WO2001025095A2

WO2001025095A2 - Automated apparatus for forming one-piece, thin, flat boxes

Info

Publication number: WO2001025095A2
Application number: PCT/US2000/027341
Authority: WO
Inventors: Dale E. Lorree; Anthony J. Grace; Peter Guttinger; Ylli Yryku
Original assignee: Avery Dennison Corporation
Priority date: 1999-10-04
Filing date: 2000-10-04
Publication date: 2001-04-12
Also published as: WO2001025095A3; AU7992700A

Abstract

A multi-station box forming apparatus is provided, with box blanks (58) being successively stored at an input station, having the sides of the base and the integral lid pre-broken beyond normal orientation with rollers at the next successive stations, gluing and forming the lid at the next station (64), and finally gluing and forming the base at the next successive station (92), with the lid portion being movably mounted to accommodate the formation and configuration of the box section intermediate the base and lid portions of the box. By fully pre-breaking the blanks to arrange beyond their final orientation, and by allowing relative movement of the lid and base during the final box formation step (119), the special shallow boxes may be automatically formed in one piece, instead of the conventional two- part boxes.

Description

AUTOMATED APPARATUS FOR FORMING ONE-PIECE. THIN. FLAT BOXES

RELATED PATENTS

Reference is made to U S Patent No. 5.878.554 granted March 19, 1999, the disclosure of which is hereby incorporated by reference into the present specification

FIELD OF THE INVENTION This invention relates to the formation of thin. flat, one-piece boxes

BACKGROUND OF THE INVENTION.

There are many known apparatus for forming one-piece boxes, and these are principally applicable to normal types of boxes where the height, length and width of the boxes are generally comparable to each other However, in the case of very flat boxes such as those for packaging sheets of labels or other sheet products, it has been customary to form the boxes m two separate parts, l e., a mam bottom or base portion and a separate lid. instead of forming the box as a single unit with the lid folding down to close the box It is understood that one reason for the use of boxes formed m two separate parts, and the failure to make one-piece boxes is the difficulty of automatically manufacturing boxes which are unusually thm and flat In this regard, it is noted that two of the present inventors approached some major box forming equipment manufacturers, and they declined interest making apparatus which would make the one-piece flat boxes of the type disclosed in this specification For a peπod of time, therefore, the flat, thm boxes continued to be made m two separate parts with a separate base and a separate lid, despite the desirability of having a one-piece box for convenience in automated sheet loading and packaging ςτ τ MAT Y OF THE INVENTION

Accordingly, there has been a long-felt need for apparatus for making one-piece, thm, flat boxes for holding sheets of labels or other similar sheet products

In accordance with the present invention, a multi-station box forming apparatus is provided, with box blanks being successively (1) stored at an input station, (2) having the sides of the base and the integral lid pre-broken beyond normal oπentation with rollers at the next successive stations, (3) gluing and forming the lid at the next station, and (4) finally gluing and forming the base at the next successive station, with the lid portion being movably mounted to accommodate the formation and configuration of the box section intermediate the base and lid portions of the box By fully pre-breakmg the blanks to arrange beyond their final oπentation. and b) allowing relative movement of the lid and base duπng the final box formation step, the special shallow boxes may be automatically formed m one piece, instead of the conventional two-part boxes

As another aspect of the invention, the box blanks are picked up and concurrently moved from station to station, by the use of a "walking beam" assembly, which cames several sets of box-holding vacuum heads to concurrently engage the box blanks and the partially formed boxes The '"walking beam" assembly shifts m position both vertically and horizontal!) . with several boxes m various stages of formation being concurrently moved from station to station Several sets of vacuum heads are also provided to hold the partially formed boxes m position as the walking beam shifts toward the rear of the assembly line, to pick up nev, blanks and move partially formed boxes forward

Preferably, the box blanks are pre-scored along the eventual box fold lines, to facilitate subsequent permanent configuπng of the boxes to their final shape

