System and method for packaging items in cartons - Patents.com

Abstract

A packaging system includes a conveyor configured to transport the group of articles and the blank along a packaging path. The packaging system includes a folding machine configured to fold a first end panel of the blank against a main panel of the blank as the group of articles and the blank advance along the packaging path, and to fold a second end panel of the blank against the main panel after the first end panel is folded. The packaging system includes an alignment machine configured to position a first side panel and a second side panel of the blank at a predetermined angle relative to the main panel as the group of articles and the blank advance along the packaging path.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to article packaging, and more particularly to systems and methods for packaging articles in cartons formed from blanks that are folded around the articles. [Background technology]

[0002] In the field of packaging, cartons are often used to carry multiple articles. Cartons are useful for allowing a group of articles to be transported, stored, and accessed by a consumer for consumption. For cost and environmental considerations, such cartons or carriers should be formed from as little material as possible and waste as little material as possible from which the cartons or carriers are formed. Further considerations include the strength and suitability of the carton to hold and transport the articles. For example, it is desirable for the articles to remain stationary within the carton. Additional considerations include the degree of automation available to form the carton around the articles. For example, it is desirable for blanks of sheet material to be fed into a packaging machine to form a carton and automatically formed (e.g., wrapped) around the article being packaged. However, due to blank design and / or carton configurations that address the above considerations, automating the formation of the carton from the blanks using machines can be difficult. Thus, those skilled in the art continue to conduct research and development in the field of article packaging. Summary of the Invention [Means for solving the problem]

[0003] Disclosed is a packaging system for forming a carton around a group of articles, and a packaging method for forming a carton around a group of articles. The following is a non-exhaustive list of examples of subject matter according to the present disclosure that may or may not be claimed.

[0004] In an example, a disclosed packaging system includes a conveyor. The conveyor is configured to transport a group of articles and a blank to be applied to a top end of the articles along a packaging path. The packaging system includes a folding machine. The folding machine is configured to fold a first end panel of the blank against a main panel of the blank as the group of articles and the blank advance along the packaging path. The folding machine is configured to fold a second end panel of the blank against a main panel of the blank after the first end panel is folded as the group of articles and the blank advance along the packaging path. The folding machine is configured to fold a first end flap of the blank against the first end panel after the first end panel is folded as the group of articles and the blank advance along the packaging path. The folding machine is configured to fold a second end flap of the blank against the second end panel after the second end panel is folded as the group of articles and the blank advance along a portion of the packaging path. The folding machine is configured to fold a first side panel of the blank against the main panel after the first and second end flaps are folded as the group of articles and blanks advance along the packaging path. The folding machine is configured to fold a second side panel of the blank against the main panel after the first and second end flaps are folded as the group of articles and blanks advance along the packaging path. The folding machine is configured to fold a first cover panel of the blank against the first side panel after the first side panel is folded as the group of articles and blanks advance along the packaging path. The folding machine is configured to fold a second cover panel of the blank against the second side panel after the second side panel is folded as the group of articles and blanks advance along a portion of the packaging path. The packaging system includes an alignment machine. An alignment machine is configured to position the first and second side panels at a predetermined angle relative to the main panel after the first and second side panels are folded while the first and second cover panels are folded.

[0005] In an example, a disclosed packaging system includes a conveyor configured to transport a group of articles and a blank to be applied to top ends of the articles along a packaging path. The packaging system includes a folding machine configured to fold a first end panel of the blank against a main panel of the blank as the group of articles and the blank advance along the packaging path. The folding machine is configured to fold a second end panel of the blank against the main panel of the blank after the first end panel is folded as the group of articles and the blank advance along the packaging path.

[0006] In an example, a disclosed packaging system includes a conveyor configured to transport a group of articles and a blank to be folded around the articles along a packaging path, and an alignment machine configured to position a first side panel and a second side panel of the blank at a predetermined angle relative to a main panel of the blank as the group of articles and the blank advance along the packaging path.

[0007] In an example, a packaging method is disclosed that includes the steps of: (1) conveying a group of articles and a blank to be applied to top ends of the articles along a packaging path; (2) folding a first end panel of the blank against a main panel of the blank as the group of articles and blanks advance along the packaging path; (3) folding a second end panel of the blank against the main panel of the blank after folding the first end panel as the group of articles and blanks advance along the packaging path; (4) folding a first end flap of the blank against the first end panel after folding the first end panel as the group of articles and blanks advance along the packaging path; (5) folding a second end flap of the blank against the second end panel after folding the second end panel as the group of articles and blanks advance along the packaging path; and (6) folding a first end flap of the blank against the main panel of the blank after folding the first end panel as the group of articles and blanks advance along the packaging path. (7) folding the first side panel of the blank against the main panel after folding the first and second end flaps; (8) positioning the first and second side panels at a predetermined angle relative to the main panel after folding the first and second side panels; (9) folding the first cover panel of the blank against the first side panel while maintaining the first side panel at the predetermined angle as the group of articles and blanks advance along a portion of the packaging path; and (10) folding the second cover panel of the blank against the second side panel while maintaining the second side panel at the predetermined angle as the group of articles and blanks advance along a portion of the packaging path.

[0008] Other examples of the disclosed packaging system and method will become apparent from the following detailed description, the accompanying drawings, and the appended claims. [Brief description of the drawings]

[0009] [Figure 1]FIG. 2 is a schematic plan view of an example blank for forming a carton. [Diagram 2] FIG. 2 is a schematic perspective view of an example blank. [Diagram 3] FIG. 2 is a schematic perspective view of an example blank joined to a group of articles. [Figure 4] FIG. 2 is a schematic perspective view of an example blank shown with first and second end panels in a folded position. [Diagram 5] FIG. 2 is a schematic perspective view of an example blank shown with first and second end flaps in a folded position. [Figure 6] FIG. 2 is a schematic perspective view of an example blank shown with first and second side panels in a folded position. [Figure 7] FIG. 2 is a schematic perspective view of an example blank shown with a second cover panel in a folded position. [Figure 8] FIG. 2 is a schematic perspective view of an example blank shown with first and second cover panels in a folded position. [Figure 9] FIG. 2 is a schematic perspective view of an example carton formed from the blank. [Figure 10] FIG. 1 is a schematic diagram of an example packaging system. [Figure 11] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 12] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 13] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 14] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 15] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 16] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 17] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 18]1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 19] 1 is a schematic perspective view of an example of a portion of a packaging system. [Figure 20] FIG. 2 is a schematic perspective end view of an example carton. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] 1-9, which diagrammatically illustrate an example of a blank 106 that may be constructed and used to form a carton 104 (e.g., as shown in FIG. 9). The blank 106 is configured to be folded or otherwise formed around a plurality (e.g., a group) of articles 102 such that at least a portion of each one of the articles 102 is packaged in the carton 104. The carton 104 is thereby configured to contain and carry the articles 102 and may also be referred to as an article carrier or carrier.

[0011] Generally, the article 102 refers to a primary package for a product. The carton 104 forms a secondary package for packaging the article 102 (e.g., at least one primary product container or package). In the examples described herein, the terms "carton," "carrier," and similar terms refer to a container for engaging and carrying an article, such as a primary product container. It is contemplated that the examples described herein are applicable to a variety of product containers, which may, but are not necessarily, tapered and / or cylindrical in shape. Exemplary articles 102 (e.g., containers) include, but are not limited to, bottles (e.g., metal bottles, glass bottles, or plastic bottles), cans (e.g., aluminum cans), tin cans, bags, packets, other similar product containers, and the like.

[0012] In one or more examples, the blank 106 is configured to form a carton 104 for packaging an arrangement of the articles 102. The articles 102 may be arranged and packaged in the carton 104 in any suitable packaging configuration, such as in a two-pack, a four-pack, a six-pack (e.g., as shown in FIGS. 2-8), a twelve-pack, etc. In the example shown in FIGS. 1-9, the arrangement is a 2×4 matrix or array. In the example shown in FIGS. 2-9, two rows of four articles 102 are provided, and the articles 102 are beverage cans, such as 12 oz. beverage cans. However, other types of articles 102 and / or other packaging configurations are contemplated. The blank 106 may thereby be configured to form a carton 104 for packaging other types, numbers, and / or sizes of articles 102 and / or for packaging the articles 102 in different arrangements or configurations.

[0013] 1 and 2, in one or more examples, the blank 106 includes multiple panels that are connected to one another by multiple fold lines. Any one of the fold lines and / or hinge lines described herein may include any suitable predetermined or preformed lines of weakness and / or separation lines, such as creases, perforations, perforations, relief cuts, etc., known to those of skill in the art and guided by the teachings provided herein. Generally, the fold lines transform the blank 106 into multiple separate but integral panels and flaps that form the carton 104. The preformed lines of weakness allow for easy folding during assembly of the carton 104.

