US2989903A - Carton opening apparatus and method - Google Patents

Description

June 27, 1961 w. H. WILCOX CARTON OPENING APPARATUS AND METHOD 4 Sheets-Sheet 1 Filed July 50, 1958 l lll INVENTOR. WILL/AM H. W/LCOX A 7' TO/PNEVS June 27, 1961 w. H. wlLcox 2,989,903

CARTON OPENING APPARATUS AND METHOD Filed July 30, 1958 4 Sheets-Sheet 2 FIG. 4

INVENTOR. WILL/AM h. W/L COX A TTO/PNEVS June 27, 1961 w. H. WILCOX 2,989,903

CARTON OPENING APPARATUS AND METHOD Filed July 30, 1958 4 Sheets-Sheet 3 FIG. 8

INVENTOR. W/LL/AM H. W/LCOX A T TO/PNEVS June 27, 1961 w. H. WILCOX CARTON OPENING APPARATUS AND METHOD 4 Sheets-Sheet 4 Filed July 50, 1958 INVENTOR. WILLIAM H. WILCOX A TTORNEVS United States Patent 2,989,903 CARTON OPENING APPARATUS AND METHOD William H. Wilcox, Stockton, Caiifi, assiguor to Fibreboard Paper Products Corporation, San Francisco, Calif., a corporation of Delaware Filed July 30, "1958, Ser. No. 751,987 16 Claims. (Cl. 93-53) This invention relates generally to an apparatus and method for erecting and opening cartons from a collapsed state. More particularly this invention relates to an apparatus and method for automatically removing individual collapsed cartons from a carton supply, positioning such individual cartons on a supporting surface and thereafter moving the individual cartons past structure intended to perform a series of operations thereon to transform the cartons from the collapsed state to the fully opened or erected tubular state so that product may be inserted into the cartons thus erected.

Desirably the apparatus of the present invention is divided into a plurality of longitudinally aligned discrete sections, each of which extends at a predetermined angle of inclination relative to the other sections of the apparatus. By providing the apparatus with such discrete inclined sections, the carton opening operation is facilitated and the method employed is simplified.

According y, the objects of the present invention, among others, include the provision of an apparatus for automatically and continuously feeding collapsed cartons from a carton supply and transporting cartons thus fed into engagement with structure intended to perform operations on the cartons until the same are transformed from the collapsed state to the erected open ended tubular state; the provision of a method for effecting such carton erecting operations; the provision of means for deflecting a carton closure flap to facilitate closure flap separation; the provision of means to maintain separation of the remainder of the carton closure flap from the deflected flap; the provision of carton supporting surfaces in said apparatus which are inclined relative to each other to facilitate flap separation and carton setting up; and the provision of means for transporting cartons from one position in the apparatus to another during the setting up operation.

These and other objects will become evident from reading the following description, in which reference is directed to the accompanying drawings which illustrate one desirable embodiment of the carton opening apparatus.

FIG. 1 is a plan view of a collapsed carton of a type adapted to be opened by the apparatus of this invention;

FIG. 2 is an isometric view of an open end of an erected carton ready to receive product therein;

FIG. 3 is a schematic isometric view of a desirableembodiment of the carton erecting apparatus of this invent-ion;

FIG. 4 is a side elevation of part of the apparatus showing means for feeding collapsed cartons from a supply and placing the same on a carton supporting surface;

FIG. 5 is a side elevation of part of the apparatus illustrating means for transferring the cartons from adjacent the carton supply to a flap deflecting means;

FIG. 6 is a side elevation of part of the apparatus illustrating means for deflecting a major flap of the carton to facilitate flap separation;

FIG. 7 is a view similar to FIG. 6 showing the deflected carton flap being separated from the remainder of the carton flap by means designed for that purpose;

FIG. 8. is a plan view of that part of the apparatus shown in FIG. 6;

FIG. 9 is a plan view of that part of the apparatus shown in FIG. 7;

2,989,903 Patented June 27, 1961 FIG. 10 is a side elevation of means for conveying a carton through a section of the apparatus;

FIG. 11 is a side elevation of means effective to set up a carton;

FIG. 12 is a side elevation which corresponds substantially to FIG. 11 and illustrates the final steps of the carton setting up operation;

FIG. 13 is a vertical section taken in the plane of line 13-43 of FIG. 7 illustrating the relationship between the conveyor means and the carton flap deflecting and separating means of the present apparatus;

FIG. 14 is a schematic view illustrating the inclination of individual sections of the apparatus relative to each other.

