METHOD AND SYSTEM FOR FORMING A PACKAGE

Abstract

A method and system for forming a package that addresses operational challenges in container packaging systems. A packaging machine may include a conveyance system that provides continuous blank transport through multiple processing stages. The system may include pre-break stages that prepare fold lines in the blank for subsequent folding operations. Leading edge manipulators may include mechanical elements with finger-like protrusions and biasing mechanisms for controlled pressure application. Trailing edge cam assemblies may include dynamic cams with engagement points mounted on rotatable shafts driven by servo motors. Tamper wheels may provide rolling surfaces with wedge-shaped recesses for secondary fold line reinforcement.

Claims

1. A system for manipulating a blank into a construct, the system comprising: a conveyor configured to propagate a blank through the system, the blank having a main panel region connected to a trailing-edge tab at a fold line; and a trailing-edge tab pre-break stage having: a cam coupled to a rotatable shaft, the system configured to rotate the cam at a first rotational velocity during which the cam contacts the trailing-edge tab and bends the trailing-edge tab along the fold line to an initial position that is at an obtuse angle with respect to the main panel, the system configured to subsequently rotate the cam at a second rotational velocity during which the cam bends the trailing-edge tab from the initial position to a final position where the trailing-edge tab is at least partially overlapped with the main panel, wherein the second rotational velocity is greater than the first rotational velocity.

2. The system of claim 1, wherein the cam bends the trailing-edge tab to the initial position and to the final position while the blank continuously propagates through the system at a constant velocity.

3. The system of claim 1, wherein the trailing-edge tab is a first trailing-edge tab and wherein the fold line is a first fold line, the blank including a second trailing-edge tab connected to the main panel at a second fold line, and wherein the cam is a first cam, the trailing-edge tab pre-break stage further having: a second cam coupled to the rotatable shaft, the system configured to simultaneously rotate the first and second cams at the first rotational velocity to simultaneously bend the first and second trailing-edge tabs along respective first and second fold lines to the initial position, the system configured to rotate the first and second cams at the second rotational velocity to simultaneously bend the first and second trailing-edge tabs to the final position.

4. The system of claim 1, wherein the rotatable shaft is controlled by a servomotor.

5. The system of claim 1, wherein the cam includes a base coupled to the shaft, the cam further including an arcuate engagement finger extending from the base to a distal end.

6. The system of claim 1, wherein the blank includes a leading edge tab connected to the main panel at a leading edge tab fold line, the system further comprising a leading edge tab pre-break stage having a breaker arm arranged to engage the leading edge tab as the blank continuously propagates through the system, the breaker arm further arranged to maintain engagement with the leading edge tab until the leading edge tab is at least partially folded over the main panel then to disengage with the leading edge tab.

7. The system of claim 6, further comprising a tamper wheel positioned after the trailing-edge tab pre-break stage, the tamper wheel including an outer rolling surface arranged to roll across the blank as the blank propagates through the system, wherein the rolling surface is interrupted by a recess, and wherein the system is configured to align the recess with the trailing-edge tab.

8. The system of claim 7, wherein the system is arranged to match a rotational velocity of the tamper wheel to a horizontal velocity of the blank as the tamper wheel rolls across the main panel, the system further arranged to increase the rotational velocity of the tamper wheel when the trailing-edge tab is at least partially aligned with the recess to further bend the trailing-edge tab about the fold line.

9. The system of claim 1, wherein the breaker arm further comprises an elongated arm culminating in a finder-like protrusion facing an engaged blank.

10. A packaging system for assembling containers with a construct, the system comprising: a conveyor configured to propagate a blank through a packager, the blank having a central panel region connected to a trailing-edge tab at a fold line; a trailing-edge tab pre-break stage having: a cam coupled to a rotatable shaft, the system configured to rotate the cam at a first rotational velocity during which the cam contacts the trailing-edge tab and bends the trailing-edge tab along the fold line to an initial position that is at an obtuse angle with respect to the main panel, the system configured to subsequently rotate the cam at a second rotational velocity during which the cam bends the trailing-edge tab from the initial position to a final position where the trailing-edge tab is at least partially overlapped with the main panel, wherein the second rotational velocity is greater than the first rotational velocity; a container feed stage configured to insert a plurality of containers into orifices disposed in the central panel; and a clipping stage configured to clip cap-enclosing panels over one or more containers.

11. The packaging system of claim 10, wherein the cam bends the trailing-edge tab to the initial position and to the final position while the blank continuously propagates through the system at a constant velocity.

12. The packaging system of claim 10, wherein the trailing-edge tab is a first trailing-edge tab and wherein the fold line is a first fold line, the blank including a second trailing-edge tab connected to the main panel at a second fold line, and wherein the cam is a first cam, the trailing-edge tab pre-break stage further having: a second cam coupled to the rotatable shaft, the system configured to simultaneously rotate the first and second cams at the first rotational velocity to simultaneously bend the first and second trailing-edge tabs along respective first and second fold lines to the initial position, the system configured to rotate the first and second cams at the second rotational velocity to simultaneously bend the first and second trailing-edge tabs to the final position.

13. The system of claim 10, wherein the blank includes a leading edge tab connected to the main panel at a leading edge tab fold line, the system further comprising a leading edge tab pre-break stage having a breaker arm arranged to engage the leading edge tab as the blank continuously propagates through the system, the breaker arm further arranged to maintain engagement with the leading edge tab until the leading edge tab is at least partially folded over the main panel then to disengage with the leading edge tab.

14. The system of claim 13, further comprising a tamper wheel positioned after the trailing-edge tab pre-break stage, the tamper wheel including an outer rolling surface arranged to roll across the blank as the blank propagates through the system, wherein the rolling surface is interrupted by a recess, and wherein the system is configured to align the recess with the trailing-edge tab.

15. The system of claim 14, wherein the system is arranged to match a rotational velocity of the tamper wheel to a horizontal velocity of the blank as the tamper wheel rolls across the main panel, the system further arranged to increase the rotational velocity of the tamper wheel when the trailing-edge tab is at least partially aligned with the recess to further bend the trailing-edge tab about the fold line.

16. The system of claim 10, wherein the at least one blank further comprises a central panel with eight orifices for engaging eight containers.

17. The system of claim 10, wherein the at least one blank further comprises a central panel with six orifices for engaging six containers.

18. A method of forming a package comprising: receiving a blank having a central panel with a plurality of orifices and cap enclosing panels connected to the central panel along fold lines; propagating the blank through a conveyance system at a constant velocity; inserting a plurality of containers through the orifices such that caps of the containers extend through the central panel; and performing a pre-break procedure on trailing-edge tabs of the blank by rotating a cam at a first rotational velocity to bend the trailing-edge tabs to an initial position at an obtuse angle with respect to the central panel, then rotating the cam at a second rotational velocity different from the first rotational velocity to bend the trailing-edge tabs to a final position where the trailing-edge tabs are at least partially overlapped with the central panel.

19. The method of claim 18, further comprising performing a leading-edge pre-break procedure by engaging leading-edge tabs of the blank with breaker arms that maintain contact with the leading-edge tabs until the leading-edge tabs are at least partially folded over the central panel.

20. The method of claim 19, further comprising tamping the trailing-edge tabs using a tamper wheel having an outer rolling surface with a recess, wherein the tamper wheel rotates at a velocity matched to the propagation velocity of the blank and increases rotational velocity when the recess aligns with the trailing-edge tabs.

21. The method of claim 20, further comprising controlling a servomotor to generate rotational velocities of the cam.

22. The method of claim 18, further comprising controlling a servomotor to generate rotational velocities of the cam.

23. A method of forming a package comprising: conveying a blank having a central panel connected to trailing-edge tabs at fold lines through a packaging system; engaging the trailing-edge tabs with cams mounted on a rotatable shaft; rotating the cams at a first velocity to bend the trailing-edge tabs along the fold lines to an obtuse angle position; rotating the cams at a second velocity different from the first velocity to fold the trailing-edge tabs forward in a direction of blank propagation; inserting containers into orifices formed in the central panel; folding cap enclosing panels connected to the central panel through multiple folding stages to create panel sections that encapsulate container caps and neck regions; and clipping the panel sections to secure the cap enclosing panels to the containers.

24. The method of claim 23, further comprising maintaining the blank at a constant propagation velocity throughout the pre-break procedure and folding operations.

