the feed rate of the sheet material can be adjusted by the controller 254, the location of the irregularity detected by the sensor 272 can also be known. More specifically, the controller 254 can plan where the irregularity will be in the successive segments created by the cutting device 250. This allows the controller 254 to initialize the discharge cycle when an irregularity is determined to be potentially problematic. The controller can include logic that allows it to determine when an irregularity planned onto a segment or box template is potentially problematic. For example, a pre-setting can be possible when an incorrect fold is planned to be located less than a predetermined distance (e.g., 2 cm) from the desired fold. In such a case, the incorrect fold can be considered problematic. Alternatively and / or in addition, the controller 254 can be programmed to determine that there is a problem with an incorrect fold when the incorrect fold is located in the B-segment of the box template 10. The controller can detect the problem situation based on the planning of the incorrect fold onto the segments and / or box template to be generated. When the controller detects the problem situation, a discard cycle is initiated.

[0093]

[0103] In this context, the controller 254 controls the cutting device 250 to It has been described that the cutting device 250 can produce a continuous box template 10, the continuous box template 10 having various differential dimensions. The different dimensions are related to the goods that must be packed in the box formed by the corresponding box template. The controller 254 collects information about the goods to be packed, including their dimensions, and produces the corresponding box template 10. The controller 254 can include a memory containing specifications of multiple box templates that are produced during use of the cutting device 250. This knowledge makes it possible to plan for irregularities and to determine when a waste segment is to be discharged. Typically, a waste segment is formed by a portion of the length of the sheet material that is between two consecutive segments. By removing the waste segment, the otherwise consecutive segments are separated from each other by a distance equal to the length of the portion of the sheet material that is cut off and discharged as the waste segment.

[0094]

[0104] The size of the discarded segment can be determined in a variety of ways. For example, A minimum size can be imposed to facilitate handling of discarded segments. In some embodiments, it may be difficult to handle extremely narrow strips in the cutting device 250. In any case, the size of the waste segment can be determined so that the irregularities are located within the waste segment. Alternatively, the size of the waste segment can be determined based on a plan, the goal being to ensure that the incorrect folds end up in segments outside the zone of concern. In such a configuration, the amount of waste is less, but the controller algorithm is more complex. The discharge of the waste segment can ensure that the irregularities do not adversely affect further processing of the box template 10 by a folding machine or other processing.

[0095]

[0105] FIG. 13 shows a plan view of the system of FIG. 12. 12. The figure further shows that the box template 10 can be made from a continuous length of sheet material 104. This process is controlled by a controller 254, which knows the specifications, i.e., the location of the cuts, the dimensions and the location of the folds, and controls the elements of the cutting device 250. FIG. 13 shows that a continuous segment of a continuous length of sheet material can form a continuous box template 10. FIG. 13 further shows a waste segment 280 located between two box templates 10. In the embodiment of FIG. 13, the waste segment 280 includes the connection 270 described above with reference to FIG. 12. FIG. 13 shows that the waste segment 280 can be ejected 244. Based on the above description and based on the illustrated figures, it will be understood that the ejection of a waste segment 280 of a predetermined size results in a box template 10 that can be more optimally produced. More optimally, it is defined that no incorrect folds are within a predetermined zone of the box template 10.

[0096]

[0106] To facilitate ejection of the waste segment 280, the waste segment 280 itself may in some circumstances actually be split so that multiple discarded segments 270 are removed in alternating fashion.

[0097]

[0107] In light of the disclosure herein, the embodiments may take various forms, or various different combinations of the features described herein. By way of example, a packaging machine used to convert substantially rigid sheet material into a packaging template for assembly into a box or other package may include: an infeed system for directing a first feed of sheet material and a second feed of sheet material into a packaging machine, the infeed system comprising: a first low friction surface and an associated first advancement mechanism, the first advancement mechanism configured to engage and advance a first feed of sheet material along the first low friction surface and into the packaging machine; and a second low friction surface and an associated second advancement mechanism configured to engage and advance a second feed of sheet material along the second low friction surface and into the packaging machine; an infeed system, wherein the first and second low friction surfaces are parallel opposing sides of a thin plate or form an acute angle, the thin plate or the acute angle being configured to allow the sheet material to advance into the packaging machine without creating any folds or creases in the sheet material and with limited or no repositioning of the infeed system; and one or more converting tools configured to perform one or more converting functions on the sheet material as it moves through the packaging machine, the one or more converting functions being selected from the group consisting of scoring, bending, folding, punching, cutting, and scoring to create a packaging template.