It has been known in the art heretofore to position a plurality of cartons in set up open ended condition on a conveyor and to move the same past a supply of product to be filled in the respective cartons. However, difliculty is often encountered in automatically erecting the cartons prior to their positioning on the conveyor for reception of the product intended to be packaged therein. The apparatus of this invention was devised to facilitate erecting of cartons from the collapsed state for receiving product.

Generally, cartons of the type here involved are formed from flexible material, such as paper board, and are of the type intended to package various products, 1such as cakes produced in a commercial bakery or the use.

Such paperboard cartons generally are fabricated by the manufacturer into a flattened or collapsed tubular configuration having longitudinally extending closure flaps at opposite ends thereof. Such cartons are shipped to the user in the collapsed state to conserve space. It thereby becomes necessary for the carton user to erect the cartons so that the same may be filled with the desired product for sale to the ultimate consumer. However, difiiculty often is encountered in the carton setting up operation in that not infrequently the cartons can not be transformed rapidly from the collapsed tubular state to the erected open tubular state without damaging the cartons.

The present invention is directed to an apparatus which automatically feeds collapsed tubular cartons from a carton supply and automatically and continuously transforms the same without damage to open tubular state at high speeds compatible with the speeds employed by available machinery for inserting product into open cartons.

Although the apparatus of this invention and the carton erecting method performed thereby may be utilized with cartons of various configurations, such apparatus is designed primarily for opening cartons of the type illustrated in FIGS. 1 and 2. Such cartons are designated 1 and generally comprise a plurality of body walls, such as 2, 3, 4 and 6, which are hingedly connected together into an annularly continuous tubular configuration in any suitable rnanner. Such body walls may have any suitable dimensional relationship, but in the embodiment illustrated, opposite walls 2 and 4 are of a width somewhat greater than the width of body walls 3 and 6. All of such wflls have equal length, however. In the collapsed condition shown in FIG. 1, body walls 4 and 6 underlie and are in contact with the inner surfaces of body walls 2 and 3.

Hingedly connected to the collapsed carton at opposite ends thereof are carton closure means in the form of opposite cooperable pairs of end closure flaps which are intended to seal the ends of the carton after the same has been filled with its intended product. Corresponding flaps at opposite ends of the cartdn generally are identical and, accordingly, the flaps at only one carton end will be 3 specifically described and discussed herein. However, similar flaps at the opposite carton end have been identified by similar reference numerals primed.

Hingedly connectedto the. margin of each of. large body walls 2 and 4 are upper and lower major closure flaps 7 and 8. A pair of minor side closure flaps 9 and 11' are hingedly connected to margins of opposite small side body walls 3 and 6. When the carton is collapsed as shown in FIG. 1, upper major flap 7 and upper minor flap 11 overlie and contact the inner faces of lower major flap 8 and lower minor fiap 9.

Minor flapsf9 and 11 are of substantially less length than major flaps 7 and 8 so that the outer free edges of flaps 7 and 8 extend longitudinally of the carton beyond the outer free edges of; minor flaps '9 and 11. This arrangement is illustrated by the erected carton shown in FIG. 2.

Cartons of the type described may be utilized for packaging various products, such as, for example, cakes produced in a commercial bakery or the like. Such cakes generally are produced in large quantities and apparatus for automatically packaging such cakes at a high rate of speed is highly desirable so that the same may be submitted to the buying public as soon after baking as possible. Accordingly, high speed carton setting up apparatus is required for use with existing high speed machinery which :is adapted to automatically insert cakes or the like into fully open cartons.

The overall apparatus of this invention is designed to transform cartons from the collapsed tubular state shown in FIG. 1 to the open ended erected tubular state shown in FIG. 2. Such apparatus may take various form but the illustrated embodiment includes a collapsed carton supply hopper 16 of any suitable design in which a supply of collapsed cartons 1 is positioned. In the embodiment illustrated, hopper 16 is positioned above the apparatus, but such hopper may be located in any convenient position relative to the apparatus.

The carton apparatus itself is divided longitudinally into three major sections, designated A, B and C for purposes of identification. (See FIGS. 3 and 14.) Desirably, each of these sections is a substantial longitudinal continuation of the other with each of such sections being inclined at a predetermined angle relative to an adjacent section. Desirably, although not necessarily, the carton supporting surface of section C extends in a substantially horizontal plane with the carton supporting surfaces of sections B and A being inclined different amounts relative to the horizontal.

The carton supporting surface of each section is defined by a pair of parallel rails 17 and 18 which extend longitudinally of the apparatus. The upper surfaces 19 and 21 of the respective rails in each section desirably are substantially flat and lie in a common plane to provide a smooth surface over which cartons may be moved. In the illustrated embodiment, rails 17 and 18 are continuous and extend throughout each of the sections comprising the apparatus. However, separate pairs of rails may be employed in each apparatus section to facilitate fabrication if so desired.