25. The method of claim 23, wherein folding the cap enclosing panels comprises operating a sequence of plows positioned at different angles to create panel sections that progressively conform to container geometries.

26. The method of claim 23, further comprising reinforcing fold lines in the trailing-edge tabs using tamper wheels with recesses that align with the tabs during rolling contact with the blank.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

[0017] FIG. 1 illustrates a plan view of a blank for forming a carrier according to an embodiment of the subject matter disclosed herein.

[0018] FIG. 2A depicts a perspective view of assembled carrier formed from the blank of FIG. 1 holding multiple containers according to an embodiment of the subject matter disclosed herein.

[0019] FIG. 2B shows a top view of the carrier of FIG. 2 according to an embodiment of the subject matter disclosed herein.

[0020] FIG. 3 illustrates a plan view of an alternative blank configuration for forming a carrier according to an embodiment of the subject matter disclosed herein.

[0021] FIG. 4 depicts a perspective view of an assembled carrier formed from the blank of FIG. 3 holding multiple containers according to an embodiment of the subject matter disclosed herein.

[0022] FIG. 5 depicts a perspective view of a portion of a machine for assembling the blanks of FIG. 1 or FIG. 3 with containers according to an embodiment of the subject matter disclosed herein.

[0023] FIG. 6 shows a sequence of images of blanks during an assembly procedure using the machine of FIG. 5 in various stages of formation according to an embodiment of the subject matter disclosed herein.

[0024] FIG. 7 depicts a portion of the machine of FIG. 5 showing an initial blank feeding stage wherein beverage containers are introduced and mechanisms perform a pre-break procedure on leading edges of each blank according to an embodiment of the subject matter disclosed herein.

[0025] FIG. 8 depicts a portion of the machine of FIG. 5 showing a stage for manipulating trailing edges of the blanks to perform a pre-break procedure according to an embodiment of the subject matter disclosed herein.

[0026] FIGS. 9A-9D illustrate the cam of FIG. 8 in various stages of a trailing edge pre-break procedure of a blank according to an embodiment of the subject matter disclosed herein.

[0027] FIGS. 10A-10E illustrate portions of the machine of FIG. 5 corresponding to the stages of assembly depicted in FIG. 6 without the blanks in the stages according to an embodiment of the subject matter disclosed herein.

[0028] FIGS. 11A-11E illustrate respective assembly stages of the blank as proceeding through the machine of FIG. 5 without the machine stage according to an embodiment of the subject matter disclosed herein.

[0029] FIGS. 12A-12E illustrate aspects of the operation of the tucker wheel of FIG. 10A in various stages of engagement with the blank according to an embodiment of the subject matter disclosed herein.

[0030] FIGS. 13A-13D illustrate aspects of the operation of the dynamic guide and latching tools of FIG. 10E in various stages of engagement with the blank according to an embodiment of the subject matter disclosed herein.

[0031] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION

[0032] In the following description, various embodiments will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the embodiments may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.

[0033] Several illustrative embodiments will now be described with respect to the accompanying drawings, which form a part hereof. The ensuing description provides embodiment(s) only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the embodiment(s) will provide those skilled in the art with an enabling description for implementing one or more embodiments. It is understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of this disclosure. In the following description, for the purposes of explanation, specific details are set forth in order to provide a thorough understanding of certain inventive embodiments. However, it will be apparent that various embodiments may be practiced without these specific details. The figures and description are not intended to be restrictive. The word example or exemplary is used herein to mean serving as an example, instance, or illustration. Any embodiment or design described herein as exemplary or example is not necessarily to be construed as preferred or advantageous over other embodiments or designs.

[0034] The present disclosure relates to packaging systems and methods for forming packages that include carriers engaged with articles. The system and method may be particularly suited for forming packages containing beverage containers, food containers, or other consumer products that require secure packaging and convenient handling. The articles may include containers of various shapes and sizes, such as plastic bottles, glass bottles, aluminum cans, or other cylindrical or non-cylindrical containers used for packaging beverages, food products, or other consumer goods.

[0035] The system may accommodate containers made from materials suitable for packaging particular food or beverage items. These materials may include various plastics such as polyethylene terephthalate (PET), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), ethylene vinyl alcohol (EVOH), and nylon. The containers may also be constructed from glass, aluminum, other metals, or any combination of these materials. The carriers themselves may be constructed from paperboard having sufficient caliper to provide greater rigidity than ordinary paper. The carrier material may also include cardboard or other materials having properties suitable for enabling the carrier to function as described. The blank material may be coated with clay coating, which may then be printed with product information, advertising, or other images. The blanks may be coated with varnish to protect printed information and may include moisture barrier layers on either or both sides. The blanks may also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

[0036] For purposes of this specification, certain orientation terminology may be used to describe the relative positions and movements of components within the system. The terms downstream and upstream refer to directions relative to the flow of materials through the packaging system, with downstream indicating the direction toward the completed package formation and upstream indicating the direction toward the initial material input. The terms lower, bottom, upper, and top indicate orientations determined in relation to fully erected carriers in their intended use position. The terms front, back, left, and right may be used to describe relative positions of components as viewed from a particular perspective within the system.

[0037] Throughout this specification, various panels, portions, tabs, flaps, fold lines, and other components of the constructs and carriers may be designated using relative terms such as first, second, third, and so forth. These designations may be used in sequential or non-sequential reference to distinguish between similar components without implying any particular order of importance or operation unless specifically indicated. Similarly, the various plows, guides, and other system components may be designated with alphabetical or numerical identifiers to facilitate description of their respective functions and positions within the overall system configuration.

[0038] FIG. 1 illustrates a flat blank 10 according to an embodiment of the subject matter disclosed herein. The blank 10 may comprise a substantially planar sheet of material that may be configured to form a carrier for engaging with a plurality of articles. The blank 10 may include a central panel 13 that may serve as a primary structural element of the carrier. The central panel 13 may be positioned substantially in the center of the blank 10 and may provide a foundation for supporting the articles when the blank 10 may be formed into a carrier configuration.

[0039] The blank 10 may include a left cap enclosing panel 14 and a right cap enclosing panel 15 that may be positioned adjacent to the central panel 13. The left cap enclosing panel 14 may be connected to the central panel 13 along a fold line 21f that may allow the left cap enclosing panel 14 to be folded relative to the central panel 13. The right cap enclosing panel 15 may be similarly connected to the central panel 13 along another fold line 21e that may permit folding movement of the right cap enclosing panel 15.

[0040] The central panel 13 may include a plurality of container cap central panel orifices 16 that may be configured to receive a portion of a beverage container cap. The container cap central panel orifices 16 may be sized and shaped to accommodate the cap and/or neck regions of individual beverage containers when engaged with the blank 10. In this embodiment, there are eight orifices to accommodate eight beverage containers. In other embodiments (e.g., FIG. 3) there may be six orifices or any other suitable number. The orifices 16 may also include biasing flaps suited to be maneuvered within the opening of the orifice to slide over the top of the cap and/or neck regions and securing the container in the orifice when passing the cap and/or neck region threshold. Further, as will be illustrated in the figures below, the left cap enclosing panel 14 may also include a container cap left panel orifices 17a that may be positioned to align with respective beverage container caps and/or neck portions when the blank 10 is in an assembled configuration. Similarly, the right cap enclosing panel 15 may include container cap right panel orifices 17b that may similarly be positioned to receive or accommodate respective beverage container caps and/or neck portions when assembled.

[0041] The central panel 13 may further include a first central panel finger holder orifice 18a and a second central panel finger holder orifice 18b. The first and second central panel finger holder orifices 18a and 18b may be configured to provide a means for a person to lift the container with beverages engaged therein. That is, in one example, a person's thumb may engage the first central panel finger holder orifice 18a and the person's index finger may engage the central panel finger holder orifice 18b to carry the overall carrier and containers assembly.

[0042] To provide additional support and reinforcement for the finger holder orifices 18a and 18b, the left cap enclosing panel 14 may include a first left panel finger holder orifice 19a and a second left panel finger holder orifice 19b. When folded (e.g., assembled), the first left panel finger holder orifice 19a and a second left panel finger holder orifice 19b are disposed coincident with the central panel finger holder orifices 18a and 18b, respectively. Likewise, the right cap enclosing panel 15 may include a first left panel finger holder orifice 20a and a second left panel finger holder orifice 20b. When folded (e.g., assembled), the first left panel finger holder orifice 20a and a second left panel finger holder orifice 20b are disposed coincident with the central panel finger holder orifices 18a and 18b, respectively.