In accordance with a feature of tne invention, as the walking beam moves forv, ard ana down, carrying the partially formeα boxes, a number of steps are accomplished at the successive stations, with (1 ) pre-breakmg or bending of the sides of the box has and bases occurring at early stations, and (2) gluing and "plunging" the lids and bases to their final shape at subsequent stations of the apparatus, and with the final formation of the one- oiece boxes invo mg relative movement of the lid and base as tne intermediate panel Betw een the hd and base is glued and the box base is "plunged" into .is final configuration In this last step, a movable guide member preferably engages the panel loimng the lid and the base of the box and moves or pivots to force this panel into its proper vertical oπentation as the base of the box is glued into its final configuration

Other objects, features and advantages of the mvention will become apparent from a consideration of the following detailed descπption and from the accompanying drawings

BRTEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a thm. flat, one-piece box which has been formed using the apparatus which will be disclosed m detail m subsequent figures of the drawings.

FIG 2 is a cross-sectional view showing the construction of a preferred embodiment of the walls of the box of FIG 1 ,

FIG 3 shows a box blank which has been pre-scored and cut to the desired dimensions for formation into the box of FIG 1 ,

FIG 4A is a schematic perspective overall view of an apparatus for forming thm, flat, one-piece boxes of the type shown m FIG 1, and illustrates the pπnciples of the invention,

FIG 4B is a diagrammatic showing of a walking beam, which shifts the partially formeα cartons from station to station in the course of the successive steps leading tow ard the completed box as shown m FIG 1,

FIG 5A shows the shape of the box blank following pre-breakmg of the sides which occurs m the first box formation station of the apparatus of FIG 4A,

FIGS 5B through 5F show the details whereby the oπginal box blank as shown m FIG 3 is formed into the configuration shown m FIG 5A.

FIGS 6A through 6F show hov. the box blanks have their end flaps pre-broken as the next successive step m the transformation of the box blank of FIG 3 into the completed box of FIG 1.

FIGS 7A through 7D show the next successive step in the box formation invoh mg the gluing and formation of the lid portion of the one-piece box FIGS. 8 A through 8C show the final step in the box formation involving the gluing and final formation of the box base, with arrangements for holding the box lid and permitting its movement as the box base is formed; and

FIG. 9 is an end view looking along the length of the box formation apparatus and showing the walking beam in its raised position.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Referring more particularly to the drawings, FIGS. 1, 2 and 3 show a thm one- piece box 12 having a base portion 14 and an integral lid portion 16 which is pivotally coupled to the base 14 along the fold line 18

FIG. 3 shows the blank 20 for forming the box 12 of FIG. 1. with the pre-score lines 22 being provided in the blank 20 in order to facilitate the formation of the completed box. Shown in FIG. 3 is the area 14' which will become the main poπion of the base 14, and the lid portion 16' which will become the main portion of the lid Associated with the base poπion 14' are the sides 24 and the end poπion 26. In addition, the inner wall 28 will complete the base of the box. and it is by this wall 28 that the lid 16 is attached to the base. The sides 30 and the end poπion 32 are secured to the central poπion 16 which will form the lid of the box. The four tabs 34 are secured to the sides 24 and to the end poπion 26 of the base, preferably by hot melt glue. Similarly, the tabs 36 are glued to the end wall 32 of the lid 16'. to complete the lid of the box which may later be folded down over the base.

FIG. 2 is a cross-sectional view showing one preferred construction for the walls and the top and bottom of the box The construction could include an upper layer 40, a lower layer 42. and a corrugated intermediate layer 44 which is glued to the top and bottom layers.