[0014] In one or more examples, the blank 106 includes a major panel 108. The major panel 108 of the blank 106 forms a lower wall of the carton 104 (e.g., a bottom panel, a foundation panel, or a mating panel).

[0015] In one or more examples, the blank 106 includes a first side panel 110. The first side panel 110 is hinged to a first side of the main panel 108, such as by a hinge connection in the form of a fold line 114. The first side panel 110 forms a first side closure structure 210 (e.g., a first side wall) of the carton 104 (e.g., as shown in Figures 8 and 9).

[0016] In one or more examples, the blank 106 includes a second side panel 112. The second side panel 112 is hinged to a second side of the main panel 108, such as by a hinge connection in the form of a fold line 116. The second side panel 112 forms a second side closure structure 210 (e.g., a second side wall) of the carton 104.

[0017] In one or more examples, the blank 106 includes a first cover panel 118 (e.g., a first top panel). The first cover panel 118 is hingedly connected to the first side panel 110, such as by a hinge connection in the form of a fold line 122.

[0018] In one or more examples, the blank 106 includes a second cover panel 120 (e.g., a second top panel). The second cover panel 120 is hingedly connected to the second side panel 112, such as by a hinge connection in the form of a fold line 124.

[0019] In one or more examples, the main panel 108 of the blank 106 includes at least one retention structure 126. The retention structure 126 is configured to retain (e.g., receive, contain, and hold) the item 102. In one or more examples, the main panel 108 includes a plurality of retention structures 126, such as eight retention structures 126 arranged in a 2×4 matrix or array (e.g., as shown in FIG. 1 ).

[0020] In one or more examples, the retaining structures 126 (e.g., each one of the retaining structures 126) include a retaining opening 128 (e.g., an item receiving opening). The retaining opening 128 forms at least a portion of the item retaining opening of the carton 104 and is configured to receive and engage a portion of the article 102 (e.g., as shown in FIG. 2).

[0021] 1 and 3, in one or more examples, the retention structures 126 (e.g., each one of the retention structures 126) include a plurality of retention tabs 130 (e.g., tines). The retention tabs 130 are arranged in annular series about the retention opening 128. The retention tabs 130 form a portion of the article retaining opening of the carton 104.

[0022] In one or more examples, the retention tabs 130 are provided (e.g., formed) by the main panel 108. In one or more examples, each one of the retention tabs 130 is hinged to the main panel 108, such as by a hinge connection in the form of a fold line. In one or more examples, the hinge connection is defined by a plurality of cuts. In one or more examples, the cuts are arranged as an annular series of cuts around the retention opening 128.

[0023] In one or more examples, each one of the retention tabs 130 includes an engagement edge opposite the hinged edge. The engagement edge is defined by a linear portion of the cut that defines the retention opening 128. In one or more examples, each engagement edge defines a portion of a polygon. The blank 106 may include any suitable number of tabs 130, such as twelve tabs 130 that together define a dodecagon, sixteen tabs 130 that together define a hexagon, etc.

[0024] In one or more examples, each one of the retention tabs 130 includes a pair of side edges. In one or more examples, the side edges are defined by notches that extend radially outward from respective vertices of the polygon, such as, for example, from respective vertices between a pair of adjacent linear portions of the notches that define a portion of the polygon. The notches are arranged to diverge from one another and define an angle therebetween, such as an angle of approximately 22.5°.

[0025] In one or more examples, the plurality of cuts may define or approximate a portion of a circle. In one or more examples, each one of the plurality of cuts may be linear in shape. In one or more examples, each one of the plurality of cuts may be arcuate or curved. In one or more examples, the cuts may have a radius of curvature equal to half the diameter of the retention opening 128 (e.g., the item retaining opening). In one or more examples, the cuts may have a radius of curvature greater than half the diameter of the retention opening 128 (e.g., the item retaining opening).

[0026] In other examples, the retention structure 126 may take a different form, such as, but not limited to, a pair of spaced apart opposing notches that define a displaceable region that forms a cover over the article and provides a pair of opposing engagement edges for engaging opposing sides of the article beneath a flange, lip, or other protrusion.

[0027] 1-3, in one or more examples, the main panel 108, the first cover panel 118, and the second cover panel 120 form a handle structure for the carton 104. In one or more examples, the blank 106 includes at least one handle opening 132. The handle opening 132 defines or forms at least a portion of a handle opening of the handle structure of the carton 104. In one or more examples, the blank 106 includes a plurality of handle openings 132, such as three handle openings 132 (e.g., as shown in FIGS. 1-3). In one or more examples, each one of the handle openings 132 is defined in, cut from, or punched from an area of ​​the main panel 108 that is centered between four of the retention openings 128 arranged as two adjacent pairs of retention openings 128.

[0028] 8 and 9, in one or more examples, the first cover panel 118 and the second cover panel 120 are positioned to be in at least a partially overlapping relationship with one another. The overlapping portions of the first cover panel 118 and the second cover panel 120 provide the carton 104 with at least one locking structure 134 (e.g., as shown in FIG. 9) for locking the first cover panel 118 and the second cover panel 120 together. In one or more examples, the carton 104 includes multiple locking structures 134, such as three locking structures 134. In one or more examples, the locking structures 134 cooperate with handle openings 132 in the main panel 108 (e.g., as shown in FIGS. 1-3) to secure the first cover panel 118 and the second cover panel 120 to the main panel 108.

[0029] 1-3, 8, and 9, in one or more examples, the locking structure 134 (e.g., as shown in FIG. 9) includes or is formed in part from a receiving portion 166 (e.g., as shown in FIGS. 1-3) formed in one of the first cover panel 118 or the second cover panel 120 (e.g., as shown in FIGS. 1-3) of the blank 106.

[0030] In one or more examples, the blank 106 includes a plurality of receivers 166, such as three receivers 166. In other examples, one, two, four or more receivers 166 may be provided on the blank 106. In one or more examples, each one of the receivers 166 is positioned to vertically register or align with a corresponding one of the handle openings 132 provided in the main panel 108.

[0031] In one or more examples, the receiver 166 includes or takes the form of a locking aperture 136 (e.g., as shown in FIGS. 2 and 3 ). In one or more examples, each one of the locking apertures 136 is an opening defined in, cut from, or punched into an area of ​​the second cover panel 120.

[0032] The locking aperture 136 in the receiver 166 may have any suitable two-dimensional shape, such as substantially circular, rectangular, or diamond-shaped, etc. In one or more examples, the corners of the locking aperture 136 are rounded or chamfered.

[0033] In one or more examples, the receiving portion 166 (e.g., the locking opening 136) includes, is defined by, or takes the form of at least one receiving tab 170, which may also be referred to as a female tab (e.g., as shown in FIG. 1). In one or more examples, the receiving portion 166 (e.g., the locking opening 136) is defined by a plurality of receiving tabs 170, such as three receiving tabs 170 (e.g., individually identified in FIG. 1 as first receiving tab 170A, second receiving tab 170B, and third receiving tab 170C). In one or more examples, the receiving tabs 170 are defined in, cut from, or punched into the area of ​​the second cover panel 120.

[0034] 1, in one or more examples, the first receiving tab 170A is hinged to the second cover panel 120 by a first hinge connection in the form of a fold line 172. In one or more examples, the second receiving tab 170B is hinged to the second cover panel 120 by a second hinge connection in the form of a fold line 174. In one or more examples, the second receiving tab 170B is hinged to the second cover panel 120 opposite the first receiving tab 170A. In one or more examples, the first receiving tab 170A is separated in part from the second receiving tab 170B by a first cut 176 (e.g., a tear line) and in part by a third receiving tab 170C. In one or more examples, the third receiving tab 170C is defined by a second cut 178 (e.g., a tear line). In one or more examples, the second break 178 is substantially "U" shaped. In one or more examples, the third receiving tab 170C is hinged to the second cover panel 120 by a third hinge link in the form of a fold line 180. In one or more examples, the third hinge link may be located adjacent to the first and / or second hinge links and substantially perpendicular to the first and / or second hinge links. In one or more examples, the third receiving tab 170C defines a notch or recess in each of the first receiving tab 170A and the second receiving tab 170B. The notch or recess is punched out from the free edge opposite the first and second hinge links, respectively.

[0035] 1-3, 8, and 9, in one or more examples, the locking structure 134 (e.g., as shown in FIG. 9) includes or is formed in part from an insert 168 (e.g., as shown in FIGS. 1-3 and 8) formed in the other of the first cover panel 118 or second cover panel 120 (e.g., as shown in FIGS. 1-3 and 8) of the blank 106. The insert 168 is configured to be received by a receiver 166 (e.g., the locking opening 136).