[0043] The blank 10 may include a left leading-edge tab 12a that may extend from one edge (e.g., a trailing edge) of the left cap enclosing panel 14. The left leading-edge tab 12a may be configured to provide structural support when the blank 10 is formed into a constructed carrier. Thus, fold lines 22a, 22b, and 22c facilitate folding the left leading-edge tab 12a to form a rectangular construct to provide support this edge of the left cap enclosing panel 14. The fold lines and associated panel contiguous with the folds line 22b and 22c may be folded and manipulated by other portions of the machine for assembly. Of particular interest in this disclosure, however, is the fold line 22a that may benefit from a pre-break procedure to assist proper additional folding and construction. Such a pre-break procedure for this left leading-edge tab 12a is discussed below with respect to FIG. 7.

[0044] The blank 10 may also include a right leading-edge tab 12b that may extend from an edge of the right cap enclosing panel 15 and may provide similar structural functionality (e.g., with fold lines similar to fold lines 22a, 22b, and 22c) to the right cap enclosing panel 15 when assembled.

[0045] The blank 10 may further include a left trailing-edge tab 11a and a right trailing-edge tab 11b. The left leading-edge tab 11a may be positioned at a trailing edge of the left cap enclosing panel 14 and is similarly configured with fold lines to form a construct to support the right cap enclosing panel 14. Likewise, the right trailing-edge tab 11b may be positioned at a trailing edge of the right cap enclosing panel 15 and is similarly configured with fold lines to form a construct to support the right cap enclosing panel 15. As before, the trailing-edge tabs 11a and 11b may benefit from a pre-break procedure to initially cause folding along fold line 22d so as to further facilitate follow-on construction. This trailing edge pre-break procedure is discussed below with respect to FIG. 8.

[0046] The blank 10 may include multiple additional fold lines that may facilitate the formation of the blank 10 into a three-dimensional carrier structure. A first fold line 21f may be positioned to define a boundary between the central panel 13 and the left cap enclosing panel 14 of the blank 10. A second fold line 21e may be positioned to allow folding movement between the central panel 13 and the right cap enclosing panel 15 of the blank 10. The blank 10 may include additional fold lines with either the right cap enclosing panel 15 or the left cap enclosing panel including a third fold line 21a, a fourth fold line 21b, a fifth fold line 21c, a sixth fold line 21d, a seventh fold line 21g, an eighth fold line 21h, a ninth fold line 21i, and a tenth fold line 21j. Each of these fold lines may be positioned to enable specific folding movements that may transform the blank 10 from a substantially planar configuration into a three-dimensional carrier structure. The fold lines may be exercised in the machine of FIG. 5 using plows, stompers, and manipulators as described below with respect to FIG. 5 and FIGS. 10a-10H.

[0047] FIG. 2A depicts an assembled carrier formed from the blank of FIG. 1 holding multiple containers according to an embodiment of the subject matter disclosed herein. Referring to FIG. 2A, the construct 20 may be formed from the blank 10 of FIG. 1 into an assembled carrier configuration that may engage with a plurality of beverage containers 25. The construct 20 may be configured to hold the beverage containers 25 in a predetermined arrangement that may facilitate handling and transportation of the containers as a single unit. The beverage containers 25 may be positioned such that their caps 26 and/or neck regions may be received within the various orifices formed in the construct 20.

[0048] The central panel 13 of the construct 20 may serve as the primary structural foundation for supporting the beverage containers 25. The central panel 13 may be positioned substantially horizontally when the construct 20 may be in its assembled configuration. The container cap central panel orifices 16 formed in the central panel 13 may receive the caps 26 and/or neck regions of the beverage containers 25. Each container cap central panel orifice 16 may be sized to accommodate the diameter of a beverage container cap 26 and/or neck region while providing sufficient engagement to secure the container in position.

[0049] The left cap enclosing panel 14 may be folded along fold line 21f (see FIG. 1) to extend upwardly from the central panel 13. The left cap enclosing panel 14 may be positioned to cover a portion of the caps 26 and/or neck regions of the beverage containers 25 located on the left side of the construct 20. The container cap left panel orifices 17a formed in the left cap enclosing panel 14 may align with the caps 26 of the left side beverage containers when the panel may be in its folded position. The alignment of the container cap left panel orifices 17a with the container cap central panel orifices 16 may create a continuous opening that may accommodate the full height of the beverage container caps 26.

[0050] The right cap enclosing panel 15 may be similarly folded along fold line 21e to extend upwardly from the central panel 13. The right cap enclosing panel 15 may be positioned to cover a portion of the caps 26 of the beverage containers 25 located on the right side of the construct 20. The container cap right panel orifices 17b formed in the right cap enclosing panel 15 may align with the corresponding caps 26 and/or neck regions when the panel may be in its assembled position. The container cap right panel orifices 17b may work in conjunction with the container cap central panel orifices 16 to provide complete enclosure around the beverage container caps 26 and/or at least partial enclosure of the neck regions of the containers.

[0051] The left leading-edge tab 11b and right leading-edge tab 11a may be folded to provide structural support at the leading edges of the construct 20, although in FIG. 2 these features have been hidden for clarity. The tabs may be configured with fold lines that may allow them to be formed into rectangular support structures.

[0052] FIG. 2B shows a top view of the carrier of FIG. 2 according to an embodiment of the subject matter disclosed herein. Referring to FIG. 2B, the construct 20 may be viewed from above to show the final assembly configuration with eight beverage containers 25 engaged therein. The top view may reveal the spatial arrangement of the beverage containers 25 within the construct 20 and may illustrate how the various panels and orifices may work together to secure the containers in their designated positions. The eight beverage containers 25 may be arranged in a rectangular pattern with four containers positioned along each side of the construct 20.

[0053] The central panel 13 may be visible from the top view and may display the eight container cap central panel orifices 16 that may accommodate the caps 26 and/or neck regions of the beverage containers 25. The container cap central panel orifices 16 may be arranged in two parallel rows with four orifices in each row. The spacing between the orifices may be configured to match the standard spacing requirements for beverage container packaging. Each container cap central panel orifice 16 may be sized to provide a secure fit around the circumference of a beverage container cap 26 and/or neck region while allowing for easy insertion during the assembly process.

[0054] The left cap enclosing panel 14 may be folded over the central panel 13 and may cover the left portion of the beverage container caps 26. The container cap left panel orifices 17a formed in the left cap enclosing panel 14 may align with the container cap central panel orifices 16 to create continuous openings for the left side beverage containers. The alignment may ensure that the beverage container caps 26 and/or neck regions may be fully enclosed within the combined orifice structure formed by both panels.

[0055] The right cap enclosing panel 15 may be similarly positioned over the central panel 13 and may cover the right portion of the beverage container caps 26 and/or neck regions. The container cap right panel orifices 17b may align with the corresponding container cap central panel orifices 16 to provide an enclosure for the right side beverage containers. The overlapping configuration of the panels may create a secure engagement system that may prevent the beverage containers 25 from becoming dislodged during handling or transportation.

[0056] The first central panel finger holder orifice 18a and second central panel finger holder orifice 18b may be visible in the top view and may provide access points for manual handling of the complete package. The finger holder orifices may be positioned to allow a user to insert fingers through the openings and lift the entire assembly of the construct 20 and engaged beverage containers 25. The reinforcement provided by the overlapping panels may strengthen the finger holder orifices and may distribute the weight of the beverage containers 25 across multiple layers of material.

[0057] FIG. 3 illustrates an alternative blank configuration with multiple openings and features according to an embodiment of the subject matter disclosed herein. FIG. 3 illustrates a flat blank 30 according to a second embodiment of the subject matter disclosed herein. The blank 30 may comprise a substantially planar sheet of material that may be configured to form a carrier for engaging with six beverage containers. The blank 30 may include a central panel 33 that may serve as a primary structural element of the carrier. The central panel 33 may be positioned substantially in the center of the blank 30 and may provide a foundation for supporting the articles when the blank 30 may be formed into a carrier configuration.

