Alignment module for irregular edges

Abstract

The present invention relates to an alignment module (11) for a converting machine (1). The alignment module includes an alignment device (30) having an upper pressing member (22), a lower conveyor (24), and a guide (26). The guide further includes a downwardly sloping entrance end (32) configured to guide a lateral portion of a blank under the guide while bringing lateral guide surfaces (40) into contact with inner segment ends (S1, S2) of the blank, the inner segment ends being positioned closer to the longitudinal center axis of the blank than the lateral portion of the blank positioned under the guide.

Description

Technical Field

[0001] The present invention relates to a converting machine for manufacturing paper and cardboard containers such as folding boxes. Specifically, the present invention relates to an alignment module configured to align a blank having irregular lateral edges in the lateral direction.

Background Art

[0002] Converting machines such as folder-gluers are used in the manufacture of paperboard boxes and cardboard boxes. These machines are configured to receive cut-to-shaped blanks and then fold and glue them to form folding boxes and other similar packaging boxes. The blank includes a cutting line that defines the overall shape of the blank and a crease line that defines the position of the fold.

[0003] To ensure that folding occurs at the position defined by the crease line, the folder-gluer includes an alignment module located upstream of the folding module. The alignment module is configured to align the blank in the lateral direction. An example of an alignment module is described in U.S. Patent No. 7,398,872.

[0004] The alignment module of U.S. Patent No. 7,398,872 includes an upper pressing member and a lower conveyor configured to receive and convey the blank in a gap therebetween. The blank is conveyed while being biased against a lateral guide in which one lateral edge extends in the conveyance direction of the blank. In this way, the blank is aligned in the lateral direction within the converting machine.

[0005] Depending on the shape of the blank, the alignment module can be configured to adjust its position relative to the left or right side of the blank. Generally, straight or uniform lateral edges are more advantageous than irregular lateral edges in terms of alignment with the guide. However, for some blanks, both the left and right lateral edges are irregular. Such types of blanks are designed to form crush lock boxes, wallet-type packaging boxes, hand-erected boxes, etc. These boxes may also have adhesive strips.

[0006] As a result, these types of blanks are difficult to align in the transport direction and pose a risk of causing the blanks to rotate during transport within the alignment module. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] U.S. Patent No. 7398872 [Overview of the project] [Problems that the invention aims to solve]

[0008] In view of the prior art, the object of the present invention is to improve the alignment of blanks having irregular lateral edges. [Means for solving the problem]

[0009] This objective is achieved by the alignment module described in claim 1.

[0010] According to a first aspect of the present invention, an alignment module for a converter is provided, which is configured to correct the lateral position of a blank being transported in the transport direction through the converter. The blank comprises a first lateral edge and a second lateral edge, the first and second lateral edges being located opposite the central longitudinal axis of the blank and extending in the transport direction. The alignment module comprises at least one alignment device having an upper pressing member, a lower conveyor, and a guide, the upper pressing member and the lower conveyor being configured to receive and transport the blank in the gap between them, and the guide being an elongated rod-shaped body having a lateral guide surface and extending in the transport direction.

[0011] The guide further includes a downward-sloping entrance end, which guides the lateral portion of the blank below the guide, while the lateral guide surface is configured to contact the inner segment edge of the blank, which is positioned closer to the central longitudinal axis of the blank than the lateral portion of the blank positioned below the guide. The downward-sloping entrance end has a wedge shape.

[0012] The first and second lateral edges are irregular and may comprise multiple segmented edges, each extending in the transport direction and positioned at different lateral locations from the central longitudinal axis of the blank. "Irregular edges" means edges that are not straight.

[0013] Each lateral periphery comprises one distal segment edge and at least one inner segment edge, the inner segment edge being positioned closer to the central longitudinal axis of the blank than the distal segment edge.

[0014] The guides are positioned laterally to the upper pressing member and the conveyor belt.