[0036] In one or more examples, the blank 106 includes a plurality of inserts 168, such as three inserts 168. In other examples, one, two, four or more inserts 168 may be provided in the blank 106. In one or more examples, each one of the inserts 168 is positioned to vertically register or align with a corresponding one of the receivers 166 and a corresponding one of the handle openings 132.

[0037] In one or more examples, the insert 168 includes or takes the form of a locking element 138 (e.g., as shown in FIGS. 1-3). In one or more examples, the locking element 138 includes, is defined by, or takes the form of at least one insert tab 140, which may also be referred to as a male tab (e.g., as shown in FIG. 1). In one or more examples, the insert 168 (e.g., the locking element 138) is defined by multiple insert tabs 140, such as two tabs 140 (e.g., individually identified in FIG. 1 as a first insert tab 140A and a second insert tab 140B). In one or more examples, the insert tab 140 is defined in, cut from, or punched into the area of ​​the first cover panel 118.

[0038] In one or more examples, the insertion tab 140 (e.g., insert portion 168) of the locking element 138 is positioned to be received in and engageable with a corresponding or respective one of the locking openings 136 (e.g., receiver 166). In one or more examples, the insertion tab 140 is positioned to be received in and engageable with a corresponding or respective one of the handle openings 132.

[0039] 1, in one or more examples, the first insert tab 140A is hinged to the first cover panel 118 by a first hinge connection in the form of fold line 182. In one or more examples, the second insert tab 140B is hinged to the first cover panel 118 by a second hinge connection in the form of fold line 184.

[0040] In one or more examples, the insert tab 140 includes at least one fold line, such as the pair of fold lines 186 and 188. In one or more examples, the pair of fold lines 186 and 188 can be arranged to splay out toward one another. In one or more examples, each one of the pair of fold lines 186 and 188 can be non-linear, such as, for example, but not limited to, arcuate or curved in shape. The non-linear fold line can encourage the insert tab 140 to return to a planar configuration to increase the security of the insert tab 140 within the locking opening 136 and the handle opening 132.

[0041] In one or more examples, the insertion tab 140 may be substantially "arrowhead" shaped to define a pair of opposing shoulders or detents for securely engaging the locking aperture 136 and / or handle opening 132. Other types and / or configurations of locking structure 134 are also contemplated.

[0042] In one or more examples, the locking structure 134 and the handle opening 132 define or form a handle opening (eg, a finger hole) of a handle structure of the carton 104 (eg, as shown in FIG. 9).

[0043] 9, in one or more examples, the first cover panel 118, the second cover panel 120, the first side panel 110, the second side panel 112, and the main panel 108 form a tubular structure of the carton 104. In one or more examples, each end of the tubular structure of the carton 104 is closed by an end closure structure 208.

[0044] 1 and 2, in one or more examples, the blank 106 includes a first end panel 142. The first end panel 142 is hingedly connected to a first end of the main panel 108, such as by a hinge connection in the form of a fold line 146. The first end panel 142 forms a first end closure structure 208 (e.g., a first end wall) of the carton 104 (e.g., as shown in FIGS. 8 and 9).

[0045] In one or more examples, the blank 106 includes a first end flap 150. The first end flap 150 is hinged to the first end panel 142, such as by a hinge connection in the form of a fold line 154.

[0046] In one or more examples, the blank 106 includes a first anchoring flap 158. The first anchoring flap 158 is hinged to a first end of the first cover panel 118, such as by a hinge connection in the form of a fold line 190. The first anchoring flap 158 is hinged to the first end flap 150, such as by a pair of hinged panels and / or fold lines. In one or more examples, the hinged pair of panels forms a gusset.

[0047] In one or more examples, a first hinged panel 192A is hinged, such as by a hinge connection in the form of a fold line, to the first end flap 158. A second hinged panel 194A is hinged, such as by a hinge connection in the form of a fold line, to the first hinged panel 192A. The second hinged panel 194A is hinged, such as by a hinge connection in the form of a fold line, to the first end flap 150.

[0048] In one or more examples, the blank 106 includes a second anchor flap 160. The second anchor flap 160 is hinged to a first end of the second cover panel 120, such as by a hinge connection in the form of a fold line 196. The second anchor flap 160 is hinged to the first end flap 150, such as by a pair of hinged panels and / or fold lines. In one or more examples, the hinged pair of panels forms a gusset.

[0049] In one or more examples, a third hinged panel 192B is hinged, such as by a hinge connection in the form of a fold line, to the second end flap 160. A fourth hinged panel 194B is hinged, such as by a hinge connection in the form of a fold line, to the third hinged panel 192B. The fourth hinged panel 194B is hinged, such as by a hinge connection in the form of a fold line, to the first end flap 150.

[0050] In one or more examples, the first end panel 142 is separated from each of the first tie flap 158 by an opening 202A formed in the blank 106 and is separated from the second tie flap 160 by an opening 202B (e.g., an aperture) formed in the blank 106. The openings 202A separate each of the pair of hinged panels 192A and 194A from the first side panel 110. The openings 202B separate each of the pair of hinged panels 192B and 194B from the second side panel 112.

[0051] In one or more examples, the blank 106 includes a second end panel 144. The second end panel 144 is hinged to a second end of the main panel 108, such as by a hinge connection in the form of a fold line 148. The second end panel 144 forms a second end closure structure 208 of the carton 104.

[0052] In one or more examples, the blank 106 includes a second end flap 152. The second end flap 152 is hinged to the second end panel 144, such as by a hinge connection in the form of a fold line 156.

[0053] In one or more examples, the blank 106 includes a third tie flap 162. The third tie flap 162 is hinged to the second end of the first cover panel 118, such as by a hinge connection in the form of a fold line 198. The third tie flap 162 is hinged to the second end flap 152, such as by a pair of hinged panels and / or fold lines. In one or more examples, the hinged pair of panels forms a gusset.

[0054] In one or more examples, a fifth hinged panel 192C is hinged, such as by a hinge connection in the form of a fold line, to the third end flap 162. A sixth hinged panel 194C is hinged, such as by a hinge connection in the form of a fold line, to the fifth hinged panel 192C. The sixth hinged panel 194C is hinged, such as by a hinge connection in the form of a fold line, to the second end flap 152.

[0055] In one or more examples, the blank 106 includes a fourth tie flap 164. The fourth tie flap 164 is hinged to the second end of the second cover panel 120, such as by a hinge connection in the form of a fold line 200. The fourth tie flap 164 is hinged to the second end flap 152, such as by a pair of hinged panels and / or fold lines. In one or more examples, the hinged pair of panels forms a gusset.

[0056] In one or more examples, a seventh hinged panel 192D is hinged, such as by a hinge connection in the form of a fold line, to the fourth end flap 164. An eighth hinged panel 194D is hinged, such as by a hinge connection in the form of a fold line, to the seventh hinged panel 192D. The eighth hinged panel 194D is hinged, such as by a hinge connection in the form of a fold line, to the second end flap 152.

[0057] In one or more examples, the second end panel 144 is separated from each of the third anchoring flaps 162 by an opening 202C formed in the blank 106 and is separated from the fourth anchoring flap 164 by an opening 202D (e.g., an aperture) formed in the blank 106. The openings 202C separate each of the pair of hinged panels 192C and 194C from the first side panel 110. The openings 202D separate each of the pair of hinged panels 192D and 194D from the second side panel 112.

[0058] 1-9, a carton 104 is constructed from a blank 106. FIGS. 1 and 2 show an example of a blank 106. FIG. 3 shows the blank 106 applied to an article 102. FIGS. 4-8 show an example of the blank 106 being formed into an erected carton 104 (e.g., as shown in FIG. 9). FIG. 9 shows the erected carton 104 with an article 102 packaged in the carton 104.

[0059] 2 and 3, in one or more examples, the blank 106 is aligned with and applied to the group of articles 102. Each one of the retention structures 126 of the blank 106 is aligned with a respective one of the articles 102 in the group. A portion (e.g., an upper portion) of each one of the articles 102 passes through a corresponding or respective retention opening 128 in the major panel 108. In one or more examples, for each one of the retention openings 128, a retention tab 130 (e.g., as shown in FIG. 3) of the retention structure 126 is folded out of the plane of the major panel 108.

[0060] In one or more examples, each tab 130 of the main panel 108 is folded around one of the articles 102 received in a respective one of the retaining structures 126. In one or more examples, the main panel 108 may deform around the article 102, such as, for example, but not limited to, a shoulder portion of the article 102. In examples where the article 102 is a can, the shoulder portion may be provided by a neck-in.

[0061] 4, in one or more examples, the blank 106 is folded about a respective fold line (e.g., fold line 146 shown in FIGS. 1 and 2) to place the first end panel 142 in a non-coplanar relationship with the main panel 108, such as approximately perpendicular, or at least substantially perpendicular, to the main panel 108. In one or more examples, the first end panel 142 is folded through an angle greater than 90° so as to be angled.