[0058] The blank 30 may include a left cap enclosing panel 34 and a right cap enclosing panel 35 that may be positioned adjacent to the central panel 33. The left cap enclosing panel 34 may be connected to the central panel 33 along a fold line 41f that may allow the left cap enclosing panel 34 to be folded relative to the central panel 33. The right cap enclosing panel 35 may be similarly connected to the central panel 33 along another fold line 41e that may permit folding movement of the right cap enclosing panel 35.

[0059] The central panel 33 may include a plurality of container cap central panel orifices 36 that may be configured to receive a portion of a beverage container cap. The container cap central panel orifices 36 may be sized and shaped to accommodate the cap of individual beverage containers when engaged with the blank 30. In this embodiment, there may be six orifices to accommodate six beverage containers. The orifices 36 may also include biasing flaps suited to be maneuvered within the opening of the orifice to slide over the top of the cap and securing the cap in the orifice when passing the cap threshold.

[0060] The left cap enclosing panel 34 may also include container cap left panel orifices 37a that may be positioned to align with beverage container caps when the blank 30 may be in an assembled configuration. Similarly, the right cap enclosing panel 35 may include container cap right panel orifices 37b that may similarly be positioned to receive or accommodate a beverage container cap when assembled.

[0061] The central panel 33 may further include a first central panel finger holder orifice 38a and a second central panel finger holder orifice 38b. The first and second central panel finger holder orifices 38a and 38b may be configured to provide a means for a person to lift the container with beverages engaged therein. To provide additional support and reinforcement for the finger holder orifices 38a and 38b, the left cap enclosing panel 34 may include a first left panel finger holder orifice 39a and a second left panel finger holder orifice 39b. When folded, the first left panel finger holder orifice 39a and second left panel finger holder orifice 39b may be disposed coincident with the central panel finger holder orifices 38a and 38b, respectively. Likewise, the right cap enclosing panel 35 may include a first right panel finger holder orifice 40a and a second right panel finger holder orifice 40b. When folded, the first right panel finger holder orifice 40a and second right panel finger holder orifice 40b may be disposed coincident with the central panel finger holder orifices 38a and 38b, respectively.

[0062] The blank 30 may include a right trailing tab 32a that may extend from one edge of the right cap enclosing panel 35. The right trailing tab 32a may be configured to provide structural support when the blank 30 may be formed into a constructed carrier. Fold lines 42a, 42b, and 42c may facilitate folding the right trailing-edge tab 32a to form a rectangular construct to provide support to this edge of the right cap enclosing panel 35. The blank 30 may also include a left trailing-edge tab 32b that may extend from an edge of the left cap enclosing panel 34 and may provide similar structural functionality to the left cap enclosing panel 34 when assembled.

[0063] The blank 30 may further include a right leading-edge tab 31a and a left leading-edge tab 31b. The right leading-edge tab 31a may be positioned at a leading edge of the right cap enclosing panel 35 and may be similarly configured with fold lines to form a construct to support the right cap enclosing panel 35. Likewise, the left leading-edge tab 31b may be positioned at a leading edge of the left cap enclosing panel 34 and may be similarly configured with fold lines to form a construct to support the left cap enclosing panel 34.

[0064] The blank 30 may include multiple fold lines that may facilitate the formation of the blank 30 into a three-dimensional carrier structure. A first fold line 41e may be positioned to define a boundary between the central panel 33 and the right cap enclosing panel 35 of the blank 30. A second fold line 41f may be positioned to allow folding movement between the central panel 33 and the left cap enclosing panel 34 of the blank 30. The blank 30 may include additional fold lines including a third fold line 41a, a fourth fold line 41b, a fifth fold line 41c, a sixth fold line 41d, a seventh fold line 41g, an eighth fold line 41h, a ninth fold line 41i, and a tenth fold line 41j. Each of these fold lines may be positioned to enable specific folding movements that may transform the blank 30 from a substantially planar configuration into a three-dimensional carrier structure.

[0065] FIG. 4 depicts an assembled carrier formed from the blank of FIG. 3 holding multiple containers according to an embodiment of the subject matter disclosed herein. Referring to FIG. 4, the construct 40 may be formed from the blank 30 of FIG. 3 into an assembled carrier configuration that may engage with a plurality of six beverage containers 25. The construct 40 may be configured to hold the beverage containers 25 in a predetermined arrangement that may facilitate handling and transportation of the containers as a single unit. The beverage containers 25 may be positioned such that their caps 26 may be received within the various orifices formed in the construct 40.

[0066] The central panel 33 of the construct 40 may serve as the primary structural foundation for supporting the six beverage containers 25. The central panel 33 may be positioned substantially horizontally when the construct 40 may be in its assembled configuration. The container cap central panel orifices 36 formed in the central panel 33 may receive the caps 26 of the beverage containers 25. Each container cap central panel orifice 36 may be sized to accommodate the diameter of a beverage container cap 26 while providing sufficient engagement to secure the container in position. The six container cap central panel orifices 36 may be arranged in a rectangular pattern with three orifices positioned along each side of the construct 40.

[0067] The left cap enclosing panel 34 may be folded along fold line 41f to extend upwardly from the central panel 33. The left cap enclosing panel 34 may be positioned to cover a portion of the caps 26 of the beverage containers 25 located on the left side of the construct 40. The container cap left panel orifices 37a formed in the left cap enclosing panel 34 may align with the caps 26 of the left side beverage containers when the panel may be in its folded position. The alignment of the container cap left panel orifices 37a with the container cap central panel orifices 36 may create a continuous opening that may accommodate the full height of the beverage container caps 26.

[0068] The right cap enclosing panel 35 may be similarly folded along fold line 41e to extend upwardly from the central panel 33. The right cap enclosing panel 35 may be positioned to cover a portion of the caps 26 of the beverage containers 25 located on the right side of the construct 40. The container cap right panel orifices 37b formed in the right cap enclosing panel 35 may align with the corresponding caps 26 when the panel may be in its assembled position. The container cap right panel orifices 37b may work in conjunction with the container cap central panel orifices 36 to provide complete enclosure around the beverage container caps 26.

[0069] The left leading-edge tab 31b and right leading-edge tab 31a may be folded to provide structural support at the leading edges of the construct 40. The tabs may be configured with fold lines that may allow them to be formed into rectangular support structures. The left trailing-edge tab 32b and right trailing-edge tab 32a may be similarly folded to provide structural reinforcement at the trailing edges of the construct 40. The trailing-edge tabs may be formed using fold lines 42a, 42b, and 42c to create three-dimensional support structures that may enhance the overall rigidity of the construct 40.

[0070] The first central panel finger holder orifice 38a and second central panel finger holder orifice 38b may be positioned to provide access points for manual handling of the complete package. The finger holder orifices may allow a user to insert fingers through the openings and lift the entire assembly of the construct 40 and engaged beverage containers 25. The first left panel finger holder orifice 39a and second left panel finger holder orifice 39b may align with the central panel finger holder orifices when the left cap enclosing panel 34 may be folded into position. Similarly, the first right panel finger holder orifice 40a and second right panel finger holder orifice 40b may align with the central panel finger holder orifices when the right cap enclosing panel 35 may be folded into position. The overlapping configuration of the finger holder orifices may provide reinforcement and may distribute the weight of the six beverage containers 25 across multiple layers of material.

[0071] FIG. 5 depicts a portion of a machine for assembling blanks of FIG. 1 or FIG. 3 with containers according to an embodiment of the subject matter disclosed herein. Referring to FIG. 5, the machine 50 may be configured to process blanks that have received a plurality of containers within the central panel and to complete processing of the construct according to the embodiments disclosed herein. The machine 50 may include a conveyance system 51 that initiates with a blank feeder 54 that may receive blanks that have at least partially received a plurality of containers. The conveyance system 51 is not shown for clarity in FIG. 5 and the machine 50 may be further supported by stanchions 53 and anchors 52. Further, additional portions of the machine 50 are not shown, such as a linear motor carousel that positions the containers, a blank feeder and an initial folding carousel that all work in conjunction with the portion of the machine 50 shown in FIG. 5.

[0072] FIG. 6 shows a sequence of images of blanks during an assembly procedure using the machine of FIG. 5 in various stages of formation according to an embodiment of the subject matter disclosed herein. Referring to FIG. 6, the conveyance system 51 may operate through a series of sequential stages that may transform flat blanks into assembled carriers engaged with beverage containers. The first stage may involve the blank feeder 54 receiving blank that includes a plurality of containers as shown in the first stage 55a. The blank may be oriented with its central panel positioned horizontally.