Points or areas or locations of transition are provided along the length of rails 17 and 18 at which the inclination of the rails relative to a reference plane, such as the horizontal, changes to define the separate apparatus sections. These points or areas or locations of angular transition serve as junctions between adjacent sections. While in the embodiment of the apparatus illustrated, three such distinct sections are provided, it should be understood that under certain circumstances more than three or less than three sections may be utilized to meet a particular need or perform a given function.

Taking reference to FIG. 14, it should be understood that as a collapsed carton passes from one inclined section to another, for example, from section A to section B, the leading edge of the carton will lie in one section while 4 the trailing edge thereof will lie in another section. Such a situation tends to cause the central portion of the carton to rise up out of contact with the supporting rails. It is to produce such a situation that the inclined sections were devised so that carton erecting could be facilitated, as Will be set out hereinafter.

Mounted adjacent one end of the apparatus for movement relative to the supply hopper 16 is feeder means 22 (FIGS. 3-5) adapted to withdraw individual collapsed cartons from the hopper and position the same on the supporting surface defined by rails 17 and 18 of section A of the apparatus. Such feeder means 22 desirably takes the form of a plurality of suction cups 23 positioned between rails 17 and 1 8 for reciprocation in an arcuate path relative to the apparatus and carton hopper 16.

The suction cups 23 may be mounted for rotation between rails 17 and 18 in anysuitabie manner and may be reciprocated by any suitable means,such as a crank or cam arrangement (not shown) which will move the cups from the lower retracted position shown in FIGS. 3 and 4 to the extended carton engaging position shown in FIG. 5 wherein the outermost carton in the hopper may be withdrawn from the hopper. Any suitable means may be incorporated with the hopper to insure that only one carton is withdrawn at a time.

While suction cups have been found to be a suitable means for feeding individual cartons from the hopper, various other means known in the art also could be utilized Cartons Withdrawn by feeder means 22 from the hopper are carried downwardly through a substantially arcuate path, and are positioned on the upper surfaces 19 and 21 of rails 17 and 18 transversely thereof with the carton closure flaps extending laterally beyond the rails. When in such position, suction cups 23 are disengaged automatically from the carton, and the same is free to be moved longitudinally along section A of the apparatus.

For effecting such' longitudinal movement, transfer means is provided desirably in the form of a pair of reciprocable bell cranks 24 and 26, which are positioned outboard of rails 17 and 18, respectively, and which are intended to reciprocate in planes extending substantially parallel thereto. Each bell crank 24 and 26 is substantially identical, as is the mechanism for actuating each bell crank. Accordingly, only bell crank 24 adjacent rail 17 and the mechanism for reciprocating the same will be specifically described. It should be understood, however, that bell cranks 24 and 26 operate in unison to move cartons from beneath hopper 16. Similar reference numerals primed are used to identify similar parts of bell crank 26 and its operating mechanism relative to bell crank 24.

Bell crank 24 is mounted for pivotal movement relative to rail. 17 mm includes a pusher arm 27 terminating in a carton engaging head 28 at its upper end. "Bell crank 24" is mounted for movement about pivot pin 29 which extends through rail 17 adjacent the bottom thereof. The other'arm 31 of bell crank 24 is pivotally connected to any suitable actuating means for effecting reciprocation of pusher arm 27 relative to cartons positioned on rails 17; In the embodiment illustrated, such actuating means takes the form of a push rod 32 connected 'at one end thereof by pivot pin 33 to arm'3-1 of bell'c'rank 24 and at its opposite end to a cam wheel or sprocket 34 by means of pivot pin 36.

Push rod 32 is eccentrically connected to sprocket 34 so that rotation of the sprocket will resultin a back and forth movement of hell crank 24 about pivot pin 29 in a well known manner. Rotationof sprocket 34 may be effected in any suitable manner. a

1n the embodiment illustrated, sprocket'34 is mounted for rotation with an axle 38 which extends between and through rails 17 and 18. It'should. be remembered that a similar bell crank sprocket arrangement also. is connected toaxle 38 outboard ofrail 18.. Upon rotation of sprocket 34 by axle 38, push rod 32 actuates bell crank 24 so that the same reciprocates about pivot pin 29 between the retracted and advanced positions shown in FIGS. 4 and 5, respectively. Movement of bell crank 24 results in a carton being pushed down the inclined supporting surface of section A toward the inclined supporting surface of section B.

