A CONTAINER CARRIER

Abstract

An apertured plastics film (100,110) for holding containers together to form a unitised carrier package, includes apertures (101) for respectively holding a single container wherein internal edge portions of each aperture form tab elements (102-105) for contacting the container when positioned within an aperture, and engaging with a beading of the container, and has a plastics cover sheet (120) applied to the apertured plastics film (100,110) and covering the apertures, wherein the plastics cover sheet (120) is attached to the apertured plastics film at least at edge portions of the apertured plastics film or edges of the apertures, and wherein a portion of the cover material (120) is deformed locally at each aperture to effect localised expansion by a former (146,151) before the apertured plastics film is applied to the containers.

Claims

1. A method of forming a carrier for unitising items comprising: providing a plastics film, forming apertures in the plastics film to provide an apertured plastics film, whereby a plurality of apertures are provided for respectively holding an item, each one of the plurality of apertures being defined between internal edge portions of the plastics film, each edge portion forming a tab for contacting an item when the item is positioned within the aperture, and applying a cover material upon the apertured plastics film to cover the plurality of apertures, and attaching the cover material to the apertured plastics film.

2. A method as claimed in claim 1, wherein the cover material is deformed locally at each aperture by contacting the cover material with a former after attaching of the cover material to the apertured plastics film.

3. A method as claimed in claim 2, wherein the former is provided upon a roller, and the apertured plastics film is brought into contact with a surface of the roller, such that the position of the former coincides with an aperture of the apertured plastics film to effect localised expansion of the cover material.

4. A method as claimed in claim 1, wherein the cover material is attached at edges of the apertured plastics film.

5. A method as claimed in claim 1, wherein the cover material is attached at edges of the respective apertures of the apertured plastics film.

6. A method as claimed in claim 1, wherein the cover material is attached at edges of the apertured plastics film and at edges of the respective apertures of the apertured plastics film.

7. A method as claimed in claim 1, wherein the cover material is attached to the apertured plastics film by bonding the cover material to the apertured plastics film.

8. A method as claimed in claim 1 wherein the cover material is attached to the apertured plastics film by the application of heat or pressure.

9. A method as claimed in claim 1, wherein the cover material comprises a plastics film which is thinner than the apertured plastics film.

10. A plastics film carrier for unitising items comprising (i) an apertured plastics film including one or more apertures arranged for receiving and holding items, and (ii) a plastics cover sheet applied to the apertured plastics film and covering the apertures, wherein the plastics cover sheet is attached to the apertured plastics film at least at edge portions of the apertured plastics film.

11. The plastics film carrier as claimed in claim 10, wherein the plastics cover sheet is a laminated plastics sheet.

12. The plastics film carrier as claimed in claim 10, wherein the plastics cover sheet is at least about 10 microns thick.

13. A plastics film carrier as claimed in claim 10, wherein the apertured plastics film comprises a plurality of apertures, each one of the plurality of apertures being defined between internal edge portions of the apertured plastics film, each edge portion forming a tab for contacting an item when the item is positioned within an aperture.

14. A packaging method for a plurality of items, wherein the items are delivered to a unitising packaging machine, collected and arranged to receive a plastics film carrier as claimed in claim 10 in a unitising operation, wherein the plastics film carrier is applied to the items using a roller.

15. A packaging method as claimed in claim 14, wherein a carrier stock of plastics film is fed to a cutting station operatively associated with the unitising packaging machine, where an apertured profile is formed in the plastics film to provide an apertured plastics film, and subsequently the apertured plastics film is presented for receiving a cover material which is applied to the apertured plastics film and attached thereto to form a covered apertured plastics film for use as a plastics film carrier.