[0015] The present invention is based on the recognition that an irregular lateral edge comprises multiple different segment edges positioned at different lateral locations. The position and length of some inner segment edges make it easier to align them than the segment edge located furthest laterally, i.e., the distal lateral edge. The lateral direction is defined as the direction perpendicular to the blank's transport direction. By providing a guide with a downwardly inclined entrance portion that presses the end of the blank downwards, the inner lateral segment edges can be accessed by the alignment surface of the guide.

[0016] According to one embodiment, the lower conveyor is positioned such that the lateral portion of the blank is not supported by the lower conveyor.

[0017] In this way, the edges are not supported and are guided downward under the alignment guide with the help of gravity.

[0018] In one embodiment, the alignment guide includes a groove configured to hold the guide edge of the blank. The guide edge is the inner edge of the blank.

[0019] In one embodiment, the alignment module includes an entrance portion where the upper pressing member is positioned at a predetermined distance from the lower conveyor, and the entrance end, which slopes downwards from the guide, is located in the entrance portion.

[0020] The alignment guide is displaceable in the lateral direction.

[0021] In one embodiment, the upper alignment module further comprises a slider, the connecting axis of the slider and the connecting axis of the guide rail coincide.

[0022] According to a second aspect of the present invention, a converter including an alignment module according to the first aspect of the present invention is provided, the converter further including a folding module and a blank rotation module configured to rotate the blank by 90°. The converter includes a second alignment module disposed between the blank rotation module and the folding module.

[0023] The blank rotation module and the second alignment module can be separate modules mounted on two separate chassis. Alternatively, the blank rotation module and the second alignment module can be a composite module having a single chassis.

[0024] Here, the present invention will be described with reference to the accompanying drawings, in which like reference numerals denote like features.

Brief Description of the Drawings

[0025] [Figure 1] It is a schematic view of a converter of the configuration of a folding-gluing machine. [Figure 2a] It is a schematic perspective view of a folding box. [Figure 2b] It is a plan view of a blank. [Figure 3] It is a schematic perspective view of an alignment module according to an embodiment of the present invention. [Figure 4] It is a schematic cross-sectional view of the alignment module and the feeder module of FIG. 3. [Figure 5a] It is a detailed plan view of the entrance portion of an alignment module according to an embodiment of the present invention. [Figure 5b] It is a cross-sectional view of the entrance portion of FIG. 5a. [Figure 6] It is a cross-sectional view of the entrance portion of FIG. 5b having a blank 2. [Figure 7] It is a top view of a feeder module and an alignment module according to an embodiment of the present invention.

Modes for Carrying Out the Invention

[0026] For drawings and details, refer to Figures 1, 2a, and 2b. The folding-gluing machine 1 is configured to receive a cut-formed blank 2 as shown in Figure 2b, and then fold and glue the blank 2 to form a folding box 2' or other folding and gluing packaging box 2'.

[0027] As shown in Figure 1, the folding-gluing machine 1 of the present invention may comprise a series of various workstations in the form of modules. The modules may include a feeder module 10, an alignment module 11, a folding pre-breaking module 12, a gluing module 14, and a folding module 16, from inlet to outlet and in the transport direction T. The folding-gluing machine 1 may further comprise a main user interface 15 and a quality control system 18.

[0028] The alignment module 11 is located downstream of the feeder module 10 in the transport direction T and is configured to laterally align the blank 2 to a predetermined lateral position. The predetermined lateral position is defined by the position of the longitudinal fold line 4 and the positions of the folding tool and auxiliary tool in the converter 1. Therefore, the alignment module 11 is configured to align the blank 2 in a direction perpendicular to the transport direction T.

