US2287015A - Process and apparatus for manufacturing paper cups - Google Patents

Description

June 23, 1942. w. E. MBERG ETAL PROCESS AND APPARATUS FOR MANUFACTURING PAPER CUPSl Filed Aug. 3, 1940 I5 Sheets-Sheet 1v Julie 23, 1942.' W E, AMBER@ ETAL 2,287,015

PROCESS AND APPARATUS POR MANUFACTURING PAPER CUPS Piied Aug. s, 1940 3 sheets-sheet 2 June 23,1942. WQ'E. AMBER@- ETL 2,287,015

PROCESS AND APPARATUS FOR MANUFACTURING PAPERl CUPS 5 Sheets-Sheet' 3 Filed Aug. 3, 1940 'forming device employed R ing devices shown in Figure 1;

Patented June 23, 1942 Universal Paper Products Company, lIll., a corporation of Illinois Application August 3.1940, serial-N0.

s claims. (CL :i3-36.2)

This invention relates to a process and paratus for the manufacture of paper cups, more particularly vto a new and and improved process v and apparatus for the manufacture of cone y shaped paper cups.

One of the objects of the invention is to provide a method of manufacturing paper cups at greatly increased speeds of production.

Another object of an improved method and apparatus for making the invention is to provide trate how said terfering with one another.

cone shaped paper cups substantially without waste.

Still another object of the invention is to provide a method of making cone shaped paper cups from strip stock such as a continuous strip of paper taken from a roll wherein certain operations are carried out on the paper farv in advance of the actual formation of the cup.

Still another object vide a method and apparatus for feeding a continuous strip of paper by means of feed rolls and a take-up mechanism to a conical cup forming mandrel in facontinuous operation, wherein the cupy forming operation is assisted by partially severing, cutting or slitting opposite edges of the strip of paper in advance of the feed rolls, this being effected by rotating severing operation knives capable of rotating at varying speeds and adjustable as to timing of rotation without stopping the cup forming operation.

Still another object of the invention is to provide a new and improved method and new and, improved devices for removing the finished cup from the forming mandrel.

Another object of the invention is to provide a new and improved method and new and improved devices ing the edge of the paper strip prior to, during and after the cup forming operation.

Another object of the invention is to provide a new and improved method and new andy improved devices for forming the apex of the cone shaped cup.

Other objects and advantages of the invention will appear by referenceto the following description in Vview of the acompanying drawings, in which:

for gripping, holding and releas.

Chicago,

Figure 3 is a detailed view taken along the line .3--3 of Figure 1;

Figure 4 is-an end view of the apparatus shown in'Figures 1 and 2; v

Figure 5 is an end view similar to Figure 4 showing only the tucking mechanism, the creasing mechanism and the forming cone to illus'- mechanisms operate without insimilar to Figof certain parts omitted Figure 6 is a partial plan view ure 2 showing a changed position of the apparatus with other parts being for clearness; vFigure y'7 is a diagrammatic view showing how the creaser operates above and below the top sur-4 face of the bottom plate..

Referring to Figure 1, it will be seen that a strip of paper .A is fed from aroll 2 through a of the invention is to prol.

Figure 1 represents partly-in section an elevaforming method and cup to accomplish the ob'- tional view of a cupv jects of this invention;

Figure 2 is a plan view with parts broken away and with some lparts rem`oved ofthe cup formgear 381s pair of feed rolls 4 and a take-up mechanism 8 to a forming mandrel 8. The paper is supported on a bottom plate I8. A knife edge I2 is provided on mandrel 8 which cooperates with a knife blade Il beneath the paper' strip A.

The apex of the conical forming mandrel is at point I8. In the full line position shown in Figure 1` the mandrel is in discharge position, that is to say, a` cup has been formed and has just been discharged or is about to be discharged. In the dotted line position shownin Figure 1 the mandrel is in the vprocess of forming the cup 'by rolling over the unsevered end of the strip and simultaneously severing the strip as the cup is formed in a single severing operation.