[0098]

[0108] In some embodiments, the first low friction surface and the second low friction surface are In other embodiments, the first low friction surface and the second low friction surface are formed on opposing sides of a unitary component.

[0099]

[0109] In some embodiments, the first advancement mechanism advances the first feed of sheet material to the packaging machine. Similarly, in some embodiments, the second advancement mechanism comprises one or more feed rollers, belts, or bands that move the second feed of sheet material into the packaging machine.

[0100]

[0110] In some embodiments, the first advancement mechanism is disposed above or on the first low friction surface. In some embodiments, the second low friction surface is disposed below or on a second side of the first low friction surface such that the second low friction surface and the first advancement mechanism are disposed on opposite sides of the first low friction surface. In some embodiments, the second advancement mechanism is disposed below or on one side of the second low friction surface such that the second advancement mechanism and the first low friction surface are disposed on opposite sides of the second low friction surface. In some embodiments, the first low friction surface and the second low friction surface form an acute angle of about 5 degrees. In some embodiments, the second low friction surface is oriented approximately parallel to the feed direction of the sheet material through the packaging machine and the first low friction surface is angled upward from the second low friction surface. In some embodiments, the first low friction surface is angled above or to one side of the feed direction of the sheet material through the packaging machine so as to form an acute angle with the feed direction of the sheet material through the packaging machine, and the second low friction surface is angled below or to a second side of the feed direction of the sheet material through the packaging machine so as to form an acute angle with the feed direction of the sheet material through the packaging machine.

[0101]

[0111] In another embodiment, a generally rigid sheet material is assembled into a box or other package. The packaging machine is used to convert the packaging template into a separating system for separating the sheet material into lengths for use in creating a packaging template, the separating system comprising: a cutting table having a cutting edge; a first knife having an attached end, a free end, and a first knife edge extending at least partially therebetween, the first knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the first knife edge and the cutting edge of the cutting table as the first knife moves between a non-operative position and an operative position; a second knife having an attached end, a free end, and a second knife edge extending at least partially therebetween, the second knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the second knife edge and the cutting edge of the cutting table as the second knife moves between the inoperative and operative positions; when the first and second knives move to the operative position, the free ends of the first and second knives are positioned adjacent to one another such that both of the free ends can pass through the sheet material; The mounting ends of the first and second knives are disposed on opposite sides of the sheet material.

[0102]

[0112] In some embodiments, the cutting edge of the cutting table lies in one plane. In some embodiments, the first knife edge is angled relative to the cutting edge of the cutting table such that the mounting end of the first knife is disposed on a first side of the plane and the free end is disposed on a second side of the plane. In some embodiments, the second knife edge is angled relative to the cutting edge of the cutting table such that the mounting end of the second knife is disposed on the first side of the plane and the free end is disposed on the second side of the plane.

[0103]

[0113] In some embodiments, the packaging machine is configured to align the first The packaging machine also includes a biasing member configured to bias the second knife against the cutting edge of the cutting table. The biasing member can include a spring. In some embodiments, the packaging machine also includes a biasing member configured to bias the second knife against the cutting edge of the cutting table. The biasing member can include a spring.

[0104]

[0114] In some embodiments, the first knife has a first knife edge that is aligned with the cutting tape. The first knife edge tapers from the attached end to the free end such that it is angled relative to the cutting edge of the tool. In some embodiments, the first knife edge has a non-cutting surface opposite the first knife edge, the first knife edge having a first end adjacent the attached end of the first knife and a second end adjacent the free end of the first knife, the second end being disposed closer to the non-cutting surface than the first end.

[0105]

[0115] In some embodiments, the second knife has a second knife edge that is aligned with the cutting tape. The second knife edge tapers from the attached end to the free end such that it is angled relative to the cutting edge of the tool. In some embodiments, the second knife edge has a non-cutting surface opposite the second knife edge, the second knife edge having a first end adjacent the attached end of the second knife and a second end adjacent the free end of the second knife, the second end being disposed closer to the non-cutting surface than the first end.

[0106]

[0116] In some embodiments, the first knife edge and the cutting edge of the cutting table The contact point between the first knife edge moves across the cutting edge as the first knife moves between the inoperative and operative positions. Similarly, in some embodiments, the contact point between the second knife edge and the cutting edge of the cutting table moves across the cutting edge as the second knife moves between the inoperative and operative positions. In some embodiments, as the contact point between the first knife edge and the cutting edge moves across the cutting edge in a first direction, the contact point between the second knife edge and the cutting edge moves across the cutting edge in a second direction that is opposite the first direction.

