Container carrier

Abstract

The present invention relates to a container carrier and to packaging systems for containers and using the same. This invention pertains to carrier stock for machine application to substantially identical containers such as beverage cans having annular chimes, cylindrical side walls, and frusto-conical walls between the chimes and the side walls. In particular, the present invention relates to plastic film having apertures to securely retain drinks cans, food cans, bottles and similar containers, a method of applying the film and the resultant combination.

Claims

1. A plastics film comprising a thin plastics sheet material, the thin plastics sheet material comprising: a plurality of quadra-arcuate apertures for holding a plurality of containers together, each container of the plurality of containers having a beading, the plurality of quadra-arcuate apertures extending in at least a first direction of the plastics film; wherein each quadra-arcuate aperture of the plurality of quadra-arcuate apertures has a center and wherein edges defining each quadra-arcuate aperture has a geometry which comprises four tabs facing the center, each tab of the four tabs being defined by peaks spaced apart by troughs, each trough defining a root at a maximum point from the center; wherein the peaks and the roots lie, respectively, on first and second circumferences relative to the center, the second circumference, when the plastics film is in unstretched form and prior to placement about a container, being equal to or greater than a beading circumference of the container; wherein each tab of the four tabs is curved such that each tab has a curved edge facing the center, each curved edge forming an arc of a circle, the circle having a radius that is greater than a distance between the curved edge and the center of each quadra-arcuate aperture of the plurality of quadra-arcuate apertures; wherein a configuration of each quadra-arcuate aperture of the plurality of quadra-arcuate apertures is such that, upon placement of each quadra-arcuate aperture about a container of the plurality of containers, each peak of each tab engages with said beading of the container, wherein the plastics film, at a point where the peaks of the tabs meet with an underside of the beading of the container of the plurality of containers, is deflected in a downwards direction to form a non-planar wave effect in at least the first direction of the plastics film as the thin plastics sheet material elastically forms a three dimensional structure to retain the plurality of containers together; and wherein the plastics film can be provided as a roll.

2. The plastics film according to claim 1, wherein each tab extends inwardly towards the center.

3. The plastics film according to claim 1, wherein the troughs comprise rectilinear corner sections.

4. The plastics film according to claim 1, wherein the plastics film is made from a material comprising at least one of polyethylene, polyethylene derivatives and plastics materials with similar mechanical properties.

5. The plastics film according to claim 1, wherein the plastics film is made from recycled plastics.

6. The plastics film according to claim 5, wherein the plastics film is made from post consumer waste (PCW) plastics.

7. The plastics film according to claim 1, wherein the plastics film is made from 100-350 μm thickness plastics sheet.

8. The plastics film according to claim 1, further comprising further apertures within the thin plastics sheet material between the plurality of quadra-arcuate apertures for holding containers, such further apertures enabling stress relief, whereby each quadra-arcuate aperture of the plurality of quadra-arcuate apertures may more simply be fastened about a container.

9. The plastics film according to claim 1, wherein each quadra-arcuate aperture of the plurality of quadra-arcuate apertures is dimensioned to fit around cylindrical walled cans.

10. The plastics film according to claim 1, wherein each quadra-arcuate aperture of the plurality of quadra-arcuate apertures is dimensioned to fit about reduced chime or necked cans.

11. The plastics film according to claim 1, wherein each quadra-arcuate aperture of the plurality of quadra-arcuate apertures is dimensioned to fit around a neck of a bottle.

12. The plastics film according to claim 1, wherein the plurality of quadra-arcuate apertures are arranged in a single row.

13. The plastics film according to claim 1, wherein the plurality of quadra-arcuate apertures are arranged in more than one row.

14. The plastics film according to claim 1, wherein the beading of the container is a chime of a beverage container.

15. The plastics film according to claim 1, wherein the plurality of quadra-arcuate apertures can be placed over the beading circumference by deflecting the tabs and without stretching the plurality of quadra-arcuate apertures.