The mandrel 8 is rotated about its o wn axis I8 by means of a shaft 20 driven from any suitable source of power. At the same time, the mandrel 8 rotates in an orbit generally shown at B in Figure 2 around the apex point I6 which is also the center of the orbit. This rotation may be effected in any suitable manner, for example, bymeans of a gear 22 on shaft 20 engaging a gear 2l on shaft 26,which in turn is fixed to a gear 28 engaging a larger gear 30. The latter stationary and is aixed to vertical spindle, 34 so that in effect the gear 28 runs around it or uses it as a track. The entire mandrel assembly is supported by a casting 32 which revolves around the' stationary spindle 34. The vertical spindle 8l is held in a stationary bolt head 36. c

The entire mandrel assembly, including casting, is rotated in an orbital path from the main drive shaft 88 connected to a suitable source of power,. not shown, and supported by means of the stationary bolt head I8. The drive shaft 38 is connected through a gear 48 to gear 48, which is fixed to the casting 82 so that as gear 48 rotates it causes gear 42 ,and at the same time casting 32 to rotate in an orbital path. The gear 30 being fixed to vertical spindle 84 is stationary` VIl() aiixed a housing upon which is mounted a rotatable wheel 44. It will be observed that the wheel 44, hereinafter referred to as the discharge wheel or kick-olf roll, occupies a position oir-center with respect to a line drawn through the center of the mandrel orbit and that its position is relatively fixed. Whenthe mandrel is in discharge position, `as shown in full lines in Figure 1, the vcompleted cup thereon is brought against the rapidly rotating wheel 44 and is thereby discharged into a chute 46 mounted in the general position shown in Figure 1 below the' plane of advance of the paper strip and olf-center with respect to the apex of the conical cup.

The rotation of the casting 82 also causes the rotation of discharge wheel 44. 'I'his is accomplished` by means of an internal gear48 which is aiiixed to the casting 32 and engages an idler gear 48 engaging with a gear 50, which-in turn drives shaft 52 fixed to a miter gear 54, the latter engaging with anothe: miter gear 56 afiixed to the kick-off roll 44.

With the point 66 coincides with the point I6 thev paper is in cup forming position. At the same time, the transverse cuts C and C1 intersect the mandrel orbit B. At this point the dog 6l! on 1 mandrel -8 is open but as soon as 'it arrives opposite the edge 68 of the paper, the arrangement of the mutilated gear assembly 64 causes the dog 68 to close on edge 68. The gripping means or dog 60 continues to remain closed until such time as the paper is wound tightly enough on the mandrel to permit the dog to be released. The winding of the cup begins before thestrip is severed.

As the mandrel continues to roll in its orbit, the strip is severed causing a small triangularly shaped piece of paper to be cutout along the line ofcut C. '-A' similar piece of paper is cut out at the end ofthe severing operation along the line of cut C1. These cut out pieces are defined4 in part by the cuts C and C1. in part by the sides of the strip, and in part bythe mandrel orbit or the orbit of the cutting knife on the mandrel.

The purpose of .the small triangularly Ishaped cut out-portions is to facilitate the advance of the edge of the strip into the opening permitted by the dog 68 in mandrel 8, and also to prevent the presence of sharp edges within the interior of the cup or on the outside thereof. It will be appreciated that these cuts C and C1 might be made in the strip by clipper knives actuated by V the rotation of the mandrel or by some other It is an important feature of the present in-- vention that the discharge wheel or kick-off roll 44 occupies a relatively fixed position, which is off-center with respect to a line drawn vertically through the center point I6 of the mandrel orbit and on the discharge side of the orbital path B. Thus, when the conical mandrel 8 is actually forming the cup, for instance, when it is in the dotted position, shown in Figure l, the'discharge wheel or kick-ofi' roll 44 is out of the way. As soon as the cup is formed and when the conical` mandrel moves into the discharge position, as shown in full lines in Figure 1, it moves against the kick-off` roll and since the kick-oil. roll is ro# tatingv at a relatively high rate of speed, it instantly causes the completed cup'to be discharged from the conical mandrel and tov fly into the chute 46 positioned below the forming position.