The box walls may be less than 1/16-mch thick and may include the three layers 40, 42 and *****4. as shown m FIG 2 With this construction, scoπng and pre-breakmg functions are preferably involved, as disclosed herembelow. to facilitate the steps of forming the boxes, so that the resultant box will maintain its fullv formed configuration without any of the sides bowing out or otherwise departing from the desired rectilinear configuration It may also be noted that the boxes may be formed of plastic (corrugated or non-corrugated), or of solid fiberboard, instead of the FIG. 2 construction In addition, instead of hot melt glue, the boxes may be held together using water-based cold glue, pressure sensitive adhesive or staples; or for plastic boxes. RF sealing or some welding, or heat sealing may be employed

The box 12 is pπmaπly intended to hold a limited number of sheets of labels, or other similar products, which usually have a size of approximately 8Vι inches by 1 1 inches, or are sized as A-4 paper, having similar dimensions of approximately 8' inches by 1 1-1 1/16 inches Accordingly, the boxes are less than 9 inches by 12 inches m size, and less than one inch or l 'Λ inches m height It is fuHher noted that dεpaπures from these dimensions to accommodate special needs are to be expected with variations of several inches m length and width, and thicknesses up to I i or 2 inches being contemplated However, m the present specification and claims, when reference is made to thm. flat, one-piece boxes, it is understood that boxes of the type descπbed heremabove are intended, and that the width and length of the boxes are at least several times, and preferably at least five times the thickness of the boxes

The remainder of the detailed descπption in the specification will be directed to the apparatus for forming the thm. flat, one-piece boxes of the type descπbed heremabove m connection w ith FIGS 1-3

Now, turning to FIGS 4A and 4B. the apparatus for forming the boxes includes a "walking Deam' 52 which shifts m position as indicated by the lines 54 and 56 to shift the paπially formed boxes from one station to the next successive station Thus for example, a stack 58 of blanks is initially engaged b> the vacuum heads 60 mounted on the head 62 suppoπed by the w alking beam 52 Then the blank is raised as indicated by the line 5^. shifted over to tne next station 6- where it is held by the vacuum cups 66 Concurrenth with the smfting of the blanks from the stack 58 of box oianks, the partially formed boxes are shifted from one box forming station to the next successive box forming station In this regard in addition to the first vacuum head 62 mounted on the w alking beam assemb 52 there are three adαiuonal vacuum heads 72 74 and 76 mounted on and supported by the walking beam 52 which are moved in the same manner as indicated bylines 54 and 56 in FIG. 4B, to shift the partially formed boxes from station to station. Of course, the course of shifting the partially formed boxes from station to station, the vacuum heads on the movable fixtures on the walking beam and at the successive stations are turned on and off as needed to hold and shift the boxes.

Now, proceeding to FIGS. 5 A through 5F, the box forming steps which occur at the first station will be considered. First, FIG. 5A shows the pre -breaking of the side walls 24, 30. 34 and 36 which will occur at this first box forming station. FIG. 5B shows the spring-loaded fixture 64 with a series of pivotally mounted rollers 82 The action of the rollers in pre-breakmg the sides of the box is best shown in FIGS. 5D. 5E. and 5F. With the movable vacuum head fixture secured to the walking beam shown schematically at 72 m FIG. 5D, the blank is held on the bottom of this fixture 72, with the edges extending out beyond the pointed sides of the fixture 72. As shown in FIGS. 5E and 5F, as the fixture 72 approaches the spring-loaded platform 65 forming part of the assembly 64, the vacuum head fixture 72 presses downwardly so that the rollers 82 will deform the sides 24. 30. 34 and 36 at an acute angle over the vacuum fixture 72 so that they are bent toward and beyond the vertical m preparation for the final formation of the box. FIG. 5C is a side view showing the rollers 82. with the spπng-loaded platform 65 being concealed m this view. The next station to which the partially formed box is transported by the walking beam 52 is shown in FIGS. 6A through 6F. The mode of operation at this station is very similar to that at the station described in connection with FIGS. 5A through 5F. with the exception that it is the ends 26 and 32 of the box that are being subject to pre-breakmg instead of the sides. In FIG. 6B, the spring-loaded platform 92 is shown with the accompanying vacuum nozzles 60 for retaining the partially formed box in place The vacuum fixture 94 is mounted on the walking beam, and brings the partially formed box to this station The rollers 96 are mounted at the ends of the box holding arrangements, and at the end of the spπng loaded table 92. so that when the vacuum fixture 94 pushes the box downward and compresses the spπngs holding the platform 92 at the upper level. the rollers 96 pre-break the ends of the box. with FIG 6F showing the mechanical construction, and FIG. 6A showing the resultant formation of the box. FIG 6E is a side view showing the rollers 96, at least partially concealing the platform 92. but still showing the vacuum nozzles 60

