Continuous dispensing reel system

Abstract

A generally continuous string of container carriers are positioned on a base (35) wherein container carriers are housed on multiple reels (40) and are spliced together between adjacent reels to form the generally continuous string and the multiple reels are arranged on at least one axle (55) for dispensing.

Claims

1. A system for dispensing a generally continuous string of container carriers, each container carrier for unitizing a plurality of containers, the system comprising: a base; two rigid sidewalls extending from the base; an axle extending between the rigid sidewalls; and at least two reels positioned around the axle, each reel including a string of container carriers that are spliced together to form a generally continuous string of container carriers, wherein each reel is back-wrapped.

2. The system of claim 1 wherein the at least two reels comprise an array of reels, each reel of the array including the string of container carriers spliced to another string of container carriers of at least one adjacent reel of the array to form the generally continuous string of container carriers.

3. The system of claim 1 comprising an additional two axles, each axle supporting at least two reels.

4. The system of claim 1 comprising a divider positioned between each adjacent reel of the at least two reels.

5. The system of claim 1 comprising a divider positioned between each adjacent reel of the at least two reels that are positioned around the axle and that share that axle.

6. The system of claim 1 wherein the rigid sidewalls form a portion of a carton containing the generally continuous string of container carriers.

7. The system of claim 1 further comprising at least additional sidewalls forming a carton.

8. The system of claim 1 comprising six reels arranged in two rows, wherein two reels of the six reels along one rigid sidewall of the two rigid sidewalls include a spliced connection and two reels of the six reels along the other rigid sidewall of the two rigid sidewalls include a spliced connection.

9. The system of claim 8 wherein two reels of the six reels in a center of the axle include a spliced connection.

10. The system of claim 1 wherein the rigid sidewalls are corrugated.

11. The system of claim 1 wherein the axle comprises a cardboard tube.

12. The system of claim 1 wherein an additional layer of reels is positioned on top of the at least two reels.

13. The system of claim 12 wherein at least one reel of container carriers in the additional layer of reels is spliced to at least one reel of container carriers in the at least two reels below.

14. A generally continuous string of container carriers, each container carrier for unitizing a plurality of containers, the generally continuous string of container carriers comprising: a first reel having a string of container carriers; a second reel having a string of container carriers, the second reel connected to the first reel with a splice, wherein the first reel and the second reel are back-wrapped; an axle supporting at least one of the first reel and the second reel; and at least two sidewalls enclosing the first reel and the second reel.

15. A package of container carriers comprising: a carton; a generally continuous string of container carriers rolled onto a plurality of reels in a generally continuous fashion wherein adjacent reels are separated by a splice, wherein an additional layer of reels is positioned on top of the plurality of reels, and wherein at least one reel of container carriers in the additional layer of reels is spliced to at least one reel of container carriers in the plurality of reels below.

16. The system of claim 14 wherein each reel is back-wrapped.

17. The package of claim 15 further comprising a pair of axles, each axle supporting two or more reels of container carriers.

18. The package of claim 17 further comprising a divider positioned between each adjacent reel on an each axle.

19. The package of claim 17 further comprising a pair of sidewalls between which each axle extends.

20. The package of claim 15 wherein the plurality of reels are arranged in a two by three array of reels within the carton.

21. A system for dispensing a generally continuous string of container carriers, each container carrier for unitizing a plurality of containers, the system comprising: a base; two rigid sidewalls extending from the base; at least one axle extending between the rigid sidewalls; and six reels arranged in two rows, wherein two reels of the six reels along one rigid sidewall of the two rigid sidewalls include a spliced connection and two reels of the six reels along the other rigid sidewall of the two rigid sidewalls include a spliced connection, wherein at least two reels are positioned around the at least one axle, each reel including a string of container carriers that are spliced together to form a generally continuous string of container carriers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above-mentioned and other features and objects of this invention will be better understood from the following detailed description taken in conjunction with the drawings wherein:

(2) FIG. 1 is a side elevational view of a string of container carriers according to the prior art;

(3) FIG. 2 is a side perspective view of a carton or package of container carriers according to the prior art;

(4) FIG. 3 is a side perspective view of a carton or package of container carriers according to one preferred embodiment of this invention;

(5) FIG. 4 is a planogram of a carton or package of container carriers according to one preferred embodiment of this invention; and

(6) FIG. 5 is a side perspective view of a carton or package of container carriers and a payoff system according to one preferred embodiment of this invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

(7) FIG. 1 shows a string of container carriers 10 as the term is used in the claimed invention. Container carriers 10 are preferably arranged in a generally continuous elongated string or strip having weakened areas between adjacent individual container carriers. Individual container carriers include two or more container receiving apertures 15 which are used to engage and unitize respective groups of containers into multipackages such as six packs, twelve packs, etc.