[0073] A preliminary stage may arrange and orient the beverage containers 25 and then position the containers such that their caps 26 and/or neck regions may be aligned with the container cap central panel orifices formed in the central panel of the blank. The containers may be pressed into engagement with the orifices such that the caps may pass through the openings and may be secured within the blank structure. A further stage of assembly (also not shown in the figures) includes partially folding the leading and trailing-edge tabs of the blank.

[0074] The second stage 55b may involve the activation of plow mechanisms that may begin the folding process of the blank. As is discussed in greater detail below, a first plow may engage with the left and right cap enclosing panels and may maneuver the panels upwardly from their initial flat position. The plow may apply controlled pressure to fold the left cap enclosing panel along its designated fold line. The left cap enclosing panel may be positioned to cover a portion of the beverage container caps located on the left side of the assembly.

[0075] The third stage 55c may comprise the operation of the second plow that may engage with the left and right cap enclosing panels. The second plow may position the left and right cap enclosing panels over the central panel. The fourth stage 55d involves a further set of plows to further manipulate panels to be ready for final enclosure with the beverage containers.

[0076] The fifth stage 55e may involve the simultaneous operation of right-side static guides and left side dynamic guides and stompers that may apply downward pressure to secure the left-side folded panels in their final positions. The stompers may use eccentric tooling to press the left cap enclosing panels firmly against the beverage container caps during progression of the assembly to ensure proper engagement. The stompers may also ensure that the container cap orifices in the side panels may be properly aligned with the central panel orifices to provide complete enclosure around the caps.

[0077] The sixth stage 55f may involve the simultaneous operation of right-side dynamic guides and stompers and with the right side of the package that may apply downward pressure to secure the right-side folded panels in their final positions. The stompers may use eccentric tooling to press the right cap enclosing panels firmly against the beverage container caps to ensure proper engagement. The stompers may also ensure that the container cap orifices in the side panels may be properly aligned with the central panel orifices to provide complete enclosure around the caps.

[0078] Referring to FIG. 7, a pre-break procedure is illustrated wherein leading-edge manipulators 54 are shown performing a pre-break procedure on the leading-edge tabs 12a and 12b of a blank 10 as the blank assembly is fed into the machine 50. The leading-edge manipulators 54 may be positioned along the conveyance system 51 to engage with the leading-edge tabs 12a and 12b before the blank 10 may proceed to subsequent assembly stages. The pre-break procedure may be configured to initiate folding along fold line 22a within the leading-edge tabs 12a and 12b to facilitate proper formation of the tabs during later assembly operations.

[0079] The blank 10 may be conveyed through the machine 50 with the leading-edge tabs 12a and 12b positioned at the front edge of the blank relative to the direction of travel. The leading-edge tab 12a may extend from the left cap enclosing panel 14 and may include fold line 22a that may require pre-breaking to ensure proper subsequent folding. Similarly, the leading-edge tab 12b may extend from the right cap enclosing panel 15 and may include a corresponding fold line that may benefit from the pre-break procedure.

[0080] The leading-edge manipulators 54 may comprise mechanical elements that may be configured to apply controlled pressure or force to the leading-edge tabs 12a and 12b. The manipulators 54 may engage with the tabs 12a and 12b utilizing finger-like protrusions pointing downward at the ends of each manipulator 54. The pre-break procedure may involve applying sufficient force to partially crease or bend the leading-edge tabs at the fold line 22a without damaging the blank as the blank progresses forward. That is, when the leading-edge tabs 12a and 12b fold far enough, the finger-like protrusions will disengage the blank 10 as the blank 10 travels far enough along the propagation path.

[0081] Beverage containers 25 may be positioned beneath the blank 10 during the pre-break procedure and supported with tooling that moves at the same velocity as the blank. Tooling and/or the containers 25 may provide support for the blank 10 while the leading-edge manipulators 54 may perform the pre-breaking operation on the leading-edge tabs 12a and 12b. The tooling that supports the containers 25 may ensure that the blank 10 may remain stable during the manipulation of the leading-edge tabs.

[0082] The leading-edge manipulators 54 may be configured to operate simultaneously on both leading-edge tabs 12a and 12b to ensure uniform processing of the blank 10. The manipulators may apply pressure in a downward direction to create the initial fold along fold line 22a in leading-edge tab 12a and the corresponding fold line in leading-edge tab 12b. The pre-break procedure may create a weakened area along the fold line 22a that may facilitate easier and more precise folding during subsequent assembly operations. In some embodiments, there are four leading-edge manipulators 54 but in other embodiments this number may be more or fewer.

[0083] Referring to FIG. 8, a portion of the machine 50 is shown in perspective to illustrate a trailing-edge pre-break procedure. As before, the overall construction of the carton formed from blank 10 may benefit from having the trailing-edge tabs 11a and 11b pre-broken for further manipulation is downstream procedures. The blank 10 may be engaged with beverage container caps at this point but are not illustrated here in order to show more clearly the trailing edge panel pre-break procedure. The blank may be propagated through this portion of the machine using two conveyor belts 60b and 60c that utilize a series of motorized wheels and an overall tension pully 60a to facilitate a pinch point 60e between belts 60b and 60c. The blank 10 is further supported by stabilizer 60d as it propagates through this section. In this reverse view, the blank 10 propagates from left to right such that the mechanism is arranged to fold the trailing-edge tabs 11a and 11b.

[0084] Dynamic cam 63 with engagement point 65 is actuated by rotation of dynamic cam shaft 62 which may rotate clockwise at varying speed. Engagement point 65 may engage trailing-edge tab 11b and may force the trailing-edge tab 11b upwards along fold line 22d. The prebreak procedure for trailing-edge tab 11b may commence when engagement point 65 may make initial contact with the underside surface of trailing-edge tab 11b. Dynamic cam 63 may continue rotating to apply progressive upward pressure against trailing-edge tab 11b. The upward force may cause trailing-edge tab 11b to begin bending along fold line 22d. The bending motion may create a partial separation of the material fibers along fold line 22d without completely severing the connection. Dynamic cam 63 may maintain contact with trailing-edge tab 11b throughout a predetermined arc of rotation. The engagement point 65 may follow a curved path that may gradually lift trailing-edge tab 11b to a predetermined angle (e.g., 120 degrees, as but one example) relative to the main body of the blank. The prebreak procedure may weaken the material along fold line 22d to facilitate subsequent folding operations. Upon completion of the prebreak cycle, dynamic cam 63 may disengage from trailing-edge tab 11b as the cam may continue its rotational motion. Note that a second dynamic cam (not shown in FIG. 8) may be attached to the same dynamic cam shaft 62 and may fold trailing-edge tab 11a.

[0085] FIG. 9A illustrates an initial stage of the trailing edge pre-break procedure wherein dynamic cam 63 may be positioned to engage with trailing-edge tab 11a (or 11b) of blank 10. The dynamic cam 63 may be mounted on dynamic cam shaft 62 and may be configured to rotate in a clockwise direction during the pre-break operation. The engagement point 65 of dynamic cam 63 may be positioned beneath trailing-edge tab 11a and may be oriented to make initial contact with the underside surface of the tab 11a. The blank 10 may be supported by the conveyance system during this stage to maintain proper positioning for the pre-break procedure.

[0086] The dynamic cam 63 may be configured with a curved profile that may allow engagement point 65 to follow a predetermined path during rotation. The engagement point 65 may be positioned at a specific location on the circumference of dynamic cam 63 to provide optimal contact with trailing-edge tab 11a. The dynamic cam shaft 62 may be connected to a drive mechanism (e.g., servomotor, stepper motor, AC motor, DC motor, linear motor, and the like) that may control the rotational speed and timing of the pre-break operation. The positioning of dynamic cam 63 relative to trailing-edge tab 11a may be calibrated to ensure proper engagement without causing damage to the blank material.

[0087] FIG. 9B depicts a subsequent stage of the trailing edge pre-break procedure wherein dynamic cam 63 may have rotated to bring engagement point 65 into contact with trailing-edge tab 11a. The rotation of dynamic cam 63 may cause engagement point 65 to apply upward pressure against the underside surface of trailing-edge tab 11a. The upward force may begin to bend trailing-edge tab 11a along fold line 22d. The bending motion may create initial stress concentration along the fold line without completely severing the material connection. This step may be performed at a first rotational velocity that achieve bending of the trailing-edge tab 11a while the blank is progressing forward.