The next station of the apparatus is shown in FIGS. 7A through 7D, with the resultant paπially formed box being shown m FIG. 7A, with the sides of the lid having been glued into position. FIG 7B shows the platform 102 with the usual vacuum holding nozzles 60 As the paπially formed canon is lowered toward the platform 102, hot melt glue is applied to the tabs 36. The lid poπion of the box is then forced downwardly and plunged into the restricted space between the walls 104 and the end wall 106 where the previously -applied hot melt glue firmly secures the tabs 36 to the lid poπion 32 to complete the formation of the lid

FIGS 8A through 8C show the final step m completing the formation of the box In this station, as the walking beam bnngs the paπially formed box down, the tabs are initially spotted with glue by the glue applicators 114, and then the base is plunged onto the platform 116 down between the walls 118 where the box formation is completed As the partially formed box is being brought down by the walking beam, the pivoting guide member 1 19 (see FIG 8C) has a guide surface 121 which is substantially coextensive with and which engages panel 28 (see FIG 8A) Then, as the base of the box is plunged downward toward base 116, between guide walls 1 18. the guide 119 rotates clockwise as shown m FIG 8C and the guide surface 121 forces the panel 28 into its desired veπical oπentation relative to base 14 of the box. as the final box configuration is obtained

Following completion of the box as noted above, the box is shifted from the station shown in FIGS 8A-8C, while the wa mg beam is advancing an additional set of paπially formed boxes This can be accomplished either by an extended poπion of the walking beam, or by a synchronized additional apparatus

Refemng now to FIG 9 of the drawings, it is an end view of the apparatus taken in the direction of the first station where the pre-break rollers 82 deform the sides of the box blanks (see FIGS 5A and 5C) In FIG 9. the walking beam frame 122 provides the mam suppoπ for the walking beam assembly 52, which includes a mam movable supporting member 124, and several outwardly extending tubular members 126 to which the movable vacuum heads, such as the box carrying vacuum head 72 are secured

As mentioned above, the walking beam assembly 52 follows the paths shown at reference numerals 54 and 56 m FIG 4B of the drawings This movement, involving both hoπzontal and vertical directions, may be accomphshed by any of a number of alternative mechanical mechanisms For example, a mam hoπzontally movable carnage may have a vertically movable sub-camage to which the walking beam is secured, and by shifting the two carnages honzontally and vertically by hydraulic and/or pneumatic cylinders, the desired movement may be provided In addition, the movement may be accomplished by a senes of belts and pulleys, and one such mechanical arrangement may be purchased from Langen Packaging. Inc , 6154 Kestrel Road, Mississauga, Ontano L5T 1Z2. Canada Incidentally , pneumatic arrangements, including the pneumatic cylinder 123, may be provided to offset the weight of the walking beam assembly, and to permit easier movement thereof In closing, it is understood that the foregoing detailed descnption and accompanying drawings relate to one illustrative preferred embodiment of the invention It is to be understood, however, that vaπous modifications and alternative constructions mav be employed without departing from tne spmt and scope of the in ention Thus, by way of example and not of limitation, the partially formed boxes may be moved from station to station by separate syncnronized mechanisms, instead of by the walking beam the pre-breakmg of the siαes could be accomplished m a single station or in four stations pre-breakmg may be accomplished by movable or pivoting flat forming members rather than by rollers, clamps may be employed instead of vacuum heads to hold the boxes, and other similar mechanical vanations in accomplishing the desired result may be employed Accordingly, the present invention is not limited to the precise arrangements show n in the drawings and descπbed in detail heremabove