(8) FIG. 2 shows a carton of fan folded stacks 20 of container carriers 10 according to the prior art. The elongated strip of container carriers 10 are preferably fan folded back and forth in alternating opposite directions resulting in horizontally extending rows of container carriers 10 forming vertically extending stacks 20. Fan folding container carriers 10, like pin-feed computer paper, preferably results in stacks 20 wherein a large amount of container carriers 10 are folded into a minimum amount of space. During the production process, container carriers 10 are preferably formed in the generally continuous, elongated string for shipment and storage in packaging, such as carton or package 15. After shipment to an application facility, such as a soft drink bottler, container carriers 10 are preferably removed from the packaging and applied, on an applicating machine, to groups of containers, such as cans, during which application container carriers 10 are separated from the elongated strip and into individual container carrier packages.

(9) In a preferred embodiment of the invention shown in FIG. 3, package 30 comprises a carton or at least two or more rigid sidewalls 50. The carton may contain two or more reels 40 of container carriers 10. A method for assembling package 30 of container carriers 10 is required that results in an efficiently filled package 30 and permits uninterrupted removal of a mostly continuous elongated strip of container carriers 10. In one preferred embodiment of this invention, package 30 is loaded with multiple reels 40 of container carriers 10. Preferably, though not necessarily, each reel 40 of container carriers 10 is separated and/or positioned using one or more dividers 60 to maintain position of and spacing between the various reels 40 of container carriers 10. This configuration helps prevent tangling and other problems encountered during loading and unloading of package 30.

(10) A system for dispensing a generally continuous string 10 of container carriers includes a base 35. The base 35 may comprise a standard pallet or may be specifically adapted to the system herein.

(11) At least two rigid sidewalls 50 preferably extend from the base 35. The rigid sidewalls 50 may comprise corrugated load bearing cardboard or similar construction. Additional sidewalls may extend between the two rigid sidewalls 50 that may be less structural but serve to protect the contents from contamination or intrusion. Alternatively, a carton may be formed of four similar sidewalls, each forming a structural rigid support for the system.

(12) One or more axles 55 may extend between the rigid sidewalls 50. The axles 55 may comprise thick wall cardboard tubes or may comprise a more rigid and reusable solution including steel, plastic or other suitable material that can support the substantial weight of two or more reels 40 of container carrier.

(13) At least two reels 40 are preferably positioned around each axle 55. The reels 40 as described each include a string 10 of container carriers. During production, the container carriers are preferably formed, such as through a punch press or rotary die, into generally continuous strings that are wound onto the reels 40 and then positioned within the subject system. Adjacent reels 40 are preferably are spliced together, so that a tail of reel A is connected to a head of reel B to form a generally continuous string 10 of container carriers.

(14) In a preferred embodiment of this invention, each additional reel 40 of container carriers 10 that is added to package 30 is connected to the previous reel 40 of container carriers 10. Preferably, an end or tail of a container carrier at a bottom of a first reel 40 of container carriers 10 is connected with a head or beginning container carrier at a top of an additional reel 40 of container carriers 10. The end container carrier is preferably connected or spliced with the beginning container carrier using a weld attachment or a heat seal. A planogram showing a preferred arrangement of reels 40 is shown in FIG. 4. Adjacent reels 40 of container carriers 10 may also be connected using other methods known to those having skill in the art.

(15) Specifically, the system preferably comprises an array of reels 40, each reel 40 of the array including a string of container carriers spliced to a string of container carriers of at least one adjacent reel 40, such as shown in FIGS. 3 and 4.

(16) In this specific embodiment, six reels 40 may be arranged in two rows, wherein two reels 40 along one rigid sidewall 50 include a spliced connection relative to each other and two reels 40 along another rigid sidewall include a spliced connection relative to each other. Further, the two reels 40 in a center of the axle 55 include a spliced connection relative to each other. As shown in FIG. 4, a preferred arrangement includes connections among Reels A-B-C-D-E-F in that order head-to-tail. This arrangement encourages continuous runoff without tangling or interruption.

(17) In a preferred embodiment, each reel 40 is preferably fully back wrapped to enable continuous head-tail splicing. Specifically, each reel 40 is manufactured so that a mid-point of the carrier length is folded and wound at a core of the reel 40 so each turn of the reel pays off the length going to the application machine and a length to be pulled to the machine after the first half of the reel is depleted.

(18) The system may further include a divider 60 positioned between each adjacent reel 40. The divider 60 may be positioned specifically between each adjacent reel that shares a common axle 55 and may prevent binding between the reels as they are unwound. Like the sidewalls 50, the dividers 60 may also be corrugated cardboard and assist in the structural integrity of the system.

(19) In one embodiment, an additional layer of reels 40 may be positioned on top of the plurality of reels 40. In this arrangement, at least one reel 40 of container carriers in the additional layer of reels is spliced to at least one reel 40 of container carriers in the plurality of reels below.

(20) According to one embodiment shown in FIG. 5, a payoff system 80 may be integrated with the subject system to provide a powered pull system. The payoff system 80 according to this invention preferably pulls material from the reel 40 at a rate matched to a speed of the application machine. Such a powered feed system preferably acts as an isolation mechanism for the flow of carrier. As a result, the powered feed or pull system would keep upstream or downstream changes in tension from effecting proper application of the carrier to containers.

(21) While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the apparatus is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.