[0029] Auxiliary modules in the form of an adhesive strip module 13 and a blank rotation module 17 can be placed between the alignment module 11 and the folding pre-breaking module 12. The adhesive strip module is configured to provide an adhesive strip (i.e., adhesive line) and a protective cover, and the adhesive strip can be used when resealing the box after initial use. Such adhesive strip modules are provided by Enpro, for example, "SPA 3.0 - Silicone Paper Applicator". The blank rotation module 17 is configured to rotate the blank 2 by 90 degrees before it enters the folding module 16. An example of a blank rotation module is described in European Patent No. 3038954.

[0030] Preferably, the second alignment module 9 is positioned between the blank rotation module 17 and the folding module 16. The blank rotation module 17 and the second alignment module 9 can be separate modules mounted on two separate chassis. Alternatively, the blank rotation module 17 and the second alignment module 9 can be a composite module having a single chassis.

[0031] After the gluing module 14 and the folding module 16, a dispensing module and an adjustment section 21 may be provided to count the flow of the roof-like material of the folding box 2' and separate it into separate batches.

[0032] The converter 1 further comprises a conveying system 19 equipped with a conveyor such as an endless belt and rollers configured to convey the blank 2 in the conveying direction T. The converter 1 also comprises a central control circuit 20 configured to control the operation of the converter 1.

[0033] To enable folding, the blank 2 is provided with fold lines 4. The first group of fold lines 4a extends in the transport direction T of the blank 2 in the alignment module 11. The first group of fold lines 4a also extends in the transport direction T of the blank 2 in the feeder module 10.

[0034] The second group of fold lines 4b is positioned perpendicular to the first group of fold lines 4a. When the blank rotation module 17 is used, the second group of fold lines 4b extends in the direction T of the blank being transported in the folding module 16.

[0035] Blank 2 has a longitudinal length La in the transport direction T in the alignment module 11. Similarly, when a blank rotation module 17 is used, blank 2 has a longitudinal length Lb in the transport direction T in the rotation module 16. For blank 2 having an irregular leading edge and an irregular trailing edge, the longitudinal lengths La and Lb are the maximum lengths of blank 2 in the transport direction T.

[0036] In the alignment module 11, the blank 2 comprises a first lateral edge portion 6a and a second lateral edge portion 6b. The first and second lateral edge portions 6a and 6b may be irregular. The lateral edge portions 6a and 6b enable the formation of flaps and folding surfaces.

[0037] The first lateral edge 6a comprises a plurality of segment edges S1 positioned at different lateral positions with respect to the central longitudinal axis C of the blank 2. The central longitudinal axis C coincides with the transport direction in the alignment module 11. Preferably, the central longitudinal axis C is located at the center of the blank 2. Similarly, the second lateral edge 6b comprises a plurality of segment edges S2 positioned at different lateral positions with respect to the central longitudinal axis C of the blank 2. The number of segment edges S1, S2 may vary depending on the type of packaging box 2' and the shape of the blank 2. The lateral position is defined as the distance in the lateral direction L, which is defined as the direction perpendicular to the transport direction T of the blank 2 in the alignment module. Thus, the lateral direction L can also be defined as the direction perpendicular to the transport direction T of the blank 2 in the feeder module 10.

[0038] Each lateral peripheral portion 6a, 6b comprises one distal segment edge D1, D2 and at least one inner segment edge S1, S2. The at least one inner segment edge S1, S2 is positioned closer to the central longitudinal axis C of the blank 2 than the distal segment edges D1, D2. The distal segment edges D1, D2 are located at the lateral ends of the blank 2 in the alignment module 11.

[0039] As shown in Figure 3, the alignment module 11 preferably comprises a first alignment device 30a and a second alignment device 30b. The first alignment device 30a is configured to contact the left side of the blank 2, and the second alignment device 30b is configured to contact the right side of the blank 2.

[0040] As can be seen best from Figure 5a, the alignment devices 30a and 30b comprise an upper pressing member 22 having a plurality of pressing rollers 23 arranged in a row, an alignment conveyor 24, and a guide 26.