In order to keep the discharge cups from piling up at the mouth of the chute a conventional type of stackermechanism may be used, as shown,-

around shaft 82 by means of adjusting lock nuts slot in shaft 88 and is pivoted -In order to form the cup, the edge of the paper so strip is gripped by means of a dog 68 on mandrel 8 which is operated from an internal shaft 62 driven by means of a mutilated Ygear assembly 64. The mutilations in gears 64 are so arranged that the dog 68 grips the paper as soon as the point 66 corresponding to the apex point of the cup (Figure 2) coincides with the point I6, which is the center of the mandrel orbit. It will be observed from Figure 2 that while the forming mandrel 8 is in the discharge position the leading edge of the paper at point 66 has notquite reached the center of the mandrel orbit I6.

However, as the mandrel 8 continues to rotate in means. An important feature of the present invention. however, resides in the discovery that it is much more advantageous to place these knives behindthe feed rolls, that is to say, between the paper roll and the feed rolls, andto employ continuously rotating clipper knives,

As sh'own in Figure 2, the knives 18 and 12 are l rotated on shafts 14 and T6, respectively. Both mechanisms .are driven synchronously by a chain and sprocket drive from a power shaft. As il' f lustrated in Figure 2, the shaft 16 thereto a miter gear 18, which in turn engages with a miter gear 88 allixed to shaft 82. At the far end of shaft 82 is affixed another miter gear 84, which engages with a miter gear 86 freely rotatable on a fixed shaft 88. Loosely mounted on shaft 82 is a gear and sprocket assembly D comprising a miter gear 88 and a sprocket 82. This assembly is rotatedfrom a source of power, not

has affixed shown, through a chain 84 passing over sprocketV The rotation from miter gear 88 is trans-l 82. mittedto the shaft 82 through miter gear 86 and miter lgear 84. It will be observed, however, that the shaft 88 on which miter gear 86 is rotatably mounted may be moved in an arcuate path and a screw 86.l The screw 86 passes through a. at point 88,. VThe loose fit of the shaft 88 plus the 86 permits the arcuate movement of shaft 88 and the .adjustment of the shaft 88 to any desired position within certain limits merely by changing the lock nuts 81. A change in position of shaft 86 with respect to shaft/82 changes the timing at which the knife 16 rotates. The amount 'of adjustment of shaft 88 is normally relatively small, say about one-fourth to one-half pivoting of screw the dottediine position I feed to the forming mandrei.

` shown in Figure 7.

. mechanisms and lthe paper sheet.

feedingof vthe paper is continued again after the severing operation bymeans of a, take-up mechawill be appreciated` for. example, -a

nism 6, as generally shown in'Figures 1 and 2.

This mechanism moves upwardly, as shown by in Figure l, to takeup the slack in the paper, and when it is time for the paper to be fed forward again, the mechanism falls downwardly thereby causing the paper to The upward and downwardv movement of the mechanism may be accomplished in any suitable manner, for example, by means of cams, or the upward movement may be accomplished by means of cams or other suitable means, while the downward movement takes place by means of gravity. Thisis made possible by the fact that the take-up mechanism is positioned directly above the plane in which the strip of paper is fed to the forming mandrel.

lA further'important feature of this invention is illustrated in Figures 1, 2, 4, feature consists in` the use of a tucking mechanism in combination with a creasing mechanism. The tucking mechanism comprises a continuously rotating finger Hw mounted by means' of a collar |02 on aA rotating shaft IIM', which may be driven in any suitable manner. The rotation of the shaft IM is so coordinated with the movement of the paper strip A and the movement of the conical mandrel 8 that .the at bladed portion |06 of the tucking finge |00 moves between the top of the paper strip'and the exterior surface of the conical mandrel A just prior to the time that the conical mandrel passes over the edge of the strip. The rotation of this tucking mechanism therefore insures that the leading edge of the paper will be properly tucked undertheapex of the forming mandrel. downwardly slightly, as shownin Figure l, this being possible due to the fact that there isa cut out recess |08 in the bottomplate Ill, as shown in Figure 2. Hence, the paper is actually unsupported at its central point. paper cannot move ready been gripped by the mandrel.