[0088] The dynamic cam 63 may continue its rotational motion to maintain contact with trailing-edge tab 11a throughout a predetermined arc of rotation. The engagement point 65 may follow the curved profile of dynamic cam 63 to provide controlled lifting force against trailing-edge tab 11a. The upward pressure may be applied gradually to avoid sudden stress that could damage the blank material. The rotation speed of dynamic cam 63 may be coordinated with the conveyance speed of blank 10 to ensure proper timing and operation of the pre-break operation.

[0089] FIG. 9C illustrates a further stage of the trailing edge pre-break procedure wherein dynamic cam 63 may have rotated to a position where engagement point 65 may be applying an upward force against trailing-edge tab 11a. The trailing-edge tab 11a may be bent to a predetermined angle relative to the main body of blank 10. The bending motion may cause partial separation of the material fibers along fold line 22d. The pre-break procedure may weaken the material structure along the fold line to facilitate subsequent folding operations.

[0090] The engagement point 65 may maintain contact with trailing-edge tab 11a while dynamic cam 63 may continue its rotational motion. The upward force applied by engagement point 65 may continue to increase during this stage of the procedure. The bending angle of trailing-edge tab 11a may be controlled by the geometric and rotational velocity profiles of dynamic cam 63 and the position of engagement point 65. The pre-break operation may create a controlled weakening of the fold line without compromising the structural integrity of the blank.

[0091] FIG. 9D shows a final stage of the trailing edge pre-break procedure wherein dynamic cam 63 may be completing its engagement cycle with trailing-edge tab 11a. The trailing-edge tab 11a may have been bent to its maximum predetermined angle during the pre-break operation. The engagement point 65 may be preparing to disengage from trailing-edge tab 11a as dynamic cam 63 may continue its rotational motion. During this stage of the prebreak operation the rotational velocity of the cam may be increased to cause the trailing-edge tab 11a to fold forward (the same direction of progression of the blank) which needs the cam to travel faster than the velocity of the blank. This velocity may be faster than the velocity of the previous operations. At the end of the prebreak procedure the velocity may very quickly go to zero to stop at the requisite prebreak angle which may be between 105 degrees and 170 degrees, between 110 degrees and 130 degrees or between 115 degrees and 125 degrees.

[0092] The pre-break procedure may be substantially complete at this stage with trailing-edge tab 11a having been weakened along fold line 22d. The dynamic cam 63 may continue rotating beyond this position to return engagement point 65 to its initial starting position for the next pre-break cycle. The trailing-edge tab 11a may retain its pre-broken condition to facilitate easier folding during subsequent assembly operations in the packaging system. As described above, second, third, fourth, etc. cams may be attached to the shaft to facilitate simultaneous breaking of trailing-edge tabs 11a and 11b.

[0093] FIGS. 10A-10E illustrate portions of the machine of FIG. 5 corresponding to the stages of assembly depicted in FIG. 6 without the blanks in the stages according to an embodiment of the subject matter disclosed herein. Likewise, FIGS. 11A-11E illustrate respective assembly stages of the blank as proceeding through the machine of FIG. 5 without the machine stage according to an embodiment of the subject matter disclosed herein.

[0094] FIG. 10A illustrates a portion of the machine 50 corresponding to the first stage 55a of assembly depicted in FIG. 6. The machine portion 60 may include two parallel rails 63a and 63b that may be positioned to guide and support blanks during the initial assembly stage. The rails 63a and 63b may be configured to maintain proper alignment of the blanks as they may be conveyed through the assembly process. The machine portion 60 may include mounting brackets 61a and 61b that may be positioned above the rails 63a and 63b respectively. The mounting brackets 61a and 61b may provide structural support for additional components that may be required during the assembly process. Two motorized actuators 62a and 62b may be positioned above and between the rails 63a and 63b. The motorized actuators 62a and 62b may serve as actuators to impart motion to tamper roller 64a and 64b that may apply controlled pressure or movement to blanks during the initial assembly stage. The motorized actuators 62a and 62b may be configured to operate in coordination with the conveyance system to ensure proper timing of assembly operations. The operation and tamping procedure utilizing the tamper roller 64a and 64b are discussed below with respect to FIGS. 12A-12D.

[0095] FIG. 11A depicts the first stage 55a of blank assembly wherein beverage containers 25 may be positioned engaged with a blank during the folding process. In this profile view, the blank shows trailing edge tabs 11a and 11b maneuvered to an upright position with respect to the plane of the blank 10. The upright position depicted may represent the trailing edge tabs 11a and 11b raised from the plan at 120-degree obtuse angle (e.g., a 60-degree acute angle) and ready for tamping as discussed next with respect to FIGS. 12A-12D.

[0096] Referring to FIG. 12A, the tamper wheel 64a may be positioned after the trailing-edge tab pre-break stage to further manipulate the leading-edge tab 12a and trailing-edge tab 11a of the blank 10. The tamper wheel 64a may include an outer rolling surface that may be arranged to roll across the blank 10 as the blank propagates through the system. The rolling surface of the tamper wheel 64a may be interrupted by a recess 66 that may be configured to align with the trailing-edge tab 11a during operation. The system may be configured to position the recess 66 in alignment with the trailing-edge tab 11a as the blank 10 moves through the tamper wheel stage.

[0097] The tamper wheel 64a may be mounted on a motorized actuator 62a that may control the rotational motion of the wheel. The motorized actuator 62a may be configured to match a rotational velocity of the tamper wheel 64a to a horizontal velocity of the blank 10 as the tamper wheel rolls across each blank. The synchronization of the rotational velocity with the horizontal velocity may ensure that the tamper wheel 64a maintains proper contact with the blank 10 without causing slippage or damage to the blank material.

[0098] Referring to FIG. 12B, the tamper wheel 64a may begin to engage with the leading-edge tab 12a as the blank 10 continues to propagate through the system. As the tamper wheel passes over the leading-edge tab 12a, the angle by which the leading-edge tab 12a was previously maneuvered is decreased and the pre-break line of weakening is reinforced by tamping. The system may be configured to monitor the position of the trailing-edge tab 11a relative to the recess 66 to ensure proper timing of the tamper operation. The tamper wheel 64a may maintain its synchronized rotational velocity with the horizontal velocity of the blank 10 during this stage of the operation.

[0099] Referring to FIG. 12C, the recess 66 of the tamper wheel 64a may begin to be at least partially aligned with the trailing-edge tab 11a. The system may be arranged to match the rotational velocity of the tamper wheel 64a to ensure that the trailing-edge tab 11a is aligned with the recess 66 when the tamper wheel engages the trailing-edge tab 11a.

[0100] Referring to FIG. 12D, the tamper wheel 64a may continue to operate at the rotational velocity while the recess 66 may be substantially aligned with the trailing-edge tab 11a. The matched rotational velocity allows for an alignment of the wedge-like recess 66 to catch the trailing-edge tab 11a and begin to tamp it down. The tamping engagement may cause the trailing-edge tab 11a to bend further about the fold line 22d beyond the angle achieved during the pre-break procedure.

[0101] Referring to FIG. 12E, the tamper wheel 64a may complete its engagement with the trailing-edge tab 11a as the recess 66 moves past the trailing-edge tab position. The system may be configured to maintain the rotational velocity of the tamper wheel 64a to match the horizontal velocity of the blank 10 after the trailing-edge tab 11a has been further manipulated. The trailing-edge tab 11a may retain its further bent configuration achieved through the tamper wheel operation. The tamper wheel 64a may continue to roll across the blank 10 with its synchronized velocity until the next blank may be encountered.

[0102] FIG. 10B illustrates a portion of the machine 50 corresponding to the second stage 55b of assembly depicted in FIG. 6. The machine portion 70 may comprise an elongated assembly that may be positioned at an angle relative to the conveyance system to facilitate the folding operations required during the second assembly stage. The machine portion 70 may include two plows 71a and 71b that may be positioned at a leading end of this portion. The plows 71a and 71b may be configured to engage with the left and right cap enclosing panels of blanks as they may be conveyed through this portion 70 of the assembly process. The machine portion 70 may include two elements 72a and 72b that may be positioned alongside the plows 71a and 71b. The elements 72a and 72b may serve as supports or anchors that may maintain proper positioning of the plows 71a and 71b during the manipulation operations.