[0107]

[0117] In some embodiments, the first knife is adapted to move between the inoperative position and the operative position. In some embodiments, the first and second knives are connected to a first actuator configured to simultaneously move the first and second knives between the inactivated and activated positions. Similarly, in some embodiments, the second knife is connected to a second actuator configured to move the second knife between the inactivated and activated positions. In some embodiments, the first and second actuators are synchronized to simultaneously move the first and second knives between the inactivated and activated positions. In some embodiments, the first and second actuators are independently operable to allow the first and second knives to be independently moved between the inactivated and activated positions.

[0108]

[0118] In some embodiments, the free ends of the first and second knives are 2.54 cm (1 inch), 0.75 inches, 0.5 inches, 0.25 inches, or 0.1 inches apart.

[0109]

[0119] In another embodiment, a generally rigid sheet material is assembled into a box or other package. The packaging machine is used to convert the packaging template into a creasing system for forming transverse creases in the sheet material, the transverse creases being oriented transversely across the sheet material and traversing a length of the sheet material; A support plate for supporting the sheet material; a first creasing roller oriented across the length of the sheet material, the first creasing roller having a first crease extending radially therefrom; The first creasing roller has a creasing ridge and is configured to be rotated to engage the first creasing ridge with the sheet material to form a crease in the sheet material.

[0110]

[0120] In some embodiments, the wrapper is oriented to transversely ... The sheet also includes a second creasing roller across the length of the sheet material, the second creasing roller having a second creasing ridge extending radially therefrom, the second creasing roller configured to be rotated to engage the second creasing ridge with the sheet material to form a crease in the sheet material.

[0111]

[0121] In some embodiments, the first and second creasing rollers are adjacent to each other. are disposed adjacent and independently operable. In some embodiments, the first and second creasing rollers are spaced apart by less than 24 inches, less than 18 inches, less than 12 inches, or no more than 6 inches. In some embodiments, the first creasing ridge comprises an insert received within and extending from a recess in the first creasing roller. In some embodiments, the second creasing ridge comprises an insert received within and extending from a recess in the second creasing roller. In some embodiments, the first and second creasing rollers are configured to alternately engage the sheet material to form creases in the sheet material. In some embodiments, the first and second creasing rollers are configured to alternately engage the sheet material to simultaneously form multiple creases in the sheet material.

[0112]

[0122] In some embodiments, the packaging machine is configured to feed the sheet material through the packaging machine. The creasing system is configured to form a crease in the sheet material as it moves through the packaging machine. In some embodiments, the first creasing roller and the support plate are disposed on opposite sides of the sheet material. In some embodiments, the first creasing roller compresses the sheet material against the support plate when the first creasing roller is rotated to engage the first creasing ridge with the sheet material to form a crease in the sheet material. In some embodiments, the second creasing roller and the support plate are disposed on opposite sides of the sheet. In some embodiments, the second creasing roller compresses the sheet material against the support plate when the second creasing roller is rotated to engage the second creasing ridge with the sheet material to form a crease in the sheet material.

[0113]

[0123] In another embodiment, the cutting unit for cutting the sheet material comprises: a cutting table having a first cutting edge; a blade having a second cutting edge; a first actuator mounted between the cutting table and the blade, the first actuator configured to move the blade relative to the cutting table during a cutting movement, the first and second cutting edges being at an angle such that a contact point between the first cutting edge and the second cutting edge during the cutting movement can be identified; and a pressure element adapted to exert a force on the blade to increase pressure between the first cutting edge and the second cutting edge at the location of the contact point.

[0114]

[0124] In some embodiments, the blade has a cutting segment with a second cutting edge. In some embodiments, the blade has an attachment segment for attachment to the first actuator. In some embodiments, the blade is attached to the first actuator via a hinge element that can be hinged about an axis. In some embodiments, the hinge element is mounted at a distance from the pressure element and configured to provide a counter force to the force such that the counter force induces a torque about the axis. In some embodiments, The first actuator is a linear actuator.