[0062] In one or more examples, the blank 106 is folded about a respective fold line (e.g., fold line 148 shown in FIGS. 1 and 2 ) to place the second end panel 144 in a non-coplanar relationship with the main panel 108, such as approximately perpendicular, or at least substantially perpendicular, to the main panel 108. In one or more examples, the second end panel 144 is folded through an angle greater than 90° so as to be angled.

[0063] 5, in one or more examples, the blank 106 is folded about respective fold lines (e.g., fold line 154 shown in FIGS. 1 and 2) to place the first end flap 150 in a non-coplanar relationship with the first end panel 142, such as approximately perpendicular or at least substantially perpendicular to the first end panel 142, and to place the first and second anchoring flaps 158 and 160 in a substantially facing relationship with the respective ones of the first and second cover panels 118 and 120 to which they are hinged.

[0064] In one or more examples, the blank 106 is folded about respective fold lines (e.g., fold line 156 shown in Figures 1 and 2) to place the second end flap 152 in a non-coplanar relationship with the second end panel 144, such as approximately perpendicular or at least substantially perpendicular to the second end panel 144, and to place the third and fourth anchoring flaps 162, 164 in a substantially facing relationship with the respective ones of the first and second cover panels 118, 120 to which they are hinged.

[0065] In one or more examples, the first end flap 150 and the second end flap 152 are folded over the top edge or onto the item 102 placed adjacent the first and second edges of the main panel 108 .

[0066] In one or more examples, the first end flap 150 and the second end flap 152 are folded to be approximately or at least substantially parallel to the main panel 108 .

[0067] In one or more examples, the first and second anchoring flaps 158, 160 are automatically folded into a substantially facing relationship with respective ones of the first and second cover panels 118, 120 to which they are hinged in response to folding the first end flap 150 relative to the first end panel 142.

[0068] In one or more examples, the third and fourth anchoring flaps 162, 164 are automatically folded into a substantially facing relationship with respective ones of the first and second cover panels 118, 120 to which they are hinged in response to folding the second end flap 152 relative to the second end panel 144.

[0069] 6, in one or more examples, the blank 106 is folded about a respective fold line (e.g., fold line 114 shown in FIGS. 1 and 2) to place the first side panel 110 in a non-coplanar relationship with the main panel 108, such as approximately perpendicular, or at least substantially perpendicular, to the main panel 108. In one or more examples, the first side panel 110 is folded through an angle greater than 90° so as to be angled.

[0070] In one or more examples, the blank 106 is folded about a respective fold line (e.g., fold line 116 shown in Figures 1 and 2) to place the second side panel 112 in a non-coplanar relationship with the main panel 108, such as approximately perpendicular, or at least substantially perpendicular, to the main panel 108. In one or more examples, the second side panel 112 is folded through an angle greater than 90° so as to be angled.

[0071] 7, in one or more examples, the blank 106 is folded about respective fold lines (e.g., fold lines 124 shown in FIGS. 1 and 2) to place the second cover panel 120 in a non-coplanar relationship with the second side panel 112, such as approximately perpendicular, or at least substantially perpendicular, to the second side panel 112. In one or more examples, the second cover panel 120 is folded over onto the top of the article 102.

[0072] 8, in one or more examples, the blank 106 is folded about respective fold lines (e.g., fold lines 122 shown in FIGS. 1 and 2) to place the first cover panel 118 in a non-coplanar relationship with the first side panel 110, such as generally perpendicular or at least substantially perpendicular to the first side panel 110. In one or more examples, the first cover panel 118 is folded over the top of the article 102 into an overlapping relationship with the second cover panel 120 to form a composite cover panel structure 206 (e.g., a top wall) of the carton 104 (e.g., as shown in FIGS. 8 and 9).

[0073] 8 and 9, in one or more examples, each one of the inserts 168 is registered and aligned with a corresponding or respective one of the receivers 166 in response to the first cover panel 118 being folded into an overlapping relationship with the second cover panel 120. The locking element 138 of each one of the inserts 168 is engaged with the locking opening 136 of the corresponding or respective one of the receivers 166 to secure (e.g., bond or couple) the first cover panel 118 to the second cover panel 120. The locking element 138 of each one of the inserts 168 may also be engaged with a corresponding or respective one of the handle openings 132 to secure (e.g., bond or couple) the first cover panel 118 and the second cover panel 120 to the main panel 108.

[0074] In one or more examples, the insertion tab 140 (e.g., as shown in FIG. 1 ) of the locking element 138 is displaced downwardly and out of the plane of the first cover panel 118 to pass through the corresponding or respective locking opening 136. In one or more examples, the receiving tab 170 is displaced downwardly and out of the plane of the second cover panel 120 in response to the downward displacement of the insertion tab 140. In one or more examples, engagement between the insertion tab 140 and the locking opening 136, such as by the receiving tab 170, prevents or inhibits disengagement of the insertion tab 140 from the locked state.

[0075] In one or more examples, the insert tab 140 and the receiving tab 170 can also serve to function as a spacer between the composite cover panel structure 206 of the carton 104 formed by the first cover panel 118 and the second cover panel 120 and the main panel 108. In one or more examples, the insert tab 140 and / or the receiving tab 170 can engage the main panel 108 around the periphery of the handle opening 132 and / or along the underside of the main panel 108. In one or more examples, the insert tab 140 and / or the receiving tab 170 can thereby serve as a tensioning member to maintain the spacing between the main panel 108 and the composite cover panel structure 206 to prevent the spacing from increasing. Additionally, the insert tab 140 and / or the receiving tab 170 may engage or abut an inside or top surface of the main panel 108, thereby providing reinforcement between and maintaining the spacing between the composite cover panel structure 206 and the main panel 108 to help prevent the spacing from becoming smaller. Thus, at least a portion of one or more of the insert tabs 140 and / or at least a portion of one or more of the receiving tabs 170 may be placed between the second cover panel 120 and the main panel 108 to maintain the spacing therebetween.

[0076] In one or more examples, at least a portion of one or more of the insert tabs 140 and / or at least a portion of one or more of the receiving tabs 170 engage with the main panel 108 and extend through the corresponding or respective handle opening 132 of the main panel 108 when folded. For example, a shoulder of the insert tab 140 and / or the receiving tab 170 can engage with an underside of the main panel 108. The underside of the main panel 108, which is the second side of the main panel 108, is opposite the first side through which the insert tab 140 is received. In one or more examples, at least one of the insert tabs 140 and / or the receiving tab 170 can provide a biasing mechanism. For example, one of the receiving tabs 170 (e.g., the third receiving tab 170C) has a natural or inherent tendency to return to an unfolded state. This can provide or supplement a resilient bias of the insert tab 140 to return to an unfolded state. The receiving tabs 170 can urge the insert tab 140 toward an end stop defined by a recessed edge of the receiving tabs 170 (e.g., first receiving tab 170A and second receiving tab 170B) that inhibits or prevents the insert tab 140 from returning to its unfolded state.

[0077] 10-20, by way of example, the present disclosure is directed to a packaging system 100. The present disclosure is also directed to any portion, subsystem, or machine of the packaging system 100.

[0078] The packaging system 100 is configured to package the articles 102 in a carton 104 by forming a blank 106 around the articles 102. The carton 104 is formed from the blank 106 (e.g., as shown in FIGS. 1 and 2). The blank 106 is folded or formed around the articles 102 (e.g., as shown in FIGS. 3-8). The articles 102 are packaged in the carton 104 (e.g., as shown in FIGS. 8 and 9). A carton 104 filled with a group of articles 102 is also referred to herein as a finished package 234 (e.g., as shown in FIG. 9).

[0079] In one or more examples, the packaging system 100 is a continuous motion packaging system for continuously packaging groups of articles 102 into cartons 104. In one or more examples, the packaging system 100 is configured to continuously process a plurality of blanks 106 to form (e.g., build or assemble) a plurality of finished cartons 104 filled with a plurality of groups of articles 102 (e.g., a plurality of finished packages 234).

[0080] 10-19 generally show a group of cans packaged within the carton 104, one skilled in the art will recognize that a variety of other products or articles 102, such as bottles or other similar product containers, may be wrapped or otherwise packaged in the carton 104 moving through the packaging system 100. The carton 104 includes a flat, wrap-around blank 106 that is designed to be folded or otherwise wrapped around a group of articles 102 that are received through a main panel 108 of the blank 106 (e.g., a bottom or base panel of the carton 104).