Claims

1 An apparatus for forming thm, flat, one-piece boxes including box bases and integral box lids, compnsmg a supply of scored blanks for forming thm. flat, one-piece boxes including a lid and a base with associated sides and ends, a plurality of successive box forming stations; a walking beam, having a plurality of sets of vacuum heads mounted thereon, for raising said box blanks and partially formed boxes from said stations and for loweπng or plunging the boxes down at the next successive station, a first one of said stations including a spnng mounted platform and rollers which roll over and pre-break the sides of said boxes as said boxes are plunged down at said first station, and another of said stations including a glue dispenser for applying glue to selected areas of said paπially formed boxes as said boxes are plunged down and said station fuπher including walls for onentmg said sides of said boxes to the desired final configuration following the application of glue

2 .An apparatus as defined m Claim 1 wherein the lids of said boxes are glued and formed at one intermediate station, and the bases of said boxes are glued and formed at a subsequent station, and wherein at said subsequent station, each said base is held by a set of vacuum heads and each said lid is mounted to be movable relative to said base, to accommodate reduction m spacing between said lid and said base as said base is glued and formed into its final configuration

3 An apparatus as defined m Claim 2 wherein said thm. flat one-piece boxes have a rear side of said base to which said lids are secured, and wherein a movable guide member is provided to engage said rear side as said box base is mov ing downward, and hold said rear side perpendicular to the onentation of said base as the box base configuration is finalized

4 An apparatus as defined in Claim 3 wherein said guide member is pivoted to move from an angle relative to the vertical where it is engaged by the box to a vertical onentation when said box base is plunged down to its final formation location

5 An apparatus as defined m Claim 1 wherein at said first station, the vacuum heads are mounted on a fixture having outer edges formed at an acute angle to the plane of the boxes, whereby when the rollers engage the sides of the boxes for pre- breakmg, the sides of the boxes are bent beyond the vertical to form an acute angle relative to the mam plane of the boxes

6 An apparatus as defined m Claim 1 wherein said box blanks have a first set of edges which extend parallel to one another and which will form sides of said lids and bases of said boxes, and a second set of edges which are perpendicular to said first set. which will form the remaining sides of said boxes, and said apparatus has first and second stations, and wherein said first and second sets of edges are pre-broken at said first and second stations, respectively

7 .An apparatus for forming thin, fiat one-piece boxes, including box bases and integral box lids, compnsmg a supply of scored blanks for forming thm flat, one-piece boxes including a lid and a base with associated sides and ends a plurality of successive box forming stations, a walking beam, having a plurality of sets of vacuum heads mounted thereon, for raising said box blanics and partially formed boxes from said stations and for lowenng or plunging the boxes down at the next successive station a first one of said stations including a spnng mounted platform and pre- breakmg mechanisms for pre-breakmg the sides of said boxes as said boxes are plunged down at said first station, another of said stations including a glue dispenser for applying glue to selected areas of said partially formed boxes as said boxes are plunged down and said station further including walls for oπentmg said sides of said boxes to the desired final configuration following the application of glue, and the lids of said boxes being glued and formed at one intermediate station, and the bases of said boxes bemg glued and formed at a subsequent station, wherein at said subsequent station, each said base is held by a set of vacuum heads and each said lid is mounted to be movable relative to said base, to accommodate reduction spacing between said lid and said base as said base is glued and formed into its final configuration

8 An apparatus as defined Claim 7 wherein said thm, flat, one-piece boxes hav e a rear side of said base to which said lids are secured, and wherein a movable guide member is provided to engage said rear side as said box base is moving downward, and hold said rear side perpendicular to the oπentation of said base as the box base configuration is finalized