[0115]

[0125] In another embodiment, a system for creating a box template includes: A sheet material supply unit; A cutting device; A controller, The supply section is provided for supplying the sheet material to the cutting device, A cutting apparatus comprising at least one cutting unit according to any one of the preceding claims, the cutting apparatus being configured to form a cut in the sheet material based on input from a controller; The system, wherein the cutting device includes a feed line that advances the cardboard in a feed direction.

[0116]

[0126] In some embodiments, the at least one cutting unit comprises at least one and a second actuator movable in a transverse direction relative to the feed line such that a position of the cutting unit can be adjusted in the transverse direction. In some embodiments, the at least one cutting unit comprises at least two cutting units disposed on opposite sides of the feed line such that the sheet material can be cut on both sides. In some embodiments, the at least two cutting units are disposed such that their first cutting edges are in a straight line. In some embodiments, the at least two cutting units can be disposed in a transverse direction such that the blades are disposed close to each other.

[0117]

[0127] In another embodiment, a cutting table having a first cutting edge and a second cutting edge A method of cutting sheet material with a cutting unit including a blade having a first cutting edge and a second cutting edge at an angle is provided. The method comprises: moving the blade relative to the cutting table in a generally linear cutting motion by a first actuator; Pressing the blade with a pressure element during the cutting movement to increase pressure between the first cutting edge and the second cutting edge at the location of the contact point.

[0118]

[0128] In some embodiments, the method further comprises: feeding the sheet material by a feed line to a cutting device including a cutting unit; and positioning the blades transversely relative to the feed line by a second actuator such that a position of the at least one cutting unit is adjustable in the transverse direction.

[0119]

[0129] In some embodiments, the cutting device is adapted to allow the sheet material to be cut on both sides. The method includes at least two cutting units arranged on either side of the feed line such that the first cutting edges of the at least two cutting units are aligned in a straight line. In some embodiments, the at least two cutting units can be arranged such that the blades are positioned close to each other during the cutting movement to enable cutting the sheet material into two separate pieces.

[0120]

[0130] In another embodiment, a box template is made from a continuous length of sheet material. The device is A sheet material supply unit; A cutting device; A controller; a sensor; a supply section adapted to supply a continuous length of sheet material to the cutting device; The cutting device uses input from the controller to create a box template. a cutting tool for cutting a continuous length of sheet material into successive segments, the sensor is configured to detect an irregularity in the continuous length of sheet material and transmit a location of the irregularity to the controller; A controller is provided for actuating a discharge cycle in the cutting device based on the location of the waste segment in the continuous length of sheet material, the discharge cycle being configured to cut and discharge the waste segment from the continuous length.

[0121]

[0131] In some embodiments, the discarded segments include irregularities. In embodiments, the controller is configured to map the irregularity onto the successive segments based on the position to determine a location of the irregularity in one of the successive segments, and the controller is provided to actuate the discharge cycle when the location is located within the predetermined zone. In some embodiments, the controller actuates the discharge cycle to discharge a waste segment for one of the successive segments, the waste segment having a size sufficient to at least move the location out of the predetermined zone. In some embodiments, the irregularity is one or more of an incorrect fold and a seam between successive lengths of sheet material.

[0122]

[0132] In some embodiments, the apparatus includes a feed roller that advances the sheet material in the direction of travel. The cutting apparatus further comprises an insert, the cutting apparatus comprising one or more blades for cutting the sheet material into successive segments and forming notches in the segments to create a box template, in some embodiments, the plurality of blades comprises a horizontal blade configured to create a cut in the sheet material in a direction transverse to the direction of movement and a vertical blade configured to make a cut in the sheet material in the direction of movement.

[0123]

[0133] In some embodiments, the cutting device forms creases in the box template. In some embodiments, the creasing mechanism comprises at least two creasing rollers extending transversely to the direction of movement and positioned adjacent to one another such that two lateral creases can be formed simultaneously with a distance between the lateral creases corresponding to the distance between the creasing rollers.

[0124]

[0134] In another embodiment, a box template is created from a continuous length of sheet material. The method is: feeding a continuous length of sheet material to a cutting device; cutting the continuous length of sheet material into successive segments using a cutting device based on input from the controller to create a box template; detecting an irregularity at a location in the continuous length of sheet material with a sensor and transmitting the location to a controller; activating a discharge cycle including severing a waste segment from the continuous length with a cutting device based on the location of the irregularity; and ejecting the waste segment from the cutting device.