FIGS. 4 and 5 also illustrate the timed relationship which exists between movement of the feeder means 22 and the transfer means comprising bell cranks 24 and 26 of the present apparatus. As shown in FIG. 4, when suction cups 23 withdraw a carton from the hopper and position the same on top of rails 17 and 18, bell cranks 24 and 26 are in the retracted position. After the car ton has been released by suction cups 23 the bell cranks move the carton down the inclined surface of section A. When the carton clears the suction cups, the suction cups may again be moved without interference to the upper position shown in FIG. 5 to withdraw another carton. The operations performed by the bell cranks and suction cups are so timed that cartons maybe withdrawn from the hopper and moved along the rails at a high rate of speed.

In this connection, suction cups 23 may be mounted for reciprocation relative to rails 17 and 18 in any suitable manner. One such suitable manner is shown in FIGS. 4 and 5 wherein the cups are pivotally mounted on the same axle 38 upon which sprocket 34 is mounted. It should be understood, however, that the suction cups are merely mounted for rotation relative to the axle, but are not driven thereby. Independent means of any suitable type may be utilized to efiect reciprocation of the suction cups about axle 38.

The apparatus of the present invention also includes means, desirably in the form of first endless conveyor chain 41, intended to move a carton from engagement with heads 28 and 28' of the bell cranks 24 and 26and from section A of the apparatus to and along section B thereof. Chain 41 is positioned to run over and between sprocket 34 and a cooperating sprocket 42 spaced therefrom (see FIG. 3) outboard of rail 17. Suitable teeth are provided about the peripheries of such sprockets. A plurality of spaced carton engaging lugs 43 are fixedly secured to endless chain 41 for movement therewith. A similar chain-lug arrangement is provided in conjunction with rail 18, and is designated 41, 43.

Each of the lugs is intended to engage any suitable trailing portion of a carton positioned on rails 17 and 18 for moving the same from the end of section A of the apparatus through section B thereof. In the embodiment illustrated, the lugs engage the trailing edges of the bottom major flaps 8 and 8' of the canton as best shown in FIGS. 7, and 11.

Because sprocket 34 is positioned beneath section A of the apparatus in the area of angular transition between inclined sections A and B (see FIGS. 6 and 7), each chain lug comes up underneath the carton as the same moves from section A to section B. This is so because, as previously noted, the central portion of the carton rises slightly off rails 17 and 18 as it passes through the area of angular transition of the rails. Accordingly, lug 43 engages the trailing edge of major flap 8 and holds minor flap 9 slightly out of the plane of major flap 8. This engagement of lug 43 with flap 8 is facilitated in that flap 8 is deflected downwardly as the carton reaches the transition point between sections A and B.

Desinably, heads 28 and 28' of bell cranks 24 and 26 remain in engagement with the carton until the conveyor chain lugs are firmly and properly engaged with flaps 8 and 8 (note FIG. 7).

The present apparatus includes means for deflecting the major closure flaps 8 and 8' downward-1y away from the remainder of the closure flaps at each end of the carton so that the flaps may be separated from each other to facilitate the carton erecting operation. In the embodiment illustrated, the flap deflecting means comprises a defleeting member in the form of an elongated slender tubular or the like cleavage finger 44 positioned outboard of rail 17 and mounted on the apparatus so that its leading portion or end 45 is positioned in substantial alignment with the location of angular transition of the rails from the angle of inclination of section A to the lesser angle of inclination of section B. Member 44 is mounted on the apparatus by means of any suitable bracket 46. A similar deflecting member is mounted outboard of rail 18 to deflect flap 8' of the carton.

As collapsed carton 1 is moved along section A towards section B by the transfer and conveyor means described, the leading edge of underlying major flap 8 of the carton 1 passes beneath leading end 45 of member 44. Because of the inclination of the carton resulting from the inclination of section A, member 44 may more easily be engaged with the upper surface of flap 8. Also, as noted previously, movement of the carton from section A to section B results in the leading and trailing edges of the carton being positioned on rail sections extending at different angles relative to each other, thereby causing the central portion of the carton to lift ofl the rails in the area of angular transition between the sections. Such tendency of the central portion of the carton to lift automatically results upon continued movement of the carton in the underlying major flap 8 being bent down by deflecting member 44 out of the plane of its associated carton body wall 4. This situation is illustrated in FIGS. 6 and 7.

As noted previously, lug 43 on chain 41 comes up beneath the carton and engages only the trailing edge of underlying major flap 8. The positioning of sprocket 34 relative to deflecting member 44 results in lug '43 engaging flap 8 just as the flap is deflected. Thereafter, bell cranks 24 and 26 retract and the carton is moved solely by the conveyor chain 41.

As shown in FIGS. 8 and 9, deflecting member 44 is mounted or positioned outboard of conveyor chain 41 so that the deflecting member will not interfere with the conveying function of lug 43. Furthermore, deflecting member 44 is so arranged that it initially contacts only the upper face of lower major flap 8 Without contacting minor flap 11 (see FIGS. 6 and 8).