16. A packaging method as claimed in claim 15, wherein the covered apertured plastics film is presented to a device including a former for locally expanding a portion of the cover material associated with an aperture.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0046] Various embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:

[0047] FIG. 1 is a plan view of a portion of a carrier stock providing an apertured plastics film for use in unitising items;

[0048] FIG. 2 is a plan view of a 22 apertured plastics film suitable for use in unitising items as a four-pack;

[0049] FIG. 3 is a plan view of an alternative a 22 apertured plastics film suitable for use in unitising items as a four-pack

[0050] FIG. 4 is a plan view of an alternative a 22 apertured plastics film suitable for use in unitising items as a four-pack;

[0051] FIGS. 5a and 5b show, from alternative perspective viewpoints, the contoured form of the apertured plastics film developed when applied to necked-in ring-pull cans;

[0052] FIGS. 6a-6g show in plan and in equivalent stage side view application of apertured plastics film to cans by means of a roller;

[0053] FIG. 7 shows a side view of a part of a unitising packaging plant where covered apertured plastics film is presented for application to items, and including a plastics cover film expanding device operable prior to unitisation of items;

[0054] FIG. 8 is a side view representing overlay of a plastics cover sheet over an apertured plastics film in the production of a covered apertured plastics film; and

[0055] FIG. 9 is an enlarged view of the part of FIG. 7 circled in dashed outline, showing a side view of part of a roller handling device having a former for deforming a plastics cover sheet to form an expanded portion of the plastics cover sheet over an aperture in the apertured plastics film.

DETAILED DESCRIPTION OF EMBODIMENTS

[0056] Apertured Plastics Film:

[0057] Referring now to FIG. 1, a portion of carrier stock of apertured plastics film 90, with six apertures abreast, is shown as an illustrative example, the apertures 91 being of a regular quadrilateral shape. Further apertures or slits 92, together with circular apertures 93 are sized and positioned to assist in the maintenance of a 3D 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 apertures, conveniently closely spaced together. In this apertured plastics film 90 the shape and position of the apertures are such that the troughs between the tabs (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.

[0058] FIG. 2 shows a portion of another form of apertured plastics film, wherein each side of a generally square aperture comprises distinct arc sections 111-114; and troughs to be formed in use can be considered to exist at the centre of adjacent arcs 115-118. This portion is suitable for forming a four item unitised package.

[0059] FIG. 3 shows a portion of a further apertured plastics film 100, which has generally square apertures 101, which have fingers 102-105 separated by portions forming small troughs 106-109 (in use). The troughs are more pronounced in comparison with the troughs formed by the apertured plastics film of FIGS. 1 and 2. Other shapes can be used for the portions of the apertured plastics film between the apertures which in use form troughs for example with regard to a requirement not to induce tears in the film. Again the distance between opposite trough portions is approximately 110% the diameter of the container at the rim.

[0060] FIG. 4 shows a portion of an apertured plastics film 80 used for unitising items typically containers such as beer cans in plan view in FIG. 4. Each aperture in the apertured plastics film 80 is of a general square shape, operably arranged to accept a circular end of a cylindrical part of a container therethrough, with four fingers or tabs 81, 82, 83 & 84 extending from indentations or troughs 85, 86, 87 & 88 having a web element connecting adjacent tabs. The troughs 85, 86, 87 & 88 lie on a radius slightly greater than the radius of the container about which the film is designed to fit in a retaining manner to hold the container in a unitised package. The edges of the tabs, which are analogous to nails extending from human 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.

[0061] FIGS. 5a and 5b show first and second perspective views of an arrangement of five beer cans retained by an apertured plastics film 80 (carrier stock) having six container apertures.

[0062] Covered Carrier

[0063] Each of the apertured plastics films illustrated in the accompanying figures may receive an overlay of a plastics cover sheet that is attached to the apertured plastics film so as to cover the apertures. The plastics cover sheet may be a laminate of a polyolefin and is even thinner than the thin apertured plastics film. The appearance of the covered plastics films is not significantly changed, and in plan view is identical to that of any of the aforedescribed apertured plastics films of FIGS. 1-4. FIG. 8 illustrates overlay of a plastics cover sheet upon an apertured plastics film viewed from one side. FIG. 9 illustrates a process step applied only to the cover material of the covered apertured plastics film. In this step a passive former is used to expand a portion of the cover material local to an aperture into an indented pouch, pocket, bulge or bubble shape in the cover material over the aperture. This slight modification to the cover material mitigates any potential inhibition of the re-configuration of the apertured plastics film to the wave-form shape during a unitising operation.

