System and method for optimizing the height of a box for shipping

Abstract

A system for closing a shipping container that has a rectangular bottom wall, upstanding side walls extending from the periphery of the bottom wall, and an open top end, includes a sled capable of moving the container between a first station and a second station spaced from the first station, and a flap-folding assembly movable with the sled. The flap-folding assembly is configured to inwardly fold flaps of the container while the sled moves the container between the first station and the second station.

1 - 19 . (canceled) 
     
     
         20 . A system for forming flaps in an open-topped, generally rectangular container having four upstanding side walls, comprising:
 a frame assembly movable vertically relative to a support for the container; and   four fold-forming assemblies connected to the frame assembly and configured to form horizontal fold lines in respective side walls of the container;   wherein the fold-forming assemblies are mounted to the frame assembly so as to be adjustable in respective orthogonal directions to accommodate a range of sizes of containers.   
     
     
         21 . A system as set forth in  claim 20 , wherein the fold-forming assemblies are configured to form at least two fold lines simultaneously. 
     
     
         22 . A method for adjusting a system for forming flaps in an open-topped, generally rectangular shipping container having four upstanding side walls for use with different size containers, the system including a frame assembly movable vertically relative to a support for the container; and four fold-forming assemblies connected to the frame assembly to form horizontal fold lines in respective side walls of the container, each of the fold-forming assemblies including opposing horizontal fold-forming members that are movable toward and away from each other to pinch the side wall therebetween to form a horizontal fold line that facilitates folding an upper portion of the side wall above the fold line relative to a lower portion of the side wall below the fold line from an upright orientation to a horizontal orientation; the method comprising the steps of:
 moving at least two of the fold-forming assemblies on the frame assembly in a direction toward or away from each other to accommodate a different size shipping container; and   replacing opposing fold-forming members of two fold-forming assemblies to provide fold-forming members that extend a width of the side wall of the container in which a fold line is to be formed.   
     
     
         23 . A method as set forth in  claim 22 , in a system having a sensor for detecting a height of a tallest item in the shipping container, where the sensor includes a pressure plate supported horizontally by the frame assembly, and the pressure plate is configured to be received within the shipping container; the method further comprises the step of replacing the pressure plate with a pressure plate configured to be received within the different size shipping container. 
     
     
         24 . (canceled) 
     
     
         25 . A method for closing an open-topped, generally rectangular shipping container having four upstanding side walls connected at respective corners where adjacent side walls meet, the method comprising the steps of:
 (a) moving a support structure vertically relative to the container;   (b) detecting a height of a tallest object inside the container;   (c) vertically cutting the side walls adjacent each corner of the container simultaneously to a depth determined as a function of the detected height of the tallest object in the container;   (d) forming horizontal fold lines in respective side walls of the container at a common height determined as a function of the detected height of the tallest object in the container; and   (e) folding flaps formed by the vertical cutting and forming steps inwardly from an upright orientation toward a horizontal orientation.   
     
     
         26 . A method as set forth in claim  26 , wherein the applying step includes providing a lid that has tabs extending in orthogonal directions, and the securing step includes folding the tabs downward over the fold lines of the container and securing the tabs to respective side walls of the container. 
     
     
         27 . A method as set forth in  claim 25 , further comprising the step of applying a lid to a top side of the container over the inwardly-folded flaps and securing the lid to the container, where the securing step preferably includes applying an adhesive to at least two tabs of the lid as the lid is moved from a magazine to the container. 
     
     
         28 - 34 . (canceled) 
     
     
         35 . The method as set forth in  claim 26 , comprising the step of applying adhesive to the container adjacent a fold line before the step of providing a lid. 
     
     
         36 . The system as set forth in  claim 20 , further comprising a container support arranged vertically below the frame assembly. 
     
     
         37 . The system as set forth in  claim 36 , wherein the container support includes a conveyor. 
     
     
         38 . The system as set forth  claim 20 , further comprising a plurality of fold-forming members that are interchangeable to form fold lines of different lengths. 
     
     
         39 . The system as set forth in  claim 20 , further comprising a sensor for detecting a height of a tallest item in the shipping container. 
     
     
         40 . The system as set forth in  claim 20 , further comprising an adhesive applicator configured to apply adhesive to at least two opposing flaps. 
     
     
         41 . The system as set forth in  claim 20 , further comprising
 a first station;   a second station spaced from the first station; and   a sled for moving a container from the first station to the second station, and a gluing assembly movable relative to the sled, the gluing assembly being configured to apply an adhesive to a side wall of a container as the sled moves from the first station to the second station for subsequent attachment of an article to the side wall of the container, with the gluing assembly preferably being mounted for movement with the sled.