In this connection, it should be understood that if an attempt were made to insert the deflecting member 44 between the leading edges of minor flap 11 and major flap 8, such operation would be extremely difficult without destroying or damaging the flaps. This is so because minor flap 11 of the collapsed carton overlies and is in contact with underlying major flap 8 throughout its entire extent. Therefore, no separating member could be inserted between the two flaps at the high speeds required to make a carton opening apparatus commercially practical without damaging the carton.

As a result, because of the shorter length of minor flap 11 relative to underlying major flap 8, flap deflecting member 44 may be engaged with flap 8 without contacting or damaging minor flap 11. As shown in FIG. 7, upon movement of the carton by lug 43 relative to stationary deflecting member 44, major flap 8 is deflected downwardly relative to the three remaining closure flaps and is completely separated therefrom. It should be understood that the deflection of lower major flap 8 by member 44 is enhanced and facilitated because of the angular difference existing between the supporting surfaces of section A and section B. Furthermore, such angular difference results in the central portion of the carton rising ofl the rails and such central portion carries upper major flap 7 therewith. As a result, flap 7 and flap 8 are separated and deflecting member 44 may enter therebetween.

Continued movement of the carton along section B results in complete isolation and separation of major flap 8 from the remaining flaps at the carton end.

To eflect complete separation of closure flap 8 from the remaining closure flaps 7, 9 and 11 and maintain such separation so that the carton may be automatically set up, means is provided desirably in the form of an elongated metal band 47 having a leading end 48 thereof positioned adjacent the trailing end of deflecting member 44. If desired, deflecting member 44 and band 47 could be formed as a single elongated member, but desirably band 47 and member 44 are formed as separate parts as illustrated to facilitate fabrication thereof.

The lea-ding end 48 of separating band 47 is positioned in substantial alignment with the trailing end of deflecting member 44. As a result, movement of a carton through the apparatus results in leading end 48 of band 47 also entering between lower major flap 8 and upper major flap 7. However, as illustrated in FIGS. 8, 9 and 13, the major portion of band 47 lies inboard of chain 41 and a thin curved portion 49 connects leading end 48 to the major portion of band 47.

Upon deflection of lower flap 8 by deflecting member 44, a space is provided betwen the leading edges of upper minor flap 11 and lower major flap 8 (see FIGS. 6 and 7). The inner edge of the curved portion 49 of band 47 is comparatively thin, such as a knife edge, and as the carton is moved by conveyor lug 43, such edge is free to enter the space between flaps '11 and 8 and separate the same (note FIG. 13). It should be understood that the edge of band portion 49 can easily enter between flaps 11 and 8 because flap 8 has first been deflected downwardly by member 44.

Continued movement of the carton results in band 47 being inserted between lower major flap 8 and the remaining three flaps 7, 9 and 11. This is so because defleotion of flap 8 also results in a space being provided between the trailing edge thereof and the leading edge of lower minor flap 9 (FIG. 7). It is into such space that the edge of band portion 49 is positioned in the same manner as the band was positioned between flaps 11 and 8., This condition of the canton with flap 8 held down by band 47 and separated from flaps 7, 9 and 11 is shown in FIG. 10.

As illustrated in FIGS. 6, 7 and 13, the curved portion 49 of band 47 is upwardly bowed a predetermined distance to provide a clearance space so that lugs 43 of conveyor chain 41 may pass beneath the separating band without contacting the same.

After lower major flap 8 has been separated from the remainder of the closure flaps, the carton is ready to be erected to the fully opened tubular condition illustrated in FIG. 2. Such canton erecting may be effected by means of a second conveyor arrangement in combination with a suitable plow member. Such second conveyor desirably includes an endless chain 50 (FIGS. 3, 11 and 12) positioned inboard of rail 17 and having mounted thereon a plurality of spaced carton set up lugs 51. Chain 50 is mounted on sprocket wheel 52 positioned on the same axle 53 on which sprocket 42 of the first conveyor means is mounted for rotation. In this manner, each conveyor may be actuated in timed relationship by a common power source. It should be understood that a similar conveyor chain 50' carrying set up lugs 51' is positioned inboard of rail 18 and also rotates about sprocket 52' on axle 53.

As shown in FIGS. 3 and 11, sprockets 52 and 52' are positioned adjacent the area of transition between sections B and C of the apparatus. As a result, when the canton is transferred by lugs 43 of the first conveyor toward section C, and as the leading edge of such carton reaches section C while the trailing portion thereof is still supported on section B, the central carton portion again tends to rise from the spaced rails 17 and 18. However, the carton as a whole is generally held down on the rails by means of the elongated separating bands which engages the lower major flaps 8 and 8'.