5 and 6.. Thisv The paperfis actually bent,

Then as4 the rotation of the forming mandrel continues, a pocket ofrmaterlal is formed at the apex of the cup. The creasing blade II2 is fixed by means of rotating shaft IIS which may be rotated in any suitable manner. The rotation is carried out in synchronism with the formation of the cup so that the overlap vportion III) arrives opposite the rotating blade II2 at the time when it is to be creased.

The method of forming paper cups in accordance with the present invention may be summarized briefly as follows. Paper of the desired width vand of a suitable type for forming paper cups is fedfrom a roll 2 by means of feed rolls 4 through take-up mechanism 6 to forming mandrel 8.` As it approaches the forming mandrel it is supported by a bottom plate I0 and as it passes into the mandrel orbit B it passes over a knife edge I2 which coincides with a portion of the mandrel orbit. Mandrel 8 rotates about its own axis and also moves in an orbital path B. When the point 86., which is to form the apex of the cup, '1s directly above the point Iii,l

the edge is accomplished by means of a dog 60 which opens and closes periodicallyy in response 60 closes and grips However, the sideways because it has al-` As the mandrel continues to rll it occupies the position shown in Figure 6. In this position there is a slight overlapping of material projecting be-` yond the apex of the cup due to the the apex 66 of the cup is slightly within the leading edge of the paper. This overlapping portion of material is generally indicated by numeral III) in Figure 6. lIn order to assure tha-tja pocket of material is properly formed at' the apex -a creasing mechanism II2 is provided which rotates continuously in a plane oblique to the plane of movement of the advancing paper strip, as It will be observed that the tucking mechanism |00 alsorotates continuously in an oblique plane vso that only at one point or in one portion of their rotations do the tucking the creasing mechanisms move into the path or plane of the paper. The creasing mechanism I I2 advances overlthe. overlapped portion IIO and presses it against the -tOp side of fact lthat .due to the fact that to any suitable actuating means such as the mutilated gear assembly 64. As the mandrel 8 approaches 'the edge 68 vof the paper strip A the dog 60 is open, causing the edge 68 to pass within the opening between the dog and an associated part of the mandrel, whereupon the dogv A the edge $8 of the paper and as the mandrel 8 continues to roll in its orbital path the-paper is held tightly against it. When the cutting edge I4 of the mandrel 8 arrives at the edge of the paper strip A it immediately begins to sever with the cutting edge I2 lying beneath the paper strip. The line pf severance coincides with the mouth of the cup` which is being formed. As each edge o'f the strip is severed, small pieces are preferably cut out along the cuts C and C1.

As previously stated, cuts C and Ci are preferablyl placed in the-paper by adjustable rotating knives 10 the feed rolls l. Thesecuts intersect the line of severance of the mandrel orbit. s As soon as the conical mandrel grips the paper and' begins to wind it into a cup, the forward movement of the paper strip A necessarily ceases the paper is held between the mandrel and the bottom plate I0.` At the same time the take-up mechanism 6' lifts up in order to take up the excess tinuously being fed forward. As soon as the mandrel 8- has completed the severing Aoperation, take-up mechanism 6 falls and moves' the paper strip A forward toward the cup forming position. Y f

After the cup is severed from the end of the paper strip, the winding operation until th cup is completely formed. As the maninstantaneous discharge of the cup into the chute 'a collar Ill to a' the paper in cooperation and .12 at a point in advance of,Y

paper which is conis continued causes the immediate and i following manner.

oblique to the plane of' the paper strip A just prior to the cup forming operation. As the blade rotates it moves over and against the top of the paper strip at one point in its' rotation. `The rest of the time it is out of the path of the paper strip. The movement into contact/with the top of thepaper stripv is eiected just prior to the The unl;v m is maxed to turn is aiiixed' to a a of arms |68 and |16.