[0081] In one or more examples, the blank 106 includes a main panel 108, a first side panel 110, a second side panel 112, a first cover panel 118, a second cover panel 120, a first end panel 142, a second end panel 144, a first end flap 150, a second end flap 152, a first tie flap 158, a second tie flap 160, a third tie flap 162, and a fourth tie flap 164 (e.g., as shown in FIGS. 1 and 2), which are folded to form the finished carton 104 (e.g., as shown in FIGS. 3-9). The first cover panel 118 and the second cover panel 120 are folded into an overlying relationship and secured or otherwise integrally joined. In one or more examples, the first cover panel 118 and the second cover panel 120 are secured together using a retention structure 126 (e.g., as shown in FIG. 9). In other examples, the first cover panel 118 and the second cover panel 120 are additionally or alternatively secured together using an adhesive.

[0082] 10 , in one or more examples, packaging system 100 includes a plurality of stations, stages, modules, subsystems, and / or machines. Each one of the stations is configured to perform (e.g., automatically or semi-automatically) one or more packaging operations. In one or more examples, packaging system 100 includes a first station 212, a second station 214, a third station 216, and a fourth station 218. However, in other examples, packaging system 100 may include other numbers and / or types of stations, such as less than three stations or more than four stations.

[0083] In one or more examples, a packaging operation or operations described in connection with any one of the stations may be associated with a different one of the stations or may be associated with additional stations configured to perform separate operations. Additionally, not all of the operations associated with packaging the articles 102 and / or forming the cartons 104 are described in detail herein or associated with specific stations of the packaging system 100. Thereby, particular packaging operations, components, and / or materials, such as those that are well known or common in the industry, are not necessarily described in detail. Thus, the illustrated examples and / or any one of the stations of the packaging system 100 are not meant to imply structural or operational limitations with respect to the illustrated examples.

[0084] In one or more examples, the first station 212 is configured to transport (e.g., continuously transport) multiple articles 102 for packaging. In one or more examples, the first station 212 receives articles 102 that are output in a non-uniform rapid manner from a filling or bottling line (not shown) and conveyed on a bulk conveyor (not shown).

[0085] In one or more examples, the second station 214 is coupled to the first station 212, such as in series with the first station 212. In one or more examples, the second station 214 is configured to receive the articles 102 from the first station 212. In one or more examples, the second station 214 is further configured to group the articles 102 (e.g., as shown in FIG. 2). In one or more examples, the second station is also configured to apply blanks 106 to the groups of articles 102 (e.g., as shown in FIG. 3).

[0086] In one or more examples, the third station 216 is coupled to the second station 214, such as in series with the second station 214. In one or more examples, the third station 216 is configured to receive, from the second station 214, the group of articles 102 and the blank 106 to be applied to the articles 102. In one or more examples, the third station 216 is further configured to fold the blank 106 around the group of articles 102 to form the carton 104 (e.g., as shown in FIGS. 4-9 ).

[0087] In one or more examples, the fourth station 218 is coupled to the third station 216, such as in series with the third station 216. In one or more examples, the fourth station 218 is configured to receive a completed package 234 (e.g., a fully formed carton 104 and a group of articles 102 packaged in the carton 104, as shown in FIG. 9 ) from the third station 216. In one or more examples, the fourth station 218 is further configured to transport and eject the completed package 234.

[0088] In one or more examples, the packaging system 100 includes a conveyor 236. The conveyor 236 is configured to transport (e.g., continuously transport) the articles 102 and blanks 106 along a packaging path that defines a direction of advancement of the articles 102 and blanks 106 during formation of the cartons 104 (e.g., as indicated by directional arrows 248 shown in FIG. 10 ).

[0089] In one or more examples, the conveyor 236 includes multiple portions associated with a particular packaging operation performed by the system 100. In one or more examples, the conveyor 236 includes an infeed conveyor 220, a grouping conveyor 222, an assembly conveyor 226, and a discharge conveyor 232, each of which forms a portion of the conveyors 236 of the packaging system 100. The conveyors 236, such as one or more of the infeed conveyor 220, the grouping conveyor 222, the assembly conveyor 226, and the discharge conveyor 232, include any suitable features and / or components common to automated conveyor lines and configured to transport articles along their upper surface, such as rollers, belts, endless chains, side lugs, front lugs, rear lugs, drive mechanisms, etc.

[0090] In one or more examples, the infeed conveyor 220 forms a portion of the first station 212. The infeed conveyor 220 may also be referred to as an article infeed conveyor or a first conveyor. The infeed conveyor 220 is configured to transport a series of articles 102 along an article infeed path (e.g., a portion of a packaging path), such as in separate lines or lanes defined by lane guides, as the articles 102 enter the packaging system 100 at its upstream end. The lane guides are configured to maintain the articles 102 in their respective lanes and redirect the lanes of articles 102 towards placement and loading positions.

[0091] In one or more examples, the packaging system 100 includes a processing machine (not shown). In one or more examples, the processing machine forms a portion of the first station 212. The processing machine is configured to receive and narrow an incoming bulk of the articles 102 into one or more lanes to create an incoming stream of the articles 102 that is, such as, one or two articles wide. The incoming stream of the articles 102 is conveyed on an infeed conveyor 220.

[0092] In one or more examples, the grouping conveyor 222 forms a portion of the second station 214. The grouping conveyor 222 may also be referred to as an article grouping conveyor or a second conveyor. In one or more examples, the grouping conveyor 222 is in communication with the infeed conveyor 220. The stream of articles 102 is transferred from the infeed conveyor 220 to the grouping conveyor 222.

[0093] In one or more examples, the grouping conveyor 222 is configured to arrange a series of articles 102 (e.g., from a stream of articles 102) in an appropriate packaging configuration, such as groups of articles 102 in a 2×4 matrix or array. For example, the grouping conveyor 222 is configured to separate the series of articles 102 into groups of the correct number of articles 102 per blank 106. In one or more examples, the grouping conveyor 222 is configured to transport the series of articles 102 along one or more article grouping paths, such as in separate lines or lanes defined by a lane guide, as the articles 102 enter the grouping conveyor 222 at an upstream end of the grouping conveyor 222 (e.g., from the infeed conveyor 220) and move along the grouping conveyor 222. The lane guide is configured to maintain the articles 102 in their respective lanes and redirect the lanes of articles 102 for arrangement in groups and for application of blanks 106.

[0094] In one or more examples, the packaging system 100 includes a machine for applying the blanks 106 to the articles 102, referred to herein as an applying machine 224. The applying machine 224 may also be referred to as a blank applying machine. In one or more examples, the applying machine 224 forms a portion of the second station 214.

[0095] In one or more examples, the applying machine 224 is configured to receive (e.g., pick up) the blanks 106. In one or more examples, the applying machine 224 is configured to transport the blanks 106 to the grouping conveyor 222. In one or more examples, the applying machine 224 is configured to apply the blanks 106 to the arranged groupings of articles 102.

[0096] In one or more examples, the applying machine 224 is configured to apply the blank 106 to the group of articles 102 such that the top ends 246 of the articles 102 extend through the main panel 108 of the blank 106 (e.g., through the retaining openings 128) and are retained by the retaining structure 126 (e.g., as shown in FIG. 3 ). In one or more examples, the applying machine 224 is configured to position the blank 106 over the group of articles 102 (e.g., as shown in FIG. 2 ) and press the blank 106 downwardly onto the group of articles 102 to attach the group of articles 102 to the main panel 108 of the blank 106 (e.g., as shown in FIG. 3 ).

[0097] In one or more examples, the packaging system 100 includes a hopper (not shown) in which a plurality of blanks 106 in a flat position are readily held for processing. In one or more examples, the hopper forms a portion of the second station 214. The blanks 106 are retrieved (e.g., received or removed) from the hopper by an application machine 224.

[0098] In one or more examples, the application machine 224 includes or takes the form of a rotary vacuum feeder (not shown). In one or more examples, the rotary vacuum feeder includes a plurality of grippers (e.g., suction cups coupled to a vacuum system). The grippers are coupled to a rotating wheel unit that is driven by a drive shaft. A drive mechanism, such as a servo motor, is used to rotate the drive shaft.

[0099] In other examples, the applying machine 224 may include additional or alternative components and / or may operate in a different manner. In one or more examples, the applying machine 224 may include or take the form of any one of a variety of other machines or tool heads configured to receive the blanks 106, position the blanks 106 relative to the group of articles 102, and apply the blanks 106 to the group of articles 102.

[0100] In one or more examples, the assembly conveyor 226 forms a portion of the third station 216. The assembly conveyor 226 may also be referred to as a carton assembly conveyor or a third conveyor. In one or more examples, the assembly conveyor 226 is in communication with the grouping conveyor 222. The groups of articles 102 with blanks 106 applied are transferred from the grouping conveyor 222 to the assembly conveyor 226.

[0101] In one or more examples, the assembly conveyor 226 is configured to transport the groups of articles 102, with the blanks 106 secured to the articles 102, along a carton assembly path, such as in separate lines or lanes defined by lane guides, as the groups of articles 102 and the blanks 106 enter the assembly conveyor 226 at an upstream end of the assembly conveyor 226 (e.g., from the grouping conveyor 222) and move along the assembly conveyor 226. The lane guides are configured to maintain the groups of articles 102 and the blanks 106 in their respective lanes for folding the blanks 106 around the groups of articles 102 to assemble the cartons 104.