[0125]

[0135] In some embodiments, the method further comprises: further comprising the step of plotting a location of the irregularity onto the successive segments to determine a location of the irregularity in one of the successive segments; The step of activating the drain cycle is carried out only when the location of the irregularity is projected to be within a predefined zone of one of the consecutive segments.

[0126]

[0136] In some embodiments, the step of planning the location of the irregularity comprises: In some embodiments, the discharge cycle further comprises determining a distance between a boundary of the zone and transmitting the distance to the controller. In some embodiments, the method also includes forming transverse creases in the box template by driving two transverse creasing rollers that are disposed adjacent to each other such that two transverse creases can be formed substantially simultaneously by synchronous driving of the two transverse creasing rollers.

[0127]

[0137] The present invention may be modified in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing specification. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A packaging machine used to convert sheet material into a packaging template for assembly into a box or other package, comprising: a separating system for separating the sheet material into lengths for use in creating the packaging template, the separating system comprising: a cutting table having a cutting edge; a first knife having an attached end, a free end, and a first knife edge extending at least partially therebetween, the first knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the first knife edge and the cutting edge of the cutting table as the first knife moves between an inoperative position and an operative position; a second knife having an attached end, a free end, and a second knife edge extending at least partially therebetween, the second knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the second knife edge and the cutting edge of the cutting table as the second knife moves between an inactive position and an active position; when the first and second knives move to the operative position, the free ends of the first and second knives are positioned adjacent to one another such that both of the free ends can pass through the sheet material; the attachment end of the first knife is disposed on one side of the sheet material and the attachment end of the second knife is disposed on the other side of the sheet material; Each of the first and second knives moves between the inoperative and operative positions by moving in a direction perpendicular to a surface of the sheet material.

2. 2. The packaging machine of claim 1, wherein the cutting edge of the cutting table lies in a plane, the first knife edge is angled relative to the cutting edge of the cutting table such that in the non-operative position, the attached end of the first knife is disposed closer or farther from the cutting edge than the free end, and the second knife edge is angled relative to the cutting edge of the cutting table such that in the non-operative position, the attached end of the second knife is disposed closer or farther from the cutting edge than the free end.

3. 10. The packaging machine of claim 1, further comprising a biasing member configured to bias the first knife against the cutting edge of the cutting table, and further comprising a biasing member configured to bias the second knife against the cutting edge of the cutting table.

4. 2. The packaging machine of claim 1, wherein the first knife tapers from the mounting end to the free end such that the first knife edge is angled relative to the cutting edge of the cutting table, and the second knife tapers from the mounting end to the free end such that the second knife edge is angled relative to the cutting edge of the cutting table.

5. 5. The packaging machine of claim 4, wherein the first knife has a non-cutting surface opposite the first knife edge, the first knife edge having a first end adjacent the attached end of the first knife and a second end adjacent the free end of the first knife, the second end being disposed closer to the non-cutting surface than the first end, and the second knife has a non-cutting surface opposite the second knife edge, the second knife edge having a first end adjacent the attached end of the second knife and a second end adjacent the free end of the second knife, the second end being disposed closer to the non-cutting surface than the first end.

6. 2. The packaging machine of claim 1, wherein the contact point between the first knife edge and the cutting edge of the cutting table moves across the cutting edge as the first knife moves between the inoperative and operative positions, and the contact point between the second knife edge and the cutting edge of the cutting table moves across the cutting edge as the second knife moves between the inoperative and operative positions.

7. 7. The packaging machine of claim 6, wherein as the contact point between the first knife edge and the cutting edge moves across the cutting edge in a first direction, the contact point between the second knife edge and the cutting edge moves across the cutting edge in a second direction opposite the first direction.

8. 2. The packaging machine of claim 1, wherein the first knife is connected to a first actuator configured to move the first knife between the inoperative and operative positions and the second knife is connected to a second actuator configured to move the second knife between the inoperative and operative positions.

9. 9. The packaging machine of claim 8, wherein the first and second actuators are synchronized to simultaneously move the first and second knives between the inoperative and operative positions, or the first and second actuators are independently operable to enable independent movement of the first and second knives between the inoperative and operative positions.

10. 10. The packaging machine of claim 1, wherein the free ends of the first and second knives are spaced apart by less than 1 inch, 0.75 inches, 0.5 inches, 0.25 inches, or 0.1 inches.