As shown in FIG. 11, when the carton reaches the transition point between sections B and C, the set up lugs 51 and 51 of the second conveyor means come up behind and engage the trailing end of the carton and tend to urge the same to the upright position. As noted in FIG. 12, desirably the set up lugs are of a length slightly greater than the height of side body walls 3 and 6 of the carton.

Because the carton is substantially held down by the separating band 47, the carton can not be moved from contact with the rails 17 and 18. Therefore, as a result of flap 8 being separated from the remainder of the flaps, the carton is automatically set up as lugs 51 and 51 engage the same, as illustrated in FIGS. 11 and 12.

However, because at this stage in the setting up operation a portion of the carton lies on each of sections B and C, there is a possibility of the carton buckling as force is applied to the trailing edge thereof by the set up lugs. To preclude such buckling, plow members 54 and 54 are provided on top of separating bands 47 and 47' (FIGS. 3, 1'1 and 12) which engage upper major flaps 7 and 7 and move the same upwardly so that buckling of the carton is precluded, and automatic setting up thereof is insured.

Upper band members 55 and 55 are provided for use in conjunction with plow members 54 and 54' and are adapted to ride beneath flaps 7 and 7' of the carton to cooperate with set up lugs 51 and 51 in maintaining the carton open to allow insertion of the product into the carton. As a result, as shown in FIG. 12, the fully erected carton is conveyed along section C of the apparatus by the set up lugs 51 and 51 of the second conveyor means with lower band 47 maintaining lower major flap 8 open and upper band 55 underlying and maintaining upper major flap 7 open.

While plow members 5-4 and 54 will temporarily deflect respective minor flaps 9, 9', 11 and 11' as the same come in contact with the plows, as the carton moves beyond the plow, such minor flaps are free to snap back to the straight out extended position shown in FIG. 3.

Desirably, bands 47 and 55 are provided along their extent with means for deflecting major flaps 7 and 8 upwardly and downwardly respectively from the horizontal so that the mouth of the carton is substantially unrestricted during the filling operation. Such means, as shown in FIG. 3, may take the form of angle sections 56 secured to the bands beyond plow 54. Other suitable arrangements also may be employed.

After the cartons have been fully opened as described, the same are carried by the lugs of the second conveyor past any suitable means for inserting a product into each of the cartons and thereafter past suitable means for defleeting inwardly the closure flaps to seal the carton and maintain the product therein. Mechanisms for automatically loading product into open cartons and for thereafter sealing the cartons are well known. Any such mechanisms may be utilized with the carton opening apparatus of this invention. It should be understood that the type of closure provided for the cartons may vary, depending upon the product packaged therein.

From the foregoing, it should be understood that the apparatus of the present invention provides means for automatically and rapidly feeding cartons from a supply, erecting the same from the flattened state and completely opening the ends thereof so that product may be inserted therein without interference from the closure flaps of the carton. It should further be understood that the various components of the apparatus are driven in timed relationship relative to each other to insure a steady, smooth, continuous flow of cartons through the apparatus without interrupted motion.

.As mentioned previously, an important feature of this invention resides in the fact that the carton supporting surfaces of sections A, B and C are each inclined relative to each other. While the exact angles of inclination of the respective surfaces are not critical, a suitable and satisfactory arrangement is obtained if the carton supporting surface of section \C extends substantially horizontally. This facilitates product insertion in that the product may be inserted into the cartons in a horizontal direction. This factor is important if the product is a cake or similar bakery goods. 7

The suitable relationship above mentioned includes positioning the supporting surface of section B so that it is inclined upwardly at approximately 7 relative to the surface of section C with the supporting surface of section A inclined upwardly at approximately 10 relative to the surface of section B. That is, a suitable arrangement is obtained if section C is horizontal, section B is inclined upwardly at 7 relative to the horizontal and section A is inclined upwardly at 17 relative to the horizontal.

This particular angular relationship, while generally satisfactory, may be varied to solve a particular problem relative to a particular type carton.

Because this apparatus is intended for use with various types and sizes of cartons, desirably the components thereof are adjustable so that such various cartons may be accommodated. For example, bands 55 and 55 may be vertically adjusted relative to bands 54 and 54'. Other cooperable components of the apparatus also may be adjusted relative to each other.

While one embodiment of the invention has been described herein, other modifications Which may become apparent to one skilled in the art, also are part of the invention and the same should be interpreted in light of the appended claims.