[0102] In one or more examples, the packaging system 100 includes a machine, referred to herein as a folding machine 228, for folding the blank 106 around the article 102. The folding machine 228 may also be referred to as a blank folding machine. In one or more examples, the folding machine 228 forms a portion of the third station 216.

[0103] In one or more examples, the folding machine 228 is configured to fold a portion of the blank 106, such as the first end panel 142, the second end panel 144, the first end flap 150, and the second end flap 152 of the blank 106 (e.g., as shown in FIGS. 4 and 5 ) around the group of articles 102 to partially form the carton 104. In one or more examples, the folding machine 228 is configured to fold another portion of the blank 106, such as the first side panel 110, the second side panel 112, the first cover panel 118, and the second cover panel 120 of the blank 106 (e.g., as shown in FIGS. 6-8 ) around the group of articles 102 to completely form the carton 104.

[0104] In one or more examples, the packaging system 100 includes a machine, referred to herein as an alignment machine 230, for aligning the blanks 106 during the formation of the cartons 104. The alignment machine 230 may also be referred to as a blank alignment machine. In one or more examples, the alignment machine 230 forms a portion of the third station 216.

[0105] In one or more examples, the alignment machine 230 is configured to properly position the blank 106 while portions of the blank 106, such as the first cover panel 118 and the second cover panel 120, are folded to form the carton 104. In one or more examples, the alignment machine 230 is further configured to maintain the blank 106 in the proper position while the locking structures 134 are formed into the carton 104, such as to secure the top cover panel 118 and the second cover panel 120 together in an overlapping relationship after being folded.

[0106] In one or more examples, the discharge conveyor 232 forms a portion of the fourth station 218. The discharge conveyor 232 may also be referred to as a package discharge conveyor or a fourth conveyor. In one or more examples, the discharge conveyor 232 is in communication with the assembly conveyor 226. Finished packages 234 are transferred from the assembly conveyor 226 to the discharge conveyor 232.

[0107] In one or more examples, the discharge conveyor 232 is configured to transport the completed packages 234 along a discharge path, such as in separate lines or lanes defined by lane guides, as the completed packages 234 enter the discharge conveyor 232 at an upstream end of the discharge conveyor 232 (e.g., from the assembly conveyor 226) and move along the discharge conveyor 232. In one or more examples, the discharge conveyor 232 is configured to transport the completed packages 234 away from the packaging system 100, such as for further packaging and / or storage.

[0108] 11 and 12, which diagrammatically illustrate portions of packaging system 100, such as third station 216. In FIG. 12, certain portions of packaging system 100 (e.g., as shown in FIG. 11) have been removed for purposes of clarity of illustration.

[0109] In one or more examples, the blank 106 is in a substantially flat configuration and is applied to a top end 246 of the articles 102 as the group of articles 102 and the blanks 106 enter the assembly conveyor 226. The first end flap 150 forms a leading end 296 of the blank 106 in the direction of advance (e.g., as indicated by directional arrow 248). The second end flap 152 forms a trailing end 298 of the blank 106 in the direction of advance.

[0110] In one or more examples, the packaging system 100 includes a series of lateral protrusions 292 configured to engage opposing sides of each of the group of articles 102. In one or more examples, the lateral protrusions 292 are configured to properly position the group of articles 102 on the assembly conveyor 226. In one or more examples, the series of lateral protrusions 292 are configured to move the group of articles 102 along a packaging path on the assembly conveyor 226. In one or more examples, the packaging system 100 includes a lateral protrusion drive 294, such as a continuous chain and drive mechanism (e.g., as shown in FIG. 11 ), configured to move the series of lateral protrusions 292.

[0111] In one or more examples, the folding machine 228 is configured to fold a first end panel 142 of the blank 106 against a main panel 108 of the blank 106 (e.g., as shown in FIG. 4 ) as the group of articles 102 applied to the top ends 246 of the articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the folding machine 228 is configured to fold a second end panel 144 of the blank 106 against a main panel 108 of the blank 106 (e.g., as shown in FIG. 4 ) as the group of articles 102 applied to the top ends 246 of the articles 102 and the blank 106 advance along a portion of the packaging path.

[0112] In one or more examples, the folding machine 228 is configured to sequentially fold the first end panel 142 and the second end panel 144. For example, the second end panel 144 is folded after the first end panel 142 is folded.

[0113] In one or more examples, the folding machine 228 is configured to fold a first end flap 150 of the blank 106 against the first end panel 142 (e.g., as shown in FIG. 5 ) as the group of articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the folding machine 228 is configured to fold a second end flap 152 of the blank 106 against the second end panel 144 (e.g., as shown in FIG. 5 ) as the group of articles 102 and the blank 106 advance along a portion of the packaging path.

[0114] In one or more examples, the folding machine 228 is configured to fold the first end flap 150 and the second end flap 152 in succession. For example, the first end flap 150 is folded after the first end panel 142 is folded. The second end flap 152 is folded after the second end panel 144 is folded. The second end flap 152 is folded after the first end flap 150 is folded.

[0115] In one or more examples, the folding machine 228 is configured to fold the first side panel 110 of the blank 106 against the main panel 108 (e.g., as shown in FIG. 6 ) as the group of articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the folding machine 228 is configured to fold the second side panel 112 of the blank 106 against the main panel 108 (e.g., as shown in FIG. 6 ) as the group of articles 102 and the blank 106 advance along a portion of the packaging path.

[0116] In one or more examples, the first side panel 110 and the second side panel 112 are folded after the first end panel 142, the second end panel 144, the first end flap 150, and the second end flap 152 have been folded. In one or more examples, the folding machine 228 is configured to fold the first side panel 110 and the second side panel 112 sequentially. In one or more examples, the folding machine 228 is configured to fold the first side panel 110 and the second side panel 112 simultaneously.

[0117] In one or more examples, the folding machine 228 is configured to fold the first cover panel 118 of the blank 106 against the first side panel 110 (e.g., as shown in FIG. 8 ) as the group of articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the folding machine 228 is configured to fold the second cover panel 120 of the blank 106 against the second side panel 112 (e.g., as shown in FIG. 7 ) as the group of articles 102 and the blank 106 advance along a portion of the packaging path.

[0118] In one or more examples, the first cover panel 118 and the second cover panel 120 are folded after the first side panel 110 and the second side panel 112 are folded. In one or more examples, the folding machine 228 is configured to sequentially fold the first cover panel 118 and the second cover panel 120. For example, the first cover panel 118 is folded after the second cover panel 120 is folded to position the first cover panel 118 and the second cover panel 120 in an overlapping relationship (e.g., as shown in FIGS. 7 and 8 ).

[0119] In one or more examples, the alignment machine 230 is configured to position the first side panel 110 and the second side panel 112 at a predetermined angle 282 (e.g., as shown in FIG. 20 ) relative to the main panel 108 as the group of articles 102 and blank 106 advance along the packaging path after the first side panel 110 and the second side panel 112 are folded and / or while the first cover panel 118 and the second cover panel 120 are being folded.

[0120] 20 , in one or more examples, the alignment machine 230 is configured to position (e.g., fold and / or hold) the first side panel 110 and the second side panel 112 in an orientation that is generally perpendicular to the main panel 108. For example, the predetermined angle 282 is approximately 90 degrees. In one or more examples, the alignment machine 230 is configured to position (e.g., fold and / or hold) the first side panel 110 and the second side panel 112 at an oblique angle to the main panel 108. For example, the predetermined angle 282 ranges from approximately 45 degrees to approximately 90 degrees, such as from approximately 60 degrees to approximately 90 degrees.

[0121] 13-16, which diagrammatically illustrate a portion of packaging system 100, and more specifically, a portion of folding machine 228. In FIGS. 13-16, certain portions of packaging system 100 (e.g., as shown in FIG. 11) have been removed for purposes of clarity of illustration.

[0122] In one or more examples, the folding machine 228 includes a lower folding wheel 242. The lower folding wheel 242 is configured to rotate about a lower axis of rotation 244. In one or more examples, the lower axis of rotation 244 is a horizontal axis. In one or more examples, the lower axis of rotation 244 is at least approximately perpendicular, such as substantially perpendicular, to a direction of travel of the articles 102 and blanks 106 along the packaging path.

[0123] In one or more examples, the folding machine 228 includes a first lower folding arm 250 and a second lower folding arm 252. The first lower folding arm 250 projects radially from the lower folding wheel 242. The second lower folding arm 252 projects radially from the lower folding wheel 242.