9 An apparatus as defined m Claim 8 wherein said guide member is pivoted to move from an angle relative to the vertical where it is engaged by the box to a vertical oπentation when said box base is plunged down to its final formation location

10 An apparatus as defined Claim 7 wherein at said first station the vacuum heads are mounted on a fixture having outer edges formed at an acute angle to the plane of the boxes, whereby when the rollers engage the sides of the boxes for pre- breaking, the sides of the boxes are bent beyond the vertical to form an acute angle relative to the mam plane of the boxes

1 1 An apparatus as defined Claim 7 wherein said box blanks have a first set of edges w nich extend parallel to one another and which w ill form sides of said lids and boxes and a second set of edges wnich are perpendicular to said first set and saiα apparatus has first and second stations, and wherein said first and second sets of edges are pre-broken at said first and second stations, respectively

12. An apparatus for the forming of shallow one-piece boxes where the hd is integral with the base of the boxes, compnsmg: a plurality of flat blanks wherein the blanks include a first poπion for forming the bottom of the box, four additional bottom narrow sections for forming the sides of the bottom of the box, tabs for secuπng the sides peφendicular to the bottom of the box, a top portion for forming the top of the box, three top narrow sections for forming sides of the top of the box. said top nanow sections being comparable m size to said bottom nano sections to overlap them, and tabs for holding said three top nanow sections peφendicular to said top portion, a plurality of box forming stations, including.

(a) a first station for stonng said box blanks; (b) second and third stations for the pre-break bending of said nanow sections of said blank which will form the sides and ends of the box, said stations both including rollers which engage the sides of said boxes and bend the sides to an acute angle configuration as the boxes are forced down past said rollers,

(c) a fourth station for forming said lids and gluing the tabs to hold the sides and end of said hd m the final position peφendicular to the top poπion of the blank, and

(d) a fifth station for forming said hd and glumg tabs to hold the two sides and the two ends of said bottom poπion of said box m position, said fourth station also including anangements for guiding said hd while permitting said hd limited movement tow ard said bottom poπion of said box as the box ends are being formed, and walking beam transfer anangements for concunently shifting blanks and paπially formed boxes from each station to tne next successive station,

13 An apparatus as defined in Claim 12 wherein said apparatus includes transfer anangements moving substantially eπically to pick up said blanks at said firs' station and form said blanks at said second, third, fouπh and fifth stations, to shift said blanks partially formed boxes substantially honzontally from station to station, and to plunge said boxes down at successive stations

14 A system as defined in Claim 12 wherein said first and second stations include an angled support for said hd blanks and inwardly biased rollers wherein said rollers force said nanow sections of the wall through an angle greater than 90 degrees to prepare the box section

15 A system for the forming of shallow one-piece boxes where the hd is integral with the base of the boxes, compnsmg a plurality of flat blanks wherein the blanks include a first portion for forming the bottom of the box, four additional bottom nanow sections for forming the sides of the bottom of the box. tabs for secunng the sides peφendicular to the bottom of the box, a top portion for forming the top of the box, three top nanow sections for forming sides of the top of the box, said top nanow sections being comparable in size to said bottom nanow sections to overlap them, and tabs for holding said three top nanow sections peφendicular to said top portion, a plurality of conveyor stations, including (a) a first station for stonng said box blanks,

(b) second and third stations for the pre-break bending of said nanow sections of said blank which will form the sides and ends of the box, said stations both including rollers which engage the sides of said boxes and bend the sides to an acute angle configuration as the boxes are forced down past said rollers (c) a fouπh station for forming said lids and glumg the tabs to hold the sides and end of said hd m the final position peφεndicular to the top poπion of the blank, and

(d) a fifth station for forming said hd and glumg tabs to hold the two sides and the two ends of said bottom poπion of said box m position, said fouπh station also including anangements for guiding said hd while permitting said d limited movement toward said bottom poπion of said box as the box ends are being formed; and transfer arrangements for concunently shifting blanks and partially formed boxes from each station to the next successive station;

16. A system as defined in Claim 15 wherein said system includes transfer anangements moving substantially vertically to pick up said blanks at said first station and form said blanks at said second, third, fouπh and fifth stations, to shift said blanks partially formed boxes substantially honzontally from station to station, and to plunge said boxεs down at successive stations.