-I claim:

1. Apparatus for deflecting a closure flap of a carton away from other closure flaps of said carton comprising first and second cooperable carton supporting surfaces, said first surface being inclined at a predetermined angle relative to said second surface, means for moving said carton continuously over said first surface and without interruption onto said second surface, and means fixedly and immovably positioned adjacent a location of angular transition between said surfaces for engaging and automatically deflecting said closure flap away from said other closure flaps as said carton is moved by said moving means from said first surface to said second surface.

2. Apparatus for transforming a carton having a plurality of closure flaps at an end thereof from the collapsed state to the open ended erected state comprising substantially longitudinally aligned first and second carton supporting surfaces, said first surface being inclined at a predetermined angle relative to said second surface, and means for deflecting one closure flap away from the remainder of said closure flaps comprising a flap deflecting member having a leading portion thereof fixedly and immovably positioned adjacent a location of angular transition between said surfaces whereby said one closure flap is positioned beneath said member and is automatically deflected thereby away from the remainder of said closure flaps as said carton is moved continuously along said first surface and without interruption onto said second surface.

3. Apparatus for opening a collapsed carton having closure flaps at an end thereof comprising means for moving said carton continuously and without interruption over a first carton supporting surface and a second carton supporting surface which extends at a predetermined angle relative to said first surface, means for deflecting and separating a closure flap from other of said closure flaps including a flap deflecting member fixedly and immovably positioned adjacent a location of angular transition between said first and second surfaces and a cooperable flap separating band extending away from said transition location toward a third carton supporting surface which extends at a predetermined angle relative to said second surface, and continuously movable carton erecting means engageable with said carton as the same reaches said third surface, said erecting means being cooperable with said separating band to automatically transform said carton from a collapsed state to an open ended erected state without interrupting movement of said carton so that the contents intended for said carton may be inserted therein.

4. Apparatus for removing an individual collapsed carton having at an end thereof opposite pairs of major and minor end closure flaps from a supply of collapsed cartons and transforming the same to open ended erected state, comprising feeder means for withdrawing said carton from said supply and positioning the same on a first carton supporting surface, means operable in timed relationship with said feeder means for moving said carton continuously and without interruption along said first surface and onto a second carton supporting surface provided as a substantial continuation of said first surface, immovable deflecting means positioned adjacent a junction of said first and second surfaces and engageable with one of said major flaps for deflecting the same away from the remainder of said flaps, means extending along said second surface and engageable over said one major flap for separating said one major flap from the remainder of said flaps and holding down the same, said carton being movable continuously and without interruption by said moving means along said second surface to a third carton supporting surface provided as a substantial continuation of said second surface, carton erecting means movable continuously and without interruption relative to said third surface in timed relationship relative to said moving means and being initially engageable with said carton adjacent a junction of said second and third surfaces, said erecting means being engageable with said carton only externally thereof and cooperable with said flap separating means in transforming said collapsed carton to said erected state, said first, second and third surfaces being substantially longitudinally aligned with each other with the planes of said first and second surfaces being inclined relative to each other and with each of said planes being inclined relative to the plane of said third surface whereby deflecting said one major flap, separating the same from the remainder of the flaps and erecting said carton is facilitated.

5. The apparatus of claim 4 wherein each of said first, second and third surfaces is defined by a pair of spaced rails.

6. The apparatus of claim 4 wherein said third surface extends in a substantially horizontal direction, said second surface extends upwardly at a predetermined angle relative to the horizontal and said first surface extends upwardly at a predetermined angle relative to said second surface.

7. Apparatus for transforming a carton having a pair of major closure flaps and a pair of minor closure flaps at an end thereof from the collapsed state to the erected state, comprising first and second carton supporting surfaces inclined relative to each other, means engageable with said carton for moving. the same continuously along said first surface and without interruption onto said second surface, a flap deflecting finger fixedly and immovably mounted in the path of movement of said major flaps at the point of angular transition between said first and second surfaces and out of the path of movement of said minor flaps whereby one major flap is engageable beneath said deflecting finger and is deflectable thereby away from the other major flap and said minor flaps as said carton is moved from said first surface onto said second surface thereby providing a clearance space therebetween; a separating band having an end aligned with said deflecting finger, an intermediate curved section positioned across the path of movement of said minor flaps, and a trailing section in the path of movement of said minor flaps and extending along said second surface whereby said band is insertable into the clearance space between the deflected major flap and the other major flap and said minor flaps and held down thereby during continued movement of said carton along said second surface; and continuously movable means engageable with a trailing portion of said carton for urging said 1 1 carton 'to the erected position while the deflected major flap is held down by said separating band.

8. The apparatus of claim 7 including a plow device positioned in the path of movement of said major and minor flaps to preclude buckling of said carton as the same is erected by said movable means engageable with said carton trailing portion.

