Container sizing apparatus and methods for fixed footprint containers

Abstract

A container forming system includes a frame having a first deck level and a second deck level above the first deck level. A cut and crimp station is at the second deck level, including one or more mechanisms configured to form a plurality of top flaps in an open container. A conveyor is operatively connected to the frame for movement relative to the frame to receive the open container with product therein at the first deck level and raise the open container up to the crimp and cut station at the second deck level, for forming the plurality of top flaps in the open container.

What is claimed is: 
     
         1 . A container forming system comprising:
 a frame having a first deck level and a second deck level above the first deck level;   a cut and crimp station at the second deck level, including:
 a cutter configured to form vertical cuts along upper portions of vertical corners of an open container to form a plurality of top flaps in the open container, and 
 a crimper configured to form horizontal fold lines for the top flaps; 
   a folding station at the second deck level, including a folder configured to fold down the plurality of top flaps of the open container to enclose contents therein, thereby forming the open container into a closed container; and   a conveyor operatively connected to the frame to: receive the open container with product therein at the first deck level and raise the open container up to the crimp and cut station at the second deck level, for forming vertical cuts in vertical corners of the open container to form the plurality of top flaps in the open container, and for crimping the horizontal fold lines into the open container for folding the plurality of top flaps, and
 transport the open container from the cut and crimp station to the folding station for folding down the plurality of top flaps. 
   
     
     
         2 . The system as recited in  claim 1 , wherein the cut and crimp station includes a measuring plate that is fixed relative to the frame, configured so that contents of the open container contact the measuring plate as the conveyor raises the open container up against the measuring plate to establish where the cutter must terminate cut lines in the open container, and where the crimper must form the horizontal fold lines in the open container. 
     
     
         3 . The system as recited in  claim 2 , further comprising:
 a controller operatively connected to control the conveyor, the cutter, the crimper, and the folder; and   a contact sensor operatively connected to the measuring plate and to the controller to detect contact between the measuring plate and the contents of the open container, and to use height of the conveyor at the point where the controller detects contact to establish the cut lines and the fold lines.   
     
     
         4 . The system as recited in  claim 3 , wherein the controller and the conveyor are configured to:
 raise the open container to a height where the measuring plate contacts the contents of the open container;   use the cutter to form the cut lines downward from a top opening of the open container down to a level where the measuring plate contacts the contents;   use the crimper to form the fold lines; and   lower the open container after forming the fold lines to clear space for the open container to clear the cutter, the crimper, and the measuring plate for egress from the cut and crimp station to the folding station.   
     
     
         5 . The system as recited in  claim 1 , wherein the cutter includes a set of shears having a shear pivot that is fixed relative to the frame. 
     
     
         6 . The system as recited in  claim 1 , wherein the crimper includes a set of pinchers including a creaser and opposed anvil configured for forming fold lines by pinching toward one another on opposite sides of a container wall, and a pincher pivot that is fixed relative to the frame. 
     
     
         7 . The system as recited in  claim 1 , wherein the folding station includes a folding armature fixed to the frame and configured to fold the plurality of flaps. 
     
     
         8 . The system as recited in  claim 1 , further comprising a lid magazine operatively connected to the frame to feed lid blanks into the conveyor. 
     
     
         9 . The system as recited in  claim 8 , wherein the lid magazine is at the second deck level. 
     
     
         10 . The system as recited in  claim 8 , wherein the conveyor is configured to transfer a lid blank from the lid magazine to a lid apply station along a main feed direction. 
     
     
         11 . The system as recited in  claim 10 , wherein the lid apply station is at the second deck level, wherein the conveyor is configured and to transfer a closed container from the folding station to the lid apply station laterally relative to the main feed direction at the second deck level. 
     
     
         12 . The system as recited in  claim 10 , wherein the lid apply station includes a lid blank folder and glue applicator each operatively connected to the frame to form the lid blank into a lid and to adhere the lid to the closed container. 
     
     
         13 . The system as recited in  claim 12 , wherein the glue applicator is configured to apply beads of glue to two opposing flaps of the lid blank and to two opposing sidewalls of the closed container for adhering the lid to the closed container around four sides of the closed container. 
     
     
         14 . The system as recited in  claim 12 , wherein the conveyor is configured to outfeed the closed container with the lid adhered thereto from the frame. 
     
     
         15 .- 20 . (canceled) 
     
     
         21 . A container forming system comprising:
 a frame having a first deck level and a second deck level above the first deck level;   a cut and crimp station at the second deck level, including one or more mechanisms configured to form a plurality of top flaps in an open container; and   a conveyor operatively connected to the frame for movement relative to the frame to:
 receive the open container with product therein at the first deck level and raise the open container up to the crimp and cut station at the second deck level, for forming the plurality of top flaps in the open container. 
   
     
     
         22 . The system as recited in  claim 21 , wherein the cut and crimp station includes a measuring plate that is fixed relative to the frame, configured so that contents of the open container contact the measuring plate as the conveyor raises the open container up against the measuring plate to establish where to form the plurality of upper flaps. 
     
     
         23 . The system as recited in  claim 22 , further comprising:
 a controller operatively connected to control the conveyor, the cut and crimp station, and the folder; and   a contact sensor operatively connected to the measuring plate and to the controller to detect contact between the measuring plate and the contents of the open container, and to use height of the conveyor at the point where the controller detects contact to establish the where to form the plurality of upper flaps.   
     
     
         24 . The system as recited in  claim 23 , further comprising:
 a folding station at the second deck level, including a folder configured to fold down the plurality of top flaps of the open container to enclose contents therein, wherein the conveyor is configured to transport the open container from the cut and crimp station to the folding station for folding down the plurality of top flaps, thereby forming the open container into a closed container.   
     
     
         25 . The system as recited in  claim 21 , further comprising a lid magazine operatively connected to the frame to feed lid blanks into the conveyor, wherein the lid magazine is at the second deck level, wherein the conveyor is configured to transfer a lid blank from the lid magazine to a lid apply station along a main feed direction, wherein the lid apply station is at the second deck level, wherein the conveyor is configured and to transfer a closed container from the folding station to the lid apply station laterally relative to the main feed direction at the second deck level. 
     
     
         26 . A method comprising:
 receiving an open container with product therein at a first deck level;   raising the open container up to a crimp and cut station at the second deck level;   forming a plurality of top flaps in the open container; and   transporting the open container from the cut and crimp station to a folding station for folding down the plurality of top flaps.   
     
     
         27 . (canceled)