16. A method of unitizing containers utilizing the plastics film of claim 1, the method comprising: receiving a container of the plurality of containers; urging the curved edge of a tab of one quadra-arcuate aperture of the plurality of quadra arcuate apertures toward an under-chime edge of the container; easing adjacent side tabs of the one quadra-arcuate aperture over a corresponding rim of the container until the curved edge of the one quadra-arcuate aperture opposite a first engaged side of the one quadra-arcuate aperture is adjacent the corresponding rim of the container; and causing the curved edge of a last tab to engage with an underside of the rim of the container, whereby to secure the plastics film with the container.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) Some preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, of which:

(2) FIGS. 1a-c show a first example of known carrier stock;

(3) FIGS. 2a, b show a second example of known carrier stock;

(4) FIG. 3a-c show a third example of known carrier stock;

(5) FIG. 4 shows a container carrier comprising strips of material;

(6) FIG. 5 shows another prior art container retaining means;

(7) FIGS. 6a, b show card and plastics laminate container retaining means;

(8) FIGS. 7a-e show examples of presently commonly used carrier stock;

(9) FIGS. 8a-c show a first embodiment of a film and the same in use;

(10) FIG. 9 shows a second embodiment.

(11) FIG. 10 shows a third embodiment;

(12) FIG. 11 shows a still further embodiment of the invention.

(13) FIGS. 12-12f detail steps in the application process;

(14) FIGS. 13a & b show manufacturing equipment in plan and side views;

(15) FIGS. 14-15 show views of a application drum in accordance with another aspect of the invention; and,

(16) FIGS. 16-21 show cans unitized with a further example of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(17) There will now be described, by way of example only, the best mode contemplated by the inventor for carrying out the present invention. In the following description, numerous specific details are set out in order to provide a complete understanding to the present invention. It will be apparent to those skilled in the art, that the present invention may be put into practice with variations of the specific.

(18) The present invention shall now be described with reference to a first embodiment as shown in FIGS. 8a-c. FIGS. 8a and 8b show first and second perspective views of an arrangement of five beer cans retained by plastics film stock having six container apertures. The plastics film is shown in plan view in FIG. 8c. Each aperture 80a is of a general square shape, operably arranged to accept a circularly cylindrical part of a container therethrough, with four fingers or tabs 81, 82, 83 & 84 extending from indentations or troughs having a web element connecting adjacent fingers. The troughs lie on a radius slightly greater than the radius of the container about which the film is designed to retain. The nails of the fingers, i.e. the portions that will abut the rim or chime of the can, are conveniently slightly curved inwardly. Indeed, in order to most closely fit about a container, the arc corresponds to an arc of a circle of a radius corresponding to a radius of the container that lies immediately adjacent the rim or chime of the container, the shape taking into account the fact that the film will adopt an undulating shape in view of the resilience of the plastics film being utilised. It is important to note that whilst the elastic properties of the film are utilised, the elastic limit of the material is not approached.

(19) In use, carrier stock provided with a number of apertures for holding a number of containers together, the stock comprising a thin plastics sheet material having a number of apertures arranged in at least a first direction. The apertures comprise a plurality of finger elements, separated by troughs, the apertures having a centre. The peak of the finger elements lie on a first circumference relative to the centre whilst the bottom of the troughs (that part of the troughs most distant from the centre) lie on a second circumference relative to the centre, the second circumference being equal to or greater than the circumference of the container. In use the peaks of the fingers engage with a beading of a container whilst the troughs, as a direct result—since they are part of the same film—are urged downwardly and outwardly. In so doing the troughs urge the film to elastically form upon placement and enable the film to adopt a three dimensional structure. Whilst the number of fingers can vary from three upwards, it has been found that a four fingered aperture (or multiple finger equivalents operable to achieve the same effect) benefits in terms of packaging of product by reason of the forces from the chime, through the finger, allow upward movement of film adjacent the troughs, whereby to create a wave effect. The three dimensional structure adopted by the film is in many ways analogous to the types of structures in vehicular manufacturing i.e. the structure is a monocoque structure where the overall strength of the finished film is greater than that of the inherently flexible material.

(20) Referring in particular to FIG. 8c, film 80 is provided with apertures 81, the apertures being defined by fingers 82-85. One aperture 81 will now be discussed: the distance between the centres of oppositely facing fingers is approximately 90% of the diameter of the portion of the container about which the aperture will close upon, whilst the distance between opposite troughs corresponds to 110% of said diameter. As can be seen, with further reference to FIGS. 8a and 8b, the fingers 82-85 abut the lower part of the chime or rim of the can and the film closely follows the necked-in portion of the container. Rather than utilising the elasticity of the material to enable containers to be retained, the film in accordance with the invention adopts a three dimensional geometrical form that enables the shape of the film to thereby provide a relatively rigid arrangement. In actual fact, rather than utilise high quality virgin plastics film of a preferred thickness in the range of 400-500 μm, the present invention can utilise recycled plastics film of a thickness of 350 μm or less. It is to be realised that whilst the weight of a single apertured film for a six-pack is of the order of a couple of grammes, globally, several thousands of tons of plastics are employed in the manufacture of container film. A reduction in the amount of plastics by 25% or more will provide a significant reduction in operating costs for any canning plant. Additionally, it is known in the art (for example EP1038791), that any buckling of a transverse web is to be minimised because of customer perception; a smooth transverse web is believed to be more aesthetically pleasing.