[0064] Unitising of Items

[0065] In use, carrier stock is provided with a number of apertures for holding a number of items, typically containers such as bottles or cans, together to form a unitised package, 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 tabs (finger elements), separated by troughs, the apertures having a centre. The peaks of the tabs lying on a first circumference relative to the centre whilst the root (bottom-most part) of the troughs (that part of the troughs most distant from the centre of the aperture) lie on a second circumference relative to the centre, the second circumference being equal to or greater than the circumference of the container. A roller device is used to apply the apertured plastics sheet material to collected items arranged for unitisation. In use the peaks of the tabs engage with a beading of a container whilst the troughs, as a direct resultsince they are part of the same filmare 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 wave-like structure. Whilst the number of tabs can vary from three upwards, it has been found that a four tabbed aperture benefits in terms of packaging of can-shaped products by reason of the forces from the chime, through the tabs, which allow upward movement of film adjacent the troughs, whereby to create a wave effect in a re-configured apertured plastics film applied over the containers. The three dimensional structure adopted by the film is in many ways analogous to a particularly strong type of structure adopted in motor vehicular manufacturing i.e. the structure known as a monocoque structure where the overall strength of the finished film achievable is greater than that of the inherently flexible material before it is applied in the unitising process.

[0066] Referring in particular to FIG. 4, film 80 is provided with apertures 81, the apertures being defined by tabs 82-85. In order to explain the use of the apertured plastics film, by way of illustration only one aperture 81 will now be discussed: the distance between the centres of oppositely facing tabs 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. 5a and 5b, the tabs 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 plastics film material to enable containers to be retained, the apertured plastics film after rolling application over the top of contains adopts a three dimensional wave-like geometrical form (as evident in FIGS. 5a and 5b) that enables the shape of the film to thereby provide a relatively rigid arrangement. This configuration adopted upon the containers is so strong that rather than require use of a high quality virgin plastics film of a preferred thickness in the range of 400-500 m, the apertured plastics film can be formed from recycled plastics film of a thickness of 350 m 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 unitising 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 from 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.

[0067] 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.

[0068] The procedure for application of the covered apertured plastics film can be conveniently formed by a number of methods. A presently preferred method will be described with reference to an apertured plastics film such as that illustrated in FIG. 4, which, for convenience shall be assumed to be receiving a can, not shown, from the right. For the purposes of discussing the interaction with the can, the presence of a plastics cover sheet applied to and attached to the apertured plastics film can be ignored since the plastics cover sheet has no role in holding the can in the unitised package being formed.

[0069] The application of the apertured plastics film to the can is realised by use of a roller device as represented in FIGS. 6a-6g.

[0070] The inside edge of 84 of the aperture is urged toward the under-chime (upper rim) of a can; the adjacent sides 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 82 to engage with an underside of the rim, thereby enabling the apertured plastics film to simply, safely and securely engaged therewith.

[0071] 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 retained by a film; previous systems cannot reliably unitize more than two containers in a process such as a fast moving production line.

[0072] Whilst the discussed example is a four sided 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 forms can be configured which operate in accordance with the disclosed concept, although, a regular four-sided aperture is likely to be more readily generally accepted in the field. The polygonal form of the aperture may be chosen to suit the item to be unitised with other like items in a unitised package.

[0073] 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.

[0074] FIGS. 6a-6g illustrate a superposition of the edges of an un-stretched aperture upon a beading 126 of a container (shown as a can) 122. FIG. 6b shows how, in a first application step associated with retaining a number of such containers with a carrier stock of apertured plastics film, an inside tab edge 121 of the aperture abuts against an underside edge of a bead 126 of the container. FIG. 6c shows how, in relation to an apertured plastics film 110 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 representation of the carrier stock of apertured plastics film is shown having an arcuate profile due to use of a roller and will be discussed in greater detail with respect to machinery below.