[0124] In one or more examples, the folding machine 228 includes a lower rotation drive 254 (e.g., as shown in FIG. 12 ). The lower rotation drive 254 is configured to rotate the lower folding wheel 242 about the lower axis of rotation 244 in a direction of rotation (e.g., as shown by directional arrow 290 in FIGS. 13 and 14 ). In one or more examples, the lower rotation drive 254 is coupled to the lower folding wheel 242 by a drive shaft (not shown). The lower rotation drive 254 includes any suitable rotation drive mechanism, such as a servo motor.

[0125] In one or more examples, the first lower fold arm 250 is configured to fold the first end panel 142 upwardly into an orientation that is generally perpendicular to the main panel 108 of the blank 106 as the lower fold wheel 242 rotates and the group of articles 102 and the blank 106 pass over the lower fold wheel 242. Rotation of the lower fold wheel 242 rotates the first lower fold arm 250 upwardly into engagement with the blank 106 as the leading end 296 of the blank 106 approaches the lower fold wheel 242. Further rotation of the lower fold wheel 242 rotates the first lower fold arm 250 upwardly and forwardly to urge the first end panel 142 upwardly toward a folded position (e.g., to fold the first end panel 142 out of the plane of the main panel 108 toward the main panel 108) as the leading end 296 of the blank 106 passes over the lower fold wheel 242. Further rotation of the lower fold wheel 242 causes the first lower fold arm 250 to rotate downward and forward out of engagement with the blank 106 as the leading end 296 of the blank 106 leaves the lower fold wheel 242 .

[0126] In one or more examples, the first downward folding arm 250 is configured to engage the first end panel 142 from below to fold the first end panel 142 upwardly relative to the main panel 108 into a folded position. In one or more examples, the first downward folding arm 250 is configured to engage the first end flap 150 from below to fold the first end flap 150 upwardly relative to the main panel 108 into a folded position.

[0127] In one or more examples, the second lower fold arm 252 is configured to fold the second end panel 144 upwardly into an orientation that is generally perpendicular to the main panel 108 as the lower fold wheel 242 rotates and the group of articles 102 and the blank 106 pass over the lower fold wheel 242. Rotation of the lower fold wheel 242 rotates the second lower fold arm 252 upwardly into engagement with the blank 106 as the trailing end 298 of the blank 106 approaches the lower fold wheel 242. Further rotation of the lower fold wheel 242 rotates the second lower fold arm 252 upwardly and forwardly to urge the second end panel 144 toward a folded position (e.g., to fold the second end panel 144 out of the plane of the main panel 108 and toward the main panel 108) as the trailing end 298 of the blank 106 passes over the lower fold wheel 242. Further rotation of the lower fold wheel 242 rotates the second lower fold arm 252 upwardly and rearwardly out of engagement with the blank 106 as the trailing end 298 of the blank 106 clears the lower fold wheel 242. Further rotation of the lower fold wheel 242 rotates the second lower fold arm 252 downwardly and forwardly away from the blank 106.

[0128] In one or more examples, the second downward folding arm 252 is configured to engage the second end panel 144 from below to fold the second end panel 144 upwardly relative to the main panel 108 into a folded position. In one or more examples, the second downward folding arm 252 is configured to engage the second end flap 152 from below to fold the second end flap 152 upwardly relative to the main panel 108 into a folded position.

[0129] In one or more examples, the second lower fold arm 252 is configured to fold the second end flap 152 into an orientation that is generally perpendicular to the second end panel 144 in the direction of travel of the group of articles 102 and the blank 106 as the lower fold wheel 242 rotates and the group of articles 102 and the blank 106 pass over the lower fold wheel 242. With the second lower fold arm 252 engaged with the blank 106 to urge the second end panel 144 into the folded position, further rotation of the lower fold wheel 242 rotates the second lower fold arm 252 downward and forward as the trailing end 298 of the blank 106 passes over the lower fold wheel 242 to engage and urge the second end flap 152 toward the folded position (e.g., to fold the second end flap 152 out of the plane of the second end panel 144 and toward the main panel 108).

[0130] In one or more examples, the second downward folding arm 252 is configured to engage the second end flap 152 from behind and / or above to fold the second end flap 152 downwardly relative to the second end panel 144 into a folded position.

[0131] In one or more examples, the first and second down fold arms 250 and 252 are angularly offset from one another. In one or more examples, the angular offset between the first and second down fold arms 250 and 252 is selected such that the first and second down fold arms 250 and 252 properly engage the blanks 106 to fold the first and second end panels 142 and 144 into a folded position as the group of articles 102 and the blanks 106 pass over the down fold wheel 242.

[0132] In one or more examples, the angular offset between the first and second down fold arms 250, 252 can be adjusted to account for various packaging parameters, such as, but not limited to, the rotational speed of the down fold wheel 242, the flow rate of the groups of articles 102 and blanks 106, the placement of the articles 102 in the groups, and the dimensions of the blanks 106. For example, at least one of the first and / or second down fold arms 250, 252 is releasably coupled to the down fold wheel 242.

[0133] In one or more examples, the first lower folding arm 250 is fixed to the lower folding wheel 242 such that it does not move relative to the lower folding wheel 242 as the lower folding wheel rotates. In one or more examples, the second lower folding arm 252 is configured to pivot about a pivot axis 328 (e.g., as shown in FIG. 15 ) relative to the lower folding wheel 242. In one or more examples, the pivot axis 328 is a horizontal axis. In one or more examples, the pivot axis 328 is at least approximately perpendicular, such as substantially perpendicular, to a direction of travel of the articles 102 and blanks 106 along the packaging path. In one or more examples, the pivot axis 328 is parallel to the lower rotation axis 244. In one or more examples, the second lower folding arm 252 is radially movable relative to the lower folding wheel 242. The pivoting and radial movement of the second downward folding arm 252 can cause the second downward folding arm 252 to continuously fold the second end panel 144 and the second end flap 152 into a folded position in one rotation of the downward folding wheel 242.

[0134] In one or more examples, the folding machine 228 further includes a cam track 256. The cam track 256 is positioned adjacent to the lower folding wheel 242. The folding machine 228 also includes a cam follower 258. The cam follower 258 is coupled to the second lower folding arm 252 and engaged with the cam track 256. In one or more examples, a pivot axis 328 extends through the cam follower 258 and the second lower folding arm 252. The second lower folding arm 252 pivots about the pivot axis 328 and moves radially relative to the lower folding wheel 242 as the cam follower 258 moves along the cam track 256.

[0135] In one or more examples, the cam track 256 includes a substantially circular region 322 (e.g., as shown in FIG. 15 ), a downwardly sloping region 324, and an upwardly sloping region 326. As the cam follower 258 moves along the circular region 322, the second downward folding arm 252 is rotated upward and forward into engagement with the blank 106, such as the second end panel 144, the second end flap 152, the third anchoring flap 162, and / or the fourth anchoring flap 164. As the cam follower 258 moves along the downwardly sloping region 324, the second downward folding arm 252 moves downward (e.g., radially inward relative to the downward folding wheel 242) relative to the blank 106 and pivots forward to fold the second end panel 144 and the second end flap 152 in a folded position. As the cam follower 258 moves along the upwardly sloping section 326, the second downward folding arm 252 moves upward relative to the blank 106 (e.g., radially outward relative to the downward folding wheel 242) and pivots rearwardly out of engagement with the blank 106.

[0136] In one or more examples, the first lower fold arm 250 includes a substantially straight body. The body of the first lower fold arm 250 includes an engagement edge configured to contact the blank 106. In one or more examples, the engagement edge of the first lower fold arm 250 is curved.

[0137] In one or more examples, the second lower folding arm 252 includes a first body portion coupled to the cam follower 258 and a second body portion extending from the first body portion at an angle, such as an oblique angle or generally perpendicular to the first body portion. The angular relationship between the first body portion and the second body portion of the second lower folding arm 252 can hook the second lower folding arm 252 over the second end panel 144 in the folded position to fold the second end flap 152 into the folded position. The second body portion of the second lower folding arm 252 includes an engagement edge configured to contact the blank 106. In one or more examples, the engagement edge of the second lower folding arm 252 is curved.

[0138] In one or more examples, a plurality of first downward folding arms 250 and a plurality of second downward folding arms 252 project radially from the downward folding wheel 242. Each one of the plurality of first downward folding arms 250 is equally angularly offset from an adjacent one of the plurality of first downward folding arms 250. Each one of the plurality of second downward folding arms 252 is equally angularly offset from an adjacent one of the plurality of second downward folding arms 252.

[0139] In one or more examples, the rotational speed of the downward folding wheel 242 is synchronized with the flow rate of the group of articles 102 and the blanks 106 as they pass over the downward folding wheel 242 so that the first downward folding arm 250 and the second downward folding arm 252 properly engage with the blanks 106 to fold the first end panel 142 and the second end panel 144 into a folded position.