(21) As will be appreciated, prior systems for linking containers more closely approach the elastic deformation limit of the plastics material. Indeed, in the apparatus as shown in U.S. Pat. No. 4,250,682 a machine is shown which engages a carrier strip and assembles the carrier strip with a plurality of articles moving in close relation thereto. The apparatus in Braun has a rotary drum with carrier stretching members for engaging, stretching and positioning the carrier strip over the tops of the articles moving there-under such that the carrier material is retained under the chime of the article. Similarly, in another teaching (EP0456357) it is stated that a carrier strip engaging assembly is used to elastically deform the engaged carrier strip for assembly with articles.

(22) Since recycled materials are more likely to have inclusions and other faults, which can compromise the strength of material that is stretched towards an elastic limit, the industry has previously not been able to accept such materials, increasing the financial burden in the packaging industry. Not only does the present invention provide a solution which uses less raw material and is according more “environmentally friendly” than prior solutions, the raw material for the present invention can indeed comprise re-cycled material or at least have a significant recycled material content.

(23) The procedure of application of the apertured film in accordance with the present invention can be conveniently formed by a number of methods. A presently preferred method will be described with reference to FIG. 8c, which, for convenience shall be assumed to be receiving a can, not shown, from the right; the inside edge of finger 84 of the aperture is urged toward the under-chime (upper rim) of a can; the adjacent side fingers 81, 83 of the aperture are then eased over the corresponding rim parts of the can until the inside edge of the aperture opposite the first engaged side of the aperture is adjacent the rim, whereupon continuing pressure enables the inside edge of the last aperture finger 82 to engage with an underside of the rim, thereby enabling the apertured film to be simply, safely and securely engaged therewith. It will be appreciated that since significant forces would not be required to enable the apertures to be placed over containers, then the machinery need not be so massive and that three or more containers may be easily be retained by a film in accordance with the invention; previous systems cannot reliably unitize more than two containers in a process such as a fast moving production line.

(24) Whilst the first example is a square aperture, it will be appreciated that a generally three fingered aperture may be provided, comprising a generally equilateral triangular configuration, and would provide a minimally fingered design with a security of retention. It will be appreciated that many polygonal form can be configured which operate in accordance with the inventions, although, a regular four-sided aperture is likely to be more readily generally accepted. Containers of other cylindrical shapes can be retained; it may be appropriate to have five, six or more fingers or tabs per aperture. Ten have been found to be a convenient limit for large domestic containers.

(25) Referring now to FIG. 9, a portion of film 90, with six apertures abreast, is shown, the apertures 91 being of a second regular quadrilateral shape. Further apertures or slits 92, together with circular apertures 93 are sized and positioned to assist in the maintenance of the monocoque film shape, once containers have been retained by the film. The circular opening 93 may be formed of difference shapes or may be replaced by a number of smaller aperture, conveniently closely spaced together. In this film the shape and position of the apertures are such that the troughs between the fingers correspond with the corners of the curved sides, the distance between opposite troughs being approximately 110% the diameter of the container at the rim.

(26) FIG. 10 shows a further portion of film 100, which has generally square apertures 101, which have fingers 102-105 separated by small troughs 106-109. The troughs are more pronounced with respect to the troughs of FIGS. 9 and 11, but may be of other shapes with regard to a requirement not to induce tears in the film. Again the distance between opposite troughs is approximately 110% the diameter of the container at the rim. FIG. 11 shows a still further embodiment, wherein each side of a generally square aperture comprises distinct arc sections 111-114; the troughs can be considered to exist at the centre of adjacent arcs 115-118. FIG. 11a shows a variant of the arcuate quadrilateral design wherein a substantially square aperture acts with tab elements having an inwardly facing arcuate tab. FIGS. 11b-11d show the variant of FIG. 11a in use.