[0075] As the roller continues to move, with reference to FIGS. 6d & 6e 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 container 122. The application forces AF, acting from a centre of the application roller, are relatively gentle and there are no forces which stretch the plastics sheet material 110 beyond its elastic limit. FIGS. 6f and 6g show corresponding plan and side view of the application process as the edge 127 is received by the rim 126 of the container 122. As illustrated, the application roller is shown as the container passes below the axis of the roller.

[0076] FIG. 7 shows a side view of part of a container unitising packaging plant, including a conveyor surface for the transport of containers illustrated here in the form of soft-drinks cans 139 or similar. Typically, the cans 139 would be fed along a conveyor to an accumulation position and automatically gathered together in close proximity in preparation for the application of the apertured plastics film by roller 132. Carrier stock providing the basis for the apertured plastics film 110 is fed from supply system 133. At a convenient position, the carrier stock is cut to provide the necessary apertures for receiving the containers. Reference may be made to GB 2 475 622 B and GB 2 485 895 B for further information on the formation of apertured plastics film and application to containers in a unitising operation. As compared with the unitising machinery illustrated in FIG. 13b of GB 2 475 622 B, it is evident that the carrier stock is further manipulated before application to items as disclosed there.

[0077] As illustrated in FIG. 8, the apertured plastics film 110 is covered before delivery for unitising containers with an applied cover material 120, which may be a plastics laminate, for example a polyethylene laminate. The cover material 120 covers the apertures completely and is attached by bonding to the apertured plastics film 110.

[0078] FIG. 9 shows in an enlarged view that part of FIG. 7 circled in dashed outline, representing processing of the covered apertured plastics film between rollers 145, and 150, respectively provided with passive formers for manipulating the cover material 120 only by cooperation through the apertures of the apertured plastics film 110 without impacting upon the apertures thereof.

[0079] In this embodiment of the method, the cover material 120 is formed into a recessed pouch covering each aperture by inserting a male former 151 into the aperture to contact and deform the cover material 120 locally at the aperture to leave an indentation or semi-collapsed bubble after the former male 151 is withdrawn. The former may be a male former which is conveniently passively mounted upon roller 150, and counter roller 145 which aids positioning and transit of the carrier stock, may have a corresponding space or female form adapted to receive the male form.

[0080] Referring to FIG. 9, the effect of the transit of the covered apertured plastics film over the roller 150 is to bring passive male former 151 into contact with the cover material 120 of the covered apertured plastics film through an aperture to deform the cover material locally over the aperture, to form an expanded portion, whilst leaving the apertured plastics film 110 unaffected. A corresponding guide roller 145 cooperates with the roller 150 to facilitate advancement of the covered apertured plastics film, and may have either an aperture or female former 146 to facilitate an indentation or recessed pouch being formed in the cover material 120 in a regular controlled manner. Continuing transit of the covered apertured plastics film away from the rollers 145, 150 removes the contact of the cover material with the male former 151 allowing the deformed part of the cover material to relax as a partially collapsed bubble over the aperture.

[0081] In embodiments of the unitising packaging method, the covered apertured plastics film may be presented to gathered containers for the purpose of forming unitised packages of containers such that with respect to a first container, the cover material 120 is between the container and the apertured plastics film 110, i.e. the latter is uppermost. In embodiments adopting cover materials of greater thickness, say greater than about 50 microns, it may be appropriate to present the covered apertured plastics film with the cover material 120 uppermost such that with respect to a first container the apertured plastics film 110 is between the container and the cover material 120. In either case, the application method using the roller device is the same, and the retention of respective ones of the gathered containers in respective apertures of the apertured plastics film is also the same.

[0082] The apertured plastics film for holding containers together to form a unitised carrier package by the disclosed method includes apertures for respectively holding a single container wherein internal edge portions of each aperture form tab elements for contacting the container when positioned within an aperture, and engaging with a beading of the container, and has a plastics cover sheet applied to the apertured plastics film and covering the apertures, wherein the plastics cover sheet is attached to the apertured plastics film at least at edge portions of the apertured plastics film and/or edges of the apertures, and wherein a portion of the cover material is deformed locally at each aperture to effect localised expansion by a former before the apertured plastics film is applied to the containers.