AThe arms Isa and mare mixed to s man |12,

as shown in Figure 2 and the latter in' turn is freely-connected to the take-up mechanism 6 in the manner shown in Figures 1. and 2. The front end of the take-up mechanism 6 is freely v supported'by means of a shaft |12 which in turn time that the conical mandrel passes over the leading edge of the strip. The movement of the blade |00, therefore, insures that the paper will be properly tucked under the apex of the forming mandrel. Actually in the modification shown in the drawings, the paper is not supported at the apex point, because there is a cut out recess |08 in the bottom pla I0 at this point. After the paper has been t cked beneath the end of the mandrel and has been Wound on the mandrel, an overlapping pbrtion'of material is formed adjacent the apex point of the cup. In order to assure that this overlapping portion is properly enclosed within the side Walls of the cup,A a creasing mechanism ||2 is provided which also rotates continuously a plane oblique to the plane of movement of he advancing paper strip. Ihe

creasing mechanism I|2 advances over the overlap portion H0 and presses it against the top side of the paper sheet. In this way a pocket of material is formed accurately and rapidly at the apex of the cup.

It will be understood that many variations may be made in themethod and apparatus described without departing from the invention. The' instrumentalities for driving the various parts of the apparatus have. not been shown because many different typesv of driving mechanisms may be employed, and anyone skilled in the art could construct the apparatus from the embodiments thereof shown herein.

The drive mechanisms for the various parts of the apparatus may-be described as follows.

The source of driving power is a motor con.- nected through a driving shaft, not shown, to a gear |22, the latter in turn being connected to a gear |24 fixed to shaft 38. `'I'he manner in which shaft 38 drives the cup forming assembly through gears 40 and 42 has already been de scribed.

Aixed to shaft 36 is a bevel gear |26 which drives a bevel gear |28 aixed to shaft |30, as shown in Figure 4. Aflixed to the other end of shaft |30 is a bevel gear |32 Awhich drives a bevel gear |34 fixed to shaft |36.

A gear |38 aiilxed to shaft |36 drives an idler gear |40 which in turn drives a gear |42 affixed to shaft |44. Shaft |44 drives the upper feed roll 4. Also xed on shaft |44 is a gear |46 which drives a gear |48, which in turn drives the lower feed roll 4as shown in Figure 1. It will be observed from Figure 2 that the shaft |44 is conventionally mounted in a pair of bear- -mounted on the main shaft |36.

is supported by a pairoi.' arms |14 and |16, freely The arm reciprocates causing the link |62 to reciprocate and thereby causing the shaft |66 to oscillate. As a result the-tak-up mechanism 6 is oscillated. In this way the paper is fed continuously through the feed rolls and the excess is taken up intermittently by the take-up mechanism 6.

The timing mechanism, which has previously been described, is operated from the shaft |36 by means of a sprocket |16 connected to chain 84.

Thelcreasing mechanism is driven in the following manner. A sprocket |66 aiiixed to shaft |36 drives a chain |82, whichin turn drives a double sprocket assembly |64 fixed on a shaft |66. The shaft |66 is also amxed to a bevel gear v88, which drives another bevel gear |90 affixed o a shaft ||6. 'Ihe shaft H6 drives the creasing V irechanism ||4 in the .manner previously described. One part of the double sprocket |64 is The tucking mechanism is driven from the shaft |04 in the manner previously described.

The stacking mechanism is operated in the following manner. An arm 202 is afllxed to shaft |86 and is rotated thereby causing the reciprocation of a con'necting link 204 which is freely connected to a second -arm 206, as shown in Figure 4. The arm 206 is xed to a shaft 208 and the shaft 206 in turn is fixed to the stacker mechanism 58. When the arm 206 is reciprocated the shaft 208 is oscillated causing the stacker 58 to reciprocate, thereby in turn causing the finished cups to be discharged into the chute 46 as they come off of the forming mandrel.

It will be understood that any suitable type of gluing mechanism may be employed in forming cupsin accordance with this invention. Ordinarily it is preferableto apply the glue between v a way, or the feed rolls 4 must be arranged in ings |50 `and |52 and that the shaft- |36 is such a way, that the glue does not come into contact with the feed rolls.

vThe invention is not limited to the formation of the particular type of cup illustrated herein. It may be employed in other cup making methods and in other cup making devices, particularly in those methods and devices in which the cup is formed from a continuous strip of paper. For

some purposes it may be desirable to omit certain parts of the apparatus, as, for instance, the rotating knives 10 and 12. The tucking and creasing mechanisms may be employed in making any type of paper cup in which there is a pocket of material at the apex, regardless of the manner in which the paper strip is fed to the forming mandrel. These mechanisms are parfor example, in excess of five cups per second per single mandrel or forming head.