11. A packaging machine used to convert sheet material into a packaging template for assembly into a box or other package, comprising: a separating system for separating the sheet material into lengths for use in creating the packaging template, the separating system comprising: a cutting table having a cutting edge; a first knife having an attached end, a free end, and a first knife edge extending at least partially therebetween, the first knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the first knife edge and the cutting edge of the cutting table as the first knife moves between an inoperative position and an operative position; a second knife having an attached end, a free end, and a second knife edge extending at least partially therebetween, the second knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the second knife edge and the cutting edge of the cutting table as the second knife moves between an inactive position and an active position; a biasing member configured to bias the first knife against the cutting edge of the cutting table; and a biasing member configured to bias the second knife against the cutting edge of the cutting table; when the first and second knives move to the operative position, the free ends of the first and second knives are positioned adjacent to one another such that both of the free ends can pass through the sheet material; A packaging machine, wherein the attachment end of the first knife is positioned on one side of the sheet material and the attachment end of the second knife is positioned on the other side of the sheet material.

12. the cutting edge of the cutting table is in one plane; the first knife edge is angled relative to the cutting edge of the cutting table such that in the inoperative position the attached end of the first knife is disposed closer or further from the cutting edge than the free end; or 12. The packaging machine of claim 11, wherein the second knife edge is angled relative to the cutting edge of the cutting table such that in the inoperative position, the attached end of the second knife is disposed closer to or farther from the cutting edge than the free end.

13. the contact point between the first knife edge and the cutting edge of the cutting table moves across the cutting edge as the first knife moves between the inoperative and operative positions; the contact point between the second knife edge and the cutting edge of the cutting table moves across the cutting edge as the second knife moves between the inoperative and operative positions; 12. The packaging machine of claim 11, wherein as the contact point between the first knife edge and the cutting edge moves across the cutting edge in a first direction, the contact point between the second knife edge and the cutting edge moves across the cutting edge in a second direction opposite the first direction.

14. the first knife is connected to a first actuator configured to move the first knife between the inactive position and the active position; the second knife is connected to a second actuator configured to move the second knife between the inactive position and the active position; the first and second actuators are configured to be synchronized to simultaneously move the first and second knives between the inactive and active positions; 12. The packaging machine of claim 11, wherein the first and second actuators are configured to be independently operable to enable independent movement of the first and second knives between the inoperative and operative positions.

15. A packaging machine for use in converting sheet material into a packaging template for assembly into a box or other package, comprising: a separating system for separating the sheet material into lengths for use in creating the packaging template, the separating system comprising: a cutting table having a cutting edge; a first knife having an attached end, a free end, and a first knife edge extending at least partially therebetween, the first knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the first knife edge and the cutting edge of the cutting table as the first knife moves between an inoperative position and an operative position; a second knife having an attached end, a free end, and a second knife edge extending at least partially therebetween, the second knife edge being angled relative to the cutting edge of the cutting table to create a single and moving point of contact between the second knife edge and the cutting edge of the cutting table as the second knife moves between an inactive position and an active position; a first actuator coupled to the first knife and configured to move the first knife between the inactive position and the active position; a second actuator coupled to the second knife and configured to move the second knife between the inactivated position and the activated position; when the first and second knives move to the operative position, the free ends of the first and second knives are positioned adjacent to one another such that both of the free ends can pass through the sheet material; the attachment end of the first knife is disposed on one side of the sheet material and the attachment end of the second knife is disposed on the other side of the sheet material; the first and second actuators are independently operable to permit the first and second knives to be moved independently between the inoperative and operative positions; a biasing member configured to bias the first knife against the cutting edge of the cutting table; and a biasing member configured to bias the second knife against the cutting edge of the cutting table.

16. the cutting edge of the cutting table is in one plane; the first knife edge is angled relative to the cutting edge of the cutting table such that in the inoperative position the attached end of the first knife is disposed closer or further from the cutting edge than the free end; or 16. The packaging machine of claim 15, wherein the second knife edge is at least one of angled relative to the cutting edge of the cutting table such that in the inoperative position, the attached end of the second knife is disposed closer to or farther from the cutting edge than the free end.

17. the contact point between the first knife edge and the cutting edge of the cutting table moves across the cutting edge as the first knife moves between the inoperative and operative positions; 16. The packaging machine of claim 15, wherein the point of contact between the second knife edge and the cutting edge of the cutting table moves across the cutting edge as the second knife moves between the inoperative and operative positions.

18. 16. The packaging machine of claim 15, wherein the first and second actuators are selectively synchronized to simultaneously move the first and second knives between the inoperative and operative positions.

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