[0041] The alignment module 11 is configured to receive the blank 2 in the gap between the upper pressing member 22 and the alignment conveyor 24. The upper pressing member 22 and the alignment conveyor 24 are positioned at a predetermined angle with respect to the transport direction T such that the lateral edges 6a and 6b of the blank 2 face the guide 26. The guide 26 is positioned such that its longitudinal extension coincides with the transport direction T.

[0042] The alignment conveyor 24 is equipped with an endless conveyor belt 25 and is configured to contact the blank 2 and drive the blank 2 forward in the transport direction T. The pressure roller 23 can be an idler roller.

[0043] The first and second alignment devices 30a and 30b are not used simultaneously. Instead, they provide the option to select which lateral edges 6a and 6b of the blank 2 to align with the guide 26.

[0044] When one of the alignment devices 30a and 30b is activated, the other alignment device becomes inactive. In the inactive alignment devices 30a and 30b, the pressure roller 23 can move upward and away from the blank 2, so that the pressure roller 23 of the inactive alignment device 30a and 30b does not come into contact with the blank 2.

[0045] As shown in Figure 5a, the alignment module 11 may include an entrance section I. The entrance section I provides a distance over which the blank 2 is not guided. This can be achieved by positioning at least a portion of the pressing rollers 23 so that they are positioned at a predetermined distance from the alignment conveyor 24. In this way, the pressing members 22 do not grip the blank 2, and the trajectory of the blank 2 in the entrance section I is not altered by the alignment device 30.

[0046] The length of the entrance section I can be configured such that the blank 2 is moved laterally only if its entire longitudinal length La is within the alignment module 11. This allows the alignment module 11 to receive the entire longitudinal length La of the blank 2 before moving it laterally. This also allows the blank 2 to exit the feeder module 10 before its trajectory changes.

[0047] The alignment side is selected based on the shape of the lateral edges 6a and 6b of the blank 2. The selection between right-side alignment and left-side alignment can be manually made by the operator by inspecting the first and second lateral edges 6a and 6b. Alternatively, the control unit 50 can perform calculations to determine which lateral edges 6a and 6b are best suited for alignment.

[0048] Ideally, long, straight distal segment edges D1, D2 are selected as suitable alignment edges. However, some blanks 2, such as those shown in Figure 2b, have irregular lateral periphery edges 6a, 6b, and the distal segment edges D1, D2 are relatively short in the transport direction T. With respect to the irregular lateral periphery edges 6a, 6b, the alignment device 11 of the present invention also enables alignment with inner segment edges S1, S2. This is advantageous when there are inner segment edges S1, S2 that are straight (in the transport direction T) and have a significant length in the transport direction T in the alignment module 11. Preferably, the significant length is about 50% of the longitudinal length La.

[0049] As is best seen in Figures 5a and 5b, the guide 26 comprises an inlet end 32, an outlet end 34, and a longitudinal guide portion 36. The inlet end 32 is inclined downward in the transport direction T. The guide 26 has an upper surface 37 and a lower surface 39. The upper surface 37 and the lower surface 39 preferably have extensions that coincide with the horizontal direction H, and the upper surface is positioned vertically above the lower surface in the vertical direction V. In the inlet section I, the upper surface 37 of the guide 26 extends further upstream than the lower side 39 of the guide 26 in the transport direction T. In this way, the guide 26 has an inlet end 32 that is inclined downward, and the guide 26 is configured to guide the lateral portion E0 of the blank below the guide 26.

[0050] The inclination angle α can be between 20° and 40°, preferably about 30°, with respect to the longitudinal extension of the guide 26. Thus, the inlet end 32 has a wedge shape and is configured to guide the distal segment ends D1, D2 and the lateral portion E0 of the blank 2 below the guide 26. This allows the front leading edge of the blank 2 to be partially guided below the guide 26. The inlet end 32 of the guide 26 can be located in an inlet section where the blank 2 is not guided laterally.