[0103] FIG. 11B depicts the second stage 55b of blank assembly wherein beverage containers 25 may be positioned vertically and may be engaged with a blank 10 during the folding process. The beverage containers 25 may be arranged side by side and may be secured within the container cap central panel orifices of the blank. The beverage containers 25 may be positioned with their caps extending through the container cap central panel orifices formed in the central panel of the blank. The containers may be held in a stable vertical orientation while the folding operations may be performed on the cap enclosing panels. In this depiction, the cap enclosing panels 10a are folded up (e.g., plowed) into a roughly 45-degree angle from the planer blank 10.

[0104] The second stage 55b may correspond to the point in the assembly process where the first plows 71a and 71b may begin engaging with the left and right cap enclosing panels of the blank. The cap enclosing panels may be maneuvered upwardly from their initial flat position to begin covering portions of the beverage container caps. The beverage containers 25 may remain in their vertical positions while the blank panels may be folded around them to create the assembled carrier configuration.

[0105] FIG. 10C illustrates a portion of the machine 50 corresponding to the third stage 55c of assembly depicted in FIG. 6. The machine portion 75 may comprise an assembly that may be configured to perform additional folding operations on the cap enclosing panels 10a of blanks during the third assembly stage. The assembly 75 may include multiple components that may be positioned to engage with different portions of the blanks 10 as they may be conveyed through this section of the packaging system.

[0106] The machine portion 75 may include a second plow assembly 76a that may be positioned on the left side of the conveyance path. The second plow assembly 76a may be configured to engage with the left cap enclosing panel of blanks 10 and may apply controlled pressure to continue the folding process initiated in the previous assembly stage. The second plow assembly 76a may include angled surfaces that may guide the left cap enclosing panel into its proper position relative to the central panel and engaged beverage containers.

[0107] A third plow assembly 76b may be positioned on the right side of the conveyance path and may be configured to engage with the right cap enclosing panel of blanks 10. The third plow assembly 76b may operate in coordination with the second plow assembly 76a to ensure simultaneous folding of both cap enclosing panels. The third plow assembly 76b may include similar angled surfaces that may guide the right cap enclosing panel into its designated position during the third assembly stage 55c.

[0108] The machine portion 75 may include guide rails 77a and 77b that may be positioned to maintain proper alignment of blanks as they may be conveyed through the third assembly stage. The guide rails 77a and 77b may be configured to prevent lateral movement of the blanks while allowing the folding operations to be performed on the cap enclosing panels. The guide rails 77a and 77b may be adjustable to accommodate blanks of different sizes or configurations.

[0109] A support structure may be positioned beneath the conveyance path and may be configured to provide structural stability for the machine portion 75. The support structure may include mounting points for the plow assemblies 76a and 76b and may ensure proper positioning of these components relative to the blanks being processed.

[0110] FIG. 11C depicts the third stage 55c of blank assembly wherein beverage containers 25 may be positioned vertically and may be engaged with a blank 10 during an advanced folding process. The beverage containers 25 may be arranged side by side and may be secured within the container cap central panel orifices of the blank. The containers 25 may be held in a stable vertical orientation while additional folding operations may be performed on the cap enclosing panels 10a-10c.

[0111] During further manipulation, the panel element may be further plowed to impart an additional fold angle in the respective left and right side of the blank 10. Thus, the panel 10a remains in the 45-dgree angle from a previous stage 55b while an additional angle is imparted (e.g., plowed) for another portion 10b of each cap-enclosing panel. As such an approximate 90-degree angle is imparted to portion 10b with respect to portion 10a.

[0112] FIG. 10D illustrates a portion 80 of the machine 50 corresponding to the fourth stage 55d of assembly depicted in FIG. 6. The machine portion 80 may comprise an assembly that may be configured to perform advanced folding and positioning operations on blanks 10 during the fourth assembly stage 55d. The assembly 80 may include multiple components that may be positioned to engage with different portions of the blanks 10 as they may be conveyed through this section of the packaging system.

[0113] The machine portion 80 may include two main parallel tracks 81a and 81b that may be positioned to guide and support blanks 10 during the fourth assembly stage. The tracks 81a and 81b may be configured to maintain proper alignment of the blanks while allowing for complex folding operations to be performed on the cap enclosing panels. The left track 81a may include mounting points for various components that may engage with the left side of blanks during processing. Similarly, the right track 81b may include corresponding mounting points for components that may engage with the right side of blanks.

[0114] The machine portion 80 may include multiple plows 79a, 79b, 81a, 81b, 82a, 82b, 84a and 84b that may extend from the main tracks 81a and 81b. The configuration of these plows may impart additional shaping of the cap enclosing panels into a shape suited for the next stage. This shape includes panels 10a, 10b, 10c, 10d, and 10e as shown in FIG. 11D. Thus, plows 79a and 79b may impart folds to realize panel 10c, plows 81a and 81b may impart folds to realize panel 10d, and plows 84a and 84b may impart folds to realize panel 10e.

[0115] Three components 79a, and 79b may be positioned at the entry point of the machine portion 80 and may be configured to receive blanks from the previous assembly stage. The plows 79a and 79b may work in coordination to ensure proper alignment and orientation of blanks as they may enter the fourth assembly stage 55d. The components may include sensors or positioning mechanisms that may verify proper blank placement before subsequent operations may be performed. The machine portion 80 may include fixtures 83a and 83b that may be spaced along the length of the assembly to provide lateral support to the plows 79a, 79b, 81a, 81b, 82a, 82b, 84a and 84b.

[0116] FIG. 11D depicts the fourth stage 55d of blank assembly wherein beverage containers 25 may be positioned vertically and may be engaged with a blank 10 during advanced panel positioning operations. The beverage containers 25 may be arranged side by side and may be secured within the container cap central panel orifices of the blank. The containers may be held in a stable vertical orientation while complex folding operations may be performed on multiple panel sections of the blank. Each cap enclosing panel may be shaped by the aforementioned plows to realize the depicted shape of panels 10a, 10b, 10c, 10d, and 10e. This stage 55d now has the shaped panels suited for clipping in the next stage 55e.

[0117] FIG. 10E illustrates a portion of the machine 50 corresponding to the fifth stage 55e of assembly depicted in FIG. 6. The machine portion may comprise a specialized dynamic guide 110 and latching tools 130 and 150 that may be configured to apply downward pressure to secure the left-side folded panels and right-side folded panels in their final positions during the fifth assembly stage 55e. The portion may include multiple directional components that may be positioned to engage with specific portions of the blanks 10 as they may be conveyed through this section of the packaging system.

[0118] In a first portion, the dynamic guide 110 may engage a left-side panel of a blank that is propagating through the machine along an exterior panel such panel 10a as depicted in FIG. 11D. In this manner, the left-side dynamic guide 110 holds the left clip enclosing panel in position while a left blade member that is part of a left-side latching tool 130 simultaneously secures the portion of the left clip enclosing panel to the containers (e.g., tucked under a neck portion) on the opposite side (e.g., the right-side containers). To assist with the holding, the dynamic guide 110 includes a belt 112 driven by internal motors at a velocity to match the propagation velocity of the engaged blank. That is, the belt 112 of the dynamic guide 110 is moving at the velocity and arranged to move the left clip enclosing panel into partial alignment with the first group of containers and to hold the left clip enclosing panel in position while the blank and the plurality of containers propagate at the velocity.

[0119] This area also includes a right static guide 113 arranged to hold the right clip enclosing panel (e.g., the opposite panel 10a) in place while the right-side latching tool 150 secures the portion of the right clip enclosing panel to the left-side containers. Each latching tool 130 and 150 may include respective actuator motors 132 and 152 for utilizing blade members to secure the clipping portions. The components are described in more detail below with respect to FIGS. 13A-13D.

[0120] FIG. 11E depicts the fifth stage 55e of blank assembly wherein beverage containers may be positioned vertically and may be engaged with a blank during clip pressing and stomping operations. The beverage containers may be arranged side by side and may be secured within the container cap central panel orifices of the blank. The containers may be held in a stable vertical orientation while stomping pressure may be applied to the left-side and right-side panel sections to secure them in their final assembled configuration.