Having thus described the invention, what we claim as new and desire to secure by Letters Patent of the United States is: y

l. A method of forming cone shaped paper cups which comprises continuously unwinding a strip of paper from a roll, continuously feeding said strip of paper with the aid of a feeding means to a forming mandrel and partially severing a marginal area of said paper strip substantially transversely by applying thereto a continuously rotating cutting force rotating about an axis running generally lengthwise with respect to the path of movement of the strip.

2. A method of forming cone shaped paper cups which comprises supplying a strip of paper to a forming mandrel, lwinding said strip on said mandrel and tucking the apex point of the cup under the apex point of the mandrel during the winding operation by a rotating force rotating in a plane oblique to the path of movement of said strip.

3. A method of vforming cone shaped paper cups which comprises forming a paper cup by winding a strip of paper on a mandrel, tucking the apex point of the cup under the apex point of the mandrel during the initial steps of the winding operation by applying a rotating force in a plane oblique to the paper strip and thereafter creasing a portion of lthe paper adjacent the apex point of the cup by applying another rotatihg force rotating in a plane oblique to the paper s rip.

4. A method of forming cone shaped paper cups which comprises advancing a strip of paper from a roll to a forming mandrel in such a manner that the point which is to form the apex of the cup is substantially unsupported, winding said strip on said mandrel and tucking the unsupported portion beneath the apex point of the mandrel when the cup is partially wound by applying thereto a frotating force rotating in a plane oblique to the path of the advancing strip of paper.

5. In an apparatus for ma? 4ng conical paper cups, feeding means arranget'. to feed a strip of paper stock from a roll of paper, forming means to form said strip of paper stock into a cone shaped paper cup, and a rotating knife positioned to one side of said strip and adapted to partially sever said strip transversely at a point between said paper roll and said feeding means.

6. In an apparatus for making paper cups, lmeans for feeding a strip of paper stock to a cup forming position, means for partially severing said paper stock before it reaches said cup forming position, said means comprising a rotating knife, and means for adjusting the timing of said knife rotation while said knife is rotating.

7. In an apparatus for making conical paper cups, a forming mandrel for winding a strip of paper into a cup, a tucking mechanism for tucking the apex point of the strip under the apexpoint of the forming mandrel, and a creasing mechanism for thereafter creasing a portion of the paper adjacent the apex point.

8. In an apparatus for making conical paper CUPS. paper into a cup, and a tucking mechanism for tucking the apex point of the paper under the apex point of the mandrel during an intermediate stage of the winding operationr 9. In an apparatus for making conical paper cups, means for feeding a strip of paper stock from a roll of paper to a conical forming mandrel including feed rolls and a take-up mechanism, a rotating knife on each side of said strip of paper between said roll of paper and said feed rolls to partially sever the edgesof said strip, a

supporting plate beneath said strip of paper adjacent the paper cup forming position, means for moving said forming mandrel about its own axis while simultaneously rotating it in an orbital path, aportion of said orbital path being above said supporting plate, a non-supporting area in said supporting plate adjacent the center of said orbital path, means to cause said forming mandrel to grip an edge of said paper strip when the point which is to form the apex of the c up substantially coincides with the center point of said orbital path, a tucking mechanism to tuck a forward edge of said strip adjacent the apex point of the cup beneath the apex point of said mandrel, said tucking mechanism comprising a rotating member rotating in a plane oblique to the plane in which the paper. strip stock is being advanced, a discharge roll occupying a substantially xed position olf-center with respect to the center of the orbital path of the forming cone, means for rotating said roll, the position I of said roll being such that at a predetermined point in its orbital path after the paper has been wound into a completed cup the forming mandrel bearing the completed cup will bring the exterior surface of the cup into contact with said rotating roll thereby causing said paper cup to be dischargedto a position below the plane of the advancing strip ofpaper, and a chutel off-center with respect to the apex of the cup while it is on the forming mandrel to catch the completed cup when itis discharged.

WALTER E. AMBERG. S'I'EPHEN W. AMBERG.

a forming mandrel for winding a strip of

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