[0051] As shown in Figure 5b, the longitudinal guide portion 36 has an alignment surface 40 configured to abut against the inner segment edges S1, S2 of the blank 2. The alignment surface 40 of the guide 26 can be flat. Alternatively, as shown in Figure 5b, the alignment surface 40 can have a groove 41. The groove 41 is configured to receive the selected inner alignment edges S1, S2 of the blank 2.

[0052] In the entrance section I, the alignment surface 40 of the guide 26 can be positioned at a predetermined lateral distance from the selected inner alignment edges S1 and S2. In this way, the guide 26 does not contact the guide edge on the blank 2 until the lateral portion E0 of the blank 2 is positioned below the guide 26.

[0053] As shown in Figure 7, the alignment module 11 is located downstream of the feeder module 10. The feeder module 10 includes a loading surface 42 configured to receive a stack of blanks 2. The loading surface 42 includes a plurality of drive belts 44 configured to contact the bottom layer of blanks 2 in the stack and drive forward in the transport direction T.

[0054] The lower conveyor 24 is positioned laterally, and the lateral portion E0 of the blank 2 extends further laterally and is not supported. The drive belt 44, which is the most distal and located on the selected guide edges S1, S2 of the blank 2, is positioned further outward than the lower conveyor 24 in the lateral direction of the alignment module 11.

[0055] This creates a lateral gap d2 in the transport path. However, the central portion of the blank 2 is supported by at least one conveyor 24. Thus, the gap d2 results in a distance over which the distal segment edges D1, D2 of the blank 2 are not supported. The gap d2 allows the distal segment edges D1, D2 to descend vertically due to gravity as the blank exits the feeder module 10. This helps the inclined entrance end 32 guide the distal segment edges D1, D2 below the guide 26.

[0056] The upper alignment module may further include a slider 28. The slider 28 is configured to contact the blank laterally with the guide 26 to prevent vertical movement of the blank. [Explanation of symbols]

[0057] 1. Converter 11 Alignment Module 22 Upper pressing member 24 Lower conveyor 26 Guide 30 Alignment devices 32 Inlet end 40 Lateral guide surface S1, S2 inner segment end

Claims

1. An alignment module (11) for a converter (1) is configured to correct the lateral position of a blank (2) being transported in the transport direction (T) through the converter, wherein the blank comprises a first lateral edge (6a) and a second lateral edge (6b), the first and second lateral edges being located on opposite sides of the central longitudinal axis (C) of the blank and extending in the transport direction. The alignment module comprises at least one alignment device (30a, 30b) having an upper pressing member (22), a lower conveyor (24), and a guide (26). The upper pressing member and the lower conveyor are configured to receive and transport the blank in the gap between them, and the guide is an elongated rod-shaped body having a lateral guide surface (40) and extending in the transport direction. The guide further comprises a downwardly inclined entrance end (32) which guides the lateral portion (E0) of the blank below the guide, while the lateral guide surface (40) is configured to contact the inner segment edges (S1, S2) of the blank, the inner segment edges being positioned closer to the central longitudinal axis of the blank than the lateral portion of the blank positioned below the guide, in the alignment module.

2. The alignment module according to claim 1, wherein the lower conveyor (24) is positioned such that the lateral portion (E0) of the blank is not supported by the lower conveyor.

3. The alignment module according to claim 1 or 2, wherein the guide comprises a groove (41) and the groove is configured to hold the inner segment edges (S1, S2) of the blank.

4. The alignment module according to claim 1, wherein the alignment module includes an entrance portion (I) in which the upper pressing member is positioned at a predetermined distance from the lower conveyor, and the entrance end that slopes downwards from the guide is located in the entrance portion (I).

5. The alignment module according to claim 1, wherein the guide is displaceable in the lateral direction.

6. The alignment module according to claim 1, further comprising a slider that contacts the blank laterally to the guide to prevent vertical movement of the blank, wherein the connecting axis (AC) of the slider and the connecting axis of the guide rail coincide.

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