[0140] In one or more examples, the folding machine 228 includes a second lower fold wheel 300 (e.g., as shown in FIG. 12 ). In these examples, the lower fold wheel 242 may also be referred to as the first lower fold wheel. In one or more examples, the second lower fold wheel 300 is substantially the same as the lower fold wheel 242.

[0141] In one or more examples, the second lower folding wheel 300 is configured to rotate about the lower axis of rotation 244. In one or more examples, a lower rotational drive 254 (e.g., as shown in FIG. 11 ) is configured to rotate the lower folding wheel 242 in the direction of rotation about the lower axis of rotation 244. In one or more examples, the folding machine 228 includes a second lower rotational drive (not shown) dedicated to the second lower folding wheel 300.

[0142] In one or more examples, the folding machine 228 includes a first downward folding arm 250 that projects radially from the second downward folding wheel 300 and a second downward folding arm 252 that projects radially from the second downward folding wheel 300. In one or more examples, the first downward folding arm 250 and the second downward folding arm 252 of the second downward folding wheel 300 are substantially similar to the first downward folding arm 250 and the second downward folding arm 252 of the downward folding wheel 242.

[0143] In one or more examples, the lower fold wheel 242 is positioned on a first side of the assembly conveyor 226 and the second lower fold wheel 300 is positioned on a second side of the assembly conveyor 226 opposite the lower fold wheel 242 such that the groups of articles 102 and blanks 106 pass between the lower fold wheel 242 and the second lower fold wheel 300 as the groups of articles 102 and blanks 106 proceed along the packaging path.

[0144] In one or more examples, the lower folding wheel 242 and the first lower folding arm 250 of the second lower folding wheel 300 are configured to engage the first end panel 142 from below to fold the first end panel 142 upwardly relative to the main panel 108 into a folded position. In one or more examples, the lower folding wheel 242 and the first lower folding arm 250 of the second lower folding wheel 300 are configured to engage the first end panel 142 from below to fold the first end flap 150 upwardly relative to the main panel 108 into a folded position. In one or more examples, to fold the first end panel 142 upwardly relative to the main panel 108 into a folded position, the first downward folding arm 250 of the downward folding wheel 242 is configured to engage the second anchoring flap 160 from below, and the first downward folding arm 250 of the second downward folding wheel 300 is configured to engage the first anchoring flap 158 from below.

[0145] In one or more examples, the lower folding wheel 242 and the second lower folding arm 252 of the second lower folding wheel 300 are configured to engage the second end panel 144 from below to fold the second end panel 144 upwardly relative to the main panel 108 into a folded position. In one or more examples, the lower folding wheel 242 and the second lower folding arm 252 of the second lower folding wheel 300 are configured to engage the second end panel 144 from below to fold the second end flap 152 upwardly relative to the main panel 108 into a folded position. In one or more examples, to fold the second end panel 144 upwardly relative to the main panel 108 into a folded position, the second downward folding arm 252 of the downward folding wheel 242 is configured to engage the fourth anchoring flap 164 from below, and the second downward folding arm 252 of the second downward folding wheel 300 is configured to engage the third anchoring flap 162 from below.

[0146] In one or more examples, the second down folding arm 252 of the down folding wheel 242 and the second down folding wheel 300 are configured to engage the second end flap 152 from behind and / or above to fold the second end flap 152 downwardly into a folded position relative to the second end panel 144. In one or more examples, the second down folding arm 252 of the down folding wheel 242 is configured to engage the fourth anchoring flap 164 from behind and / or above and the second down folding arm 252 of the second down folding wheel 300 is configured to engage the third anchoring flap 162 from behind and / or above to fold the second end flap 152 downwardly into a folded position relative to the second end panel 144.

[0147] In one or more examples, the folding machine 228 further includes a second cam track 302 (e.g., as shown in FIG. 12 ). The second cam track 302 is positioned adjacent to the second lower fold wheel 300. The folding machine 228 also includes a second cam follower (not shown) that is coupled to the second lower fold arm 252 of the second lower fold wheel 300 and engaged with the second cam track 302. In one or more examples, the second cam track 302 and the second cam follower associated with the second lower fold wheel 300 are substantially the same as the cam track 256 and the cam follower 258 associated with the lower fold wheel 242.

[0148] In one or more examples, a second plurality of first down folding arms 250 and a second plurality of second down folding arms 252 project radially from the second down folding wheel 300. Each one of the second plurality of first down folding arms 250 is equally angularly offset from an adjacent one of the second plurality of first down folding arms 250. Each one of the second plurality of second down folding arms 252 is equally angularly offset from an adjacent one of the second plurality of second down folding arms 252.

[0149] In one or more examples, the rotational speed of the second downward folding wheel 300 is synchronized with the rotational speed of the downward folding wheel 242 and the flow rate of the group of articles 102 and the blanks 106 so that the first downward folding arms 250 and the second downward folding arms 252 of the downward folding wheel 242 and the second downward folding wheel 300 properly engage with the blanks 106 to fold the first end panel 142 and the second end panel 144 into a folded position as the group of articles 102 and the blanks 106 pass over and between the downward folding wheel 242 and the second downward folding wheel 300.

[0150] In one or more examples, the folding machine 228 includes an end flap fold guide 262, such as a pair of end fold guides 262 (e.g., as shown in FIGS. 13, 14, and 16). In one or more examples, the end flap fold guides 262 are positioned above the lower folding wheels 242. In one or more examples, the end flap fold guides 262 extend along at least a portion of the packaging path. The end flap fold guides 262 are configured to fold the first end flap 150 as the blank 106 advances under the end flap fold guides 262 into an orientation that is generally perpendicular to the first end panel 142, opposite the direction of advancement of the group of articles 102 and the blank 106.

[0151] In one or more examples, the end flap fold guide 262 (e.g., each one of the pair of end flap fold guides 262) includes an engagement end that extends in an upstream direction of the packaging path. In one or more examples, the end flap fold guide 262 includes a plow, a rotating plate, a rotating rod, or other mechanism configured to passively urge the first end flap 150 into the folded position as the blank 106 advances under the end flap fold guide 262. The end flap fold guide 262 includes an engagement edge configured to contact the blank 106. In one or more examples, the engagement end of the end flap fold guide 262 is curved.

[0152] In one or more examples, the end flap fold guide 262 is configured to engage the first end flap 150 as the blank 106 advances under the end flap fold guide 262. In one or more examples, the first lower fold arm 250 is configured to hold the first end flap 150 in an upwardly folded orientation such that the end flap fold guide 262 can further fold the first end flap 150 into a folded position.

[0153] In one or more examples, the end flap fold guide 262 is positioned between the lower fold wheel 242 and the second lower fold wheel 300 .

[0154] In one or more examples, the folding machine 228 includes an anchoring flap fold guide 264, such as a pair of anchoring flap guides 264 (e.g., as shown in FIGS. 13, 14, and 16). In one or more examples, the anchoring flap fold guides 264 are positioned above the lower folding wheels 242 and below the end flap fold guides 262. In one or more examples, the anchoring flap fold guides 264 extend along at least a portion of the wrapping path.

[0155] In one or more examples, the anchor flap fold guide 264 is configured to fold the first anchor flap 158 and the second anchor flap 160 of the blank 106 into an orientation that is generally parallel to the main panel 108, opposite the direction of advancement of the group of articles 102 and the blank 106, as the blank 106 advances under the anchor flap fold guide 264. In one or more examples, the anchor flap fold guide 264 is configured to fold the first anchor flap 158 and the second anchor flap 160 into a facing relationship with a respective one of the first cover panel 118 and the second cover panel 120 to which they are hinged.

[0156] In one or more examples, the anchor flap fold guide 264 is configured to fold the third anchor flap 162 and the fourth anchor flap 164 of the blank 106 into an orientation that is generally parallel to the main panel 108 in the direction of advancement of the group of articles 102 and the blank 106 as the blank 106 advances under the anchor flap fold guide 264. In one or more examples, the anchor flap fold guide 264 is configured to fold the third anchor flap 162 and the fourth anchor flap 164 into a facing relationship with a respective one of the first cover panel 118 and the second cover panel 120 to which they are hinged.

[0157] In one or more examples, the anchoring flap fold guide 264 (e.g., each one of the pair of anchoring flap fold guides 264) includes an engagement end that extends in an upstream direction of the packaging path. In one or more examples, the anchoring flap fold guide 264 includes a plow, a rotating plate, a rotating rod, or other mechanism configured to passively urge the anchoring flaps 158, 160, 162, 164 into a folded position as the blank 106 advances under the end flap fold guide 262. The anchoring flap fold guide 264 includes an engagement edge configured to contact the blank 106. In one or more examples, the engagement end of the anchoring flap fold guide 264 is curved.

[0158] In one or more examples, the anchor