9. Apparatus for transforming a carton from a collapsed state to an erected open ended state, said carton comprising a body having at an end thereof a pair of minor end closure flaps and a pair of major end closure flaps which extend beyond outer edges of said minor flaps, said carton when in said collapsed state having one minor flap and one major flap overlying the other minor and major flaps, said apparatus comprising a supporting surface over which said carton is movable with said major and minor flaps extending laterally beyond said supporting surface, said supporting surface comprising two distinct sections one of which is angularly inclined upwardly relative to the other, the other surface section being a substantial continuation of said one section and operatively meeting the same at a location of angular transition between said sections, mechanism for moving said carton along and from said one section onto and along said other section with said underlying major flap in leading relationship, and means positioned adjacent said location of angular transition for separating said underlying major flap from the remaining flaps of said carton and for positively holding down the same so that said carton may be erected; said flap separating and holding down means comprising a flap deflecting member mounted outboard of said surface sections a distance sufficient to contact said major flaps and to clear said minor flaps when said carton is moved therepast, and a flap hold down band extending along said other surface section inboard of said deflecting member, said underlying carton major flap being automatically positioned beneath said deflecting member when said carton is moved from said one surface section onto said other section wherebysuch flap is positively separated from all the remaining carton flaps and whereby the carton may be held down by said band engaging the thus separated flap as carton movement is continued.

10. The apparatus of claim 9 including carton erecting means engageable solely with the exterior of said carton for effecting carton erection whereby the need for inserting an erecting member into said carton to effect erection thereof is precluded, said erecting means comprising a movable member engageable with a trailing portion of said carton while said underlying major flap is held down by said band, said movable member being cooperable primarily with said hold down band in effecting carton erection.

11. The apparatus of claim 10 in which said carton supporting surface includes a third section which is angularly related to said other supporting surface section, said movable member being initially engageable with said carton adjacent the location of angular transition between said other surface section and said third section.

12. The apparatus of claim 11 which includes means for precluding buckling of said carton while the same is being erected and for maintaining the carton end open and free of restriction by said pairs of flaps after erection to permit filling of product therein.

13. A method of separating a single closure flap from other closure flaps of a carton having opposite pairs of major and minor closure flaps at an end thereof, comprising moving said carton in a first predetermined path with one major flap and one minor flap underlying the other major and minor flaps and with said underlying major flap in leading relationship during carton movement, positioning a flap deflecting member adjacent said first carton path at a location to contact said major flaps and to clear said minor flaps, changing the direction of movement of said carton from said first predetermined path to a second predetermined path which is angularly related to said first path as said carton approaches said deflecting member, engaging said leading underlying major flap beneath said deflecting member as said carton moves from said first path into said second path whereby such flap is deflected by said member away from the remaining flaps of said carton, and moving said carton along said second predetermined path and maintaining said deflected flap separated from the remaining flaps of said carton.

14. The method of claim 13 including providing a flap separating band along said second predetermined path of carton movement, and inserting said separating hand between said deflected underlying major flap and the remainder of said closure flaps whereby said underlying flap is held down by said band as said carton moves along said second path.

15. A method of transforming a carton having opposite pairs of major and minor end closure flaps at an end thereof from the collapsed state to the erected open ended state, comprising moving said carton in a first predetermined path with one major flap and one minor flap underlying the other major and minor flaps and with said underlying major flap in leading relationship during carton movement, positioning a flap deflecting member adjacent said first carton path at a location to contact said major flaps and to clear said minor flaps, changing the direction of movement of said carton from said first path to a second predetermined path which is angularly related to said first path as said carton approaches said deflecting member, engaging said leading underlying major flap beneath said deflecting member as said carton moves from said first path into said second path whereby such flap is deflected by said member away from the remaining carton flaps, maintaining said deflected major flap separated and held down and away from said remaining flaps as said carton is moved along said second path, and engaging and urging forwardly a trailing folded edge portion of said carton as said deflected flap is held down to effect erection of said carton without inserting any erecting mechanism into said carton during erection thereof.

16. The method of claim 15 including moving said carton from said second path into a third predetermined path which is angularly related to both said first and second paths as said carton trailing edge is urged forwardly to facilitate erection thereof, and precluding buckling of said carton as the same moves from said second path into said third path.

References Cited in the file of this patent UNITED STATES PATENTS Re. 24,668 Rodman July 21, 1959 2,009,828 Wild July 30, 1935 2,068,163 Bowersock et al. Jan. 19, 1937 2,750,856 Ferguson et al. June 19, 1956 2,906,392 Galloway Sept. 29, 1959

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