[0121] The assembly, now shown in its final assembled state, culminates with panel sections 10a, 10b, 10c, 10d, and 10e folded into secured positions. The panel sections 10a, 10b and 10c form an encapsulating section that surrounds the cap and neck regions of engaged containers 25. The panel 10d is now pressed down into the cavity between container cap and neck regions and panel 10e is pressed into secured alignment tucked under a neck region of an opposite side container(s). Likewise, the opposite side panels are arranged similarly with a corresponding panel 10d (not shown separately) pressed down into the cavity between container cap and neck regions and a corresponding second panel 10e (not shown separately) is pressed into secured alignment tucked under a neck region of the other opposite side container(s).

[0122] The fifth stage 55e may correspond to the point in the assembly process where the stomping mechanisms may apply controlled downward pressure to the left cap enclosing panel to ensure proper alignment and engagement with the beverage container caps. The stomping operation may press the left cap enclosing panel firmly against the container caps and/or neck regions of an opposite side set of containers to create a secure connection between the panel orifices and the container caps and/or neck regions. The pressure application may be calibrated to provide sufficient force to secure the panel without damaging the blank material or displacing the beverage containers from their designated positions.

[0123] FIGS. 13A-13D illustrate aspects of the operation of the dynamic guide and latching tools of FIG. 10E in various stages of engagement with the blank according to an embodiment of the subject matter disclosed herein. Referring to FIG. 13A, the left latching tool 130 may be positioned to engage with a left clip enclosing panel of a blank during the fifth assembly stage 55e. The left latching tool 130 may include a left blade member 134 that may be configured to travel in an eccentric path during the latching operation. The left blade member 134 may be arranged to move vertically to secure a portion of the left clip enclosing panel to a first group of the plurality of containers while simultaneously moving horizontally at the first velocity that matches the propagation speed of the blank through the assembly system.

[0124] The left latching tool 130 may include a first arm 136a that may extend from a first base region to a first distal region. The first arm 136a may be pivotably mounted at the first base region to allow rotational movement during the latching operation. A second arm 136b may extend from a second base region to a second distal region and may be positioned parallel to the first arm 136a. The left blade member 134 may be pivotably coupled (via mount 137) between the first distal region of the first arm 136a and the second distal region of the second arm 136b. The pivotable coupling may allow the left blade member 134 to maintain proper orientation relative to the blank surface during the eccentric motion cycle.

[0125] The first arm 136a and the second arm 136b may be arranged to synchronously rotate about their respective first base region and second base region. The synchronous rotation may ensure that the left blade member 134 may follow a predetermined eccentric path that coordinates vertical and horizontal movement components. The first arm 136a may be coupled to a drive motor 132 that may provide the rotational power for the latching operation. The drive motor 132 may be configured to operate at variable speeds to accommodate different phases of the eccentric motion cycle.

[0126] The second arm 136b may be coupled to the first arm 136a via a belt 138 that may transmit rotational motion from the drive motor 132. The belt 138 may ensure that both arms rotate in synchronization to maintain proper blade member positioning throughout the latching cycle. The belt 138 may be configured with appropriate tension to prevent slippage during high-speed operations while allowing smooth power transmission between the arms.

[0127] Referring to FIG. 13B, the left latching tool 130 may be shown in an intermediate position of the eccentric motion cycle. The left blade member 134 may be positioned to engage with panel section 10e of the left clip enclosing panel. The eccentric path of the left blade member 134 may cause the blade to approach the panel section 10e at an angle that facilitates proper insertion beneath the neck regions of the containers 25. The vertical component of the blade movement may allow the blade member 134 to lift the panel section 10e while the horizontal component may guide the panel into its secured position.

[0128] The drive motor 132 may continue to rotate the first arm 136a while the belt 137 may simultaneously rotate the second arm 136b. The coordinated rotation may cause the left blade member 134 to follow a curved trajectory that combines downward vertical motion with forward horizontal motion. The eccentric path may be calibrated to match the propagation velocity of the blank and containers through the assembly system to ensure proper timing of the latching operation.

[0129] Referring to FIG. 13C, a right latching tool 150 may be positioned to engage with a right clip enclosing panel during the fifth assembly stage 55e. The right latching tool 150 may include a right blade member 154 that may be configured to travel in an eccentric path similar to the left blade member 134. The right blade member 154 may be arranged to move vertically to secure a portion of the right clip enclosing panel to a second group of the plurality of containers while simultaneously moving horizontally at the first velocity.

[0130] The right latching tool 150 may include a third arm 156a that may extend from a third base region to a third distal region. A fourth arm 156b may extend from a fourth base region to a fourth distal region and may be positioned to work in coordination with the third arm 156a. The right blade member 154 may be pivotably coupled between the third distal region of the third arm 156a and the fourth distal region of the fourth arm 156b. The coupling arrangement may allow the right blade member 154 to maintain proper angular orientation during the eccentric motion cycle.

[0131] The third arm 156a and the fourth arm 156b may be arranged to synchronously rotate about their respective base regions. The third arm 156a may be coupled to a second drive motor 152 that may provide rotational power for the right latching tool 150. The fourth arm 156b may be coupled to the third arm 156a via a second belt 158 that may transmit rotational motion to ensure synchronized operation of both arms.

[0132] Referring to FIG. 13D, the right latching tool 150 may be shown in an intermediate position of the eccentric motion cycle. The right blade member 154 may be positioned to engage with panel section 10e of the right clip enclosing panel. The eccentric path of the right blade member 154 may cause the blade to approach the panel section 10e at an angle that facilitates proper insertion beneath the neck regions of the containers 25. The vertical component of the blade movement may allow the blade member 154 to lift the panel section 10e while the horizontal component may guide the panel into its secured position.

[0133] The coordinated operation of the left latching tool 130 and right latching tool 150 may ensure that both clip enclosing panels may be simultaneously secured to their respective container groups. The eccentric motion of both blade members may be timed to occur while the blank and containers may be propagating through the assembly system at velocity. The horizontal velocity component of each blade member may match the propagation velocity to maintain proper engagement with the moving blank throughout the latching operation.

[0134] In the foregoing specification, embodiments of the disclosure have been described with reference to numerous specific details that can vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the disclosure, and what is intended by the applicants to be the scope of the disclosure, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. The specific details of particular embodiments can be combined in any suitable manner without departing from the spirit and scope of embodiments of the disclosure.

[0135] Any of the features of the various embodiments of the disclosure can be combined with replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure. The carrier styles and panel configurations described above are included by way of example.

[0136] In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carrier to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

[0137] As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.

[0138] In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding there along. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.

[0139] The above embodiments may be described as having one or more panels adhered together by glue during erection of the carrier embodiments. The term glue is intended to encompass all manner of adhesives commonly used to secure carrier panels in place.

[0140] The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.

[0141] Additionally, spatially relative terms, such as bottom or top and the like can be used to describe an element and/or feature's relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as a bottom surface can then be oriented above other elements or features. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0142] Terms and, or, and and/or, as used herein, may include a variety of meanings that also is expected to depend at least in part upon the context in which such terms are used. Typically, or if used to associate a list, such as A, B, or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B, or C, here used in the exclusive sense. In addition, the term one or more as used herein may be used to describe any feature, structure, or characteristic in the singular or may be used to describe some combination of features, structures, or characteristics. However, it should be noted that this is merely an illustrative example and claimed subject matter is not limited to this example. Furthermore, the term at least one of if used to associate a list, such as A, B, or C, can be interpreted to mean any combination of A, B, and/or C, such as A, B, C, AB, AC, BC, AA, AAB, ABC, AABBCCC, etc.

[0143] Reference throughout this specification to one example, an example, certain examples, or exemplary implementation means that a particular feature, structure, or characteristic described in connection with the feature and/or example may be included in at least one feature and/or example of claimed subject matter. Thus, the appearances of the phrase in one example, an example, in certain examples, in certain implementations, or other like phrases in various places throughout this specification are not necessarily all referring to the same feature, example, and/or limitation. Furthermore, the particular features, structures, or characteristics may be combined in one or more examples and/or features.

[0144] In the preceding detailed description, numerous specific details have been set forth to provide a thorough understanding of claimed subject matter. However, it will be understood by those skilled in the art that claimed subject matter may be practiced without these specific details. In other instances, methods and apparatuses that would be known by one of ordinary skill have not been described in detail so as not to obscure claimed subject matter. Therefore, it is intended that claimed subject matter not be limited to the particular examples disclosed, but that such claimed subject matter may also include all aspects falling within the scope of appended claims, and equivalents thereof.