(27) A significant advantage of the present invention is that the mechanical properties of the material are only required to be strong enough to hold the cans, and not stand up to the rigours and high stretch of the standard application processes encountered in the prior art. Not only does this have significant advantages in the manufacturing processes (reduced operating forces incur less wear for application machines and thus further reduce operating costs), and also enables the use of cheaper plastics to be employed. Indeed, recycled plastics such as low grade Post Consumer Waste (e.g. low density polyethylene—LDPE) can be employed which also satisfies the perennial demands of market requirements in that the basic consumable materials are cheaper. As discussed above, in view of the materials not needing to be stretched to particular limits, the thickness of the basic product can also be reduced i.e. the thickness can be 300 μm (or less): the issue of the presence of inclusions or not is of no consequence. A preferred thickness for such stock for prior systems in an unstressed condition has been in a range from approximately 16 mils (400 μm) to approximately 17.5 mils (445 μm). The present invention allows the use of raw material that can be purchased at far more favourable rates than specified high quality material.

(28) A preferred method of application utilises a simple roll on application method as shall be disclosed in detail hereinafter; a simple machine can be utilised in manufacturing industry; since great stretching forces are not applied, lever arm and/or hydraulic operations can be minimised and the strength of the machine need not be great, as a direct result compared to systems which stretch plastics towards and beyond their elastic limits. The use of simpler and cheaper machines will also enable the systems to be operated by smaller manufacturing concerns and thereby increase markets.

(29) FIGS. 12a-12f show a superposition of the edges of an un-stretched aperture upon a beading 126 of a container 122. FIG. 12a shows how, in a first application step associated with retaining a number of containers with a stock of apertured plastics sheeting in accordance with the present invention. An inside tab edge 121 of the aperture abuts against an underside edge of a bead 126 of the container. FIG. 12b shows how, in relation to the apertured plastics sheet stock 100 an application roller will rotate with respect to a container passing underneath in a direction perpendicular to the roller axis. The roller is not shown, although the stock is shown having an arcuate profile and will be discussed in greater detail with respect to machinery below.

(30) As the roller continues to move, with reference to FIGS. 12c & 12d the side edges 123 & 125 of the aperture diverge elastically to surround the sides of the container beading 126. It will be appreciated that this figure is part cross-section in the plane of the beading 126 and part side-perspective view of the can 122. The application forces AF, acting from a centre of the application roller, are relatively gentle—no forces which stretch the plastics sheet material beyond its elastic limit are present.

(31) FIGS. 12e and 12f show corresponding plan and side view of the application process as the edge 127 is received by the rim of the container 126—as shown, the application roller is shown as the container passes below the axis of the roller

(32) As discussed above, in view of the reduced forces necessary to assemble containers, system power requirements would be reduced and energy consumption would be reduced. For example, by having the system applying film to containers in 6-12 rank widths, then packing stations can be made more compact and simplify distribution since larger widths of format negate a need to divert packs after application ready for tray packing process. A still further advantage in having a wider operating width is that the overall velocity of machinery can be reduced. Compared to a 2-rank packing system, the operating speed is one third to one sixth the speed of such 2-rank packing systems. This will have concomitant advantages in the lifetime, reliability (down-times are expensive) and cost in the conveyor, the motors and supporting equipment. Equally the demands on material would be reduced, also permitting the use of lower grade material.

(33) With reference to FIGS. 13a & 13b, there are shown plan and side views of an otherwise standard conveyor system 130 for the transport of containers in the form of soft-drinks cans 139 or similar. In particular, with reference to FIG. 13a, the cans 139 are fed along a conveyor to an accumulation position 134 (proceeding in a direction indicated by arrow 138). In the accumulation position, the containers are brought towards each other in close proximity in preparation for the application of the apertured retaining sheet, performed by roller 132 which receive sheet 110 from sheeting supply system 133. Cutting apparatus controlled between the units labelled 136 enable appropriate pack sizes to be produced. With reference to FIG. 13b, sheeting supply mandrel 135 can co-operate with another mandrel (not shown) to provide a continuous supply of sheeting to the roller 132. As is known, seamless connection of separate sheets can be performed to provide effective continuous operation, or at least almost continuous operation of the system.

(34) FIGS. 14 and 16 show, respectively side and detail view of the application drum and production line conveyor arrangement. FIGS. 17-21 show cans unitized with a further example of a carrier stock in accordance with the invention.

(35) It will be appreciated that, since the containers can be arranged in 6+ wide lines, then different lines may be packaged differently using known techniques, adding variability to the production line process. Additionally, it would be possible, with appropriate channelling, to have cross over with other products (brands) whereby a perceived need for other machines/systems is not necessary. The carrier stock is formed, for example by die-cutting, from a single sheet of resilient polymeric material, such as low density polyethylene. Known carrier stock has been formed of high quality plastics sheet, such as low density polyethylene.