17. A system for the forming of shallow one-piece boxes where the lid is integral with the base of the boxes, comprising: a plurality of flat blanks wherein the blanks include a first portion for forming the bottom of the box, four additional bottom nanow sections for forming the sides of the bottom of the box. tabs for securing the sides peφendicular to the bottom of the box, a top portion for forming the top of the box, three top narrow sections for forming sides of the top of the box, said top nanow sections being comparable m size to said bottom nanow sections to overlap them, and tabs for holding said three top nano sections pεφεndicular to said top poπion. a plurality of conveyor stations, including

(a) a first station for stonng said box blanks.

(b) second and third stations for the pre-break bending of said nanow sections of said blank which will form the sides and ends of tne box. said stations both including rollers which engage the sides of said boxes and bend the sides to an acute angle configuration as thε boxεs are forced down past said rollers.

(c) a fouπh station for forming said lids and glu g the tabs to hold thε sides and end of said hd in thε final position peφεndicular to the top poπion of tne blank, and (d) a fifth station for forming said hd and glumg tabs to hold the two sides and the two ends of said bottom portion of said box in position, said fourth station also including anangements for guiding said hd while permitting said hd limited movement toward said bottom portion of said box as the box ends are being formed, and transfer anangements for concunently shifting blanks and partially formed boxes from each station to the next successive station, said transfer anangements moving substantially vertically to pick up said blanks at said first station and form said blanks at said second, third, fourth and fifth stations, to shift said blanks partially formed boxes substantially honzontally from station to station, and to plunge said boxes down at successive stations

18 An apparatus for forming thm. flat, one-piece boxes, including box bases and integral box lids, compnsmg a supply of scored blanks for forming thin, flat, one-piece boxes including a hd and a base with associated sides and ends, a plurality of successive box forming stations, mechanical transfer anangements for raising said box blanks and partially formed boxes from said stations and for lo enng or plunging the boxes down at the next successive station the lids of said boxes being glued and formed at one intermediate station the bases of said boxes being glued and formed at a subsequent station, wherein at said subsequent station, each said base is held m place and each said lid is mounted to be movable relative to said base to accommodate reduction in spacing between said hd and said base as said base is glued and formed into its final configuration, and said thm flat one-piece boxes having a rear side of said base to which said lids are secured and wherein a movablε guidε mεmber is provided to engage said rear side as said box base is moving downward, and hold said rear side peφendicular to the onεntation of said basε as tnε box base configuration is finalized

19. An apparatus as defined in Claim 18 wherein said guidε member is pivotally mounted to move from an angle relative to the vertical where it is engaged by the box to a vertical orientation when said box base is plunged down to its final formation location.

20. An apparatus for forming thin, flat, one-piece boxes, including box bases and integral box lids, comprising: a supply of scored blanks for forming thin, flat, one-piece boxes including a lid and a base with associated sides and ends; a plurality of successive box forming stations; mechanical transfer anangements for raising said box blanks and partially formed boxes from said stations and for lowering or plunging the boxes down at the next successive station; a first one of said stations including a spring mounted platform and pre- breaking mechanisms for pre-breaking thε sides of said boxes as said boxes are plunged down at said first station; and at said first station, the boxes are mounted on a fixture having outer edges formed at an acute anglε to the plane of the boxεs, whereby when the rollers engage the sides of othε boxes for pre-breaking, the sidees of thε boxes are bent beyond the vertical to form an acute angle relative to the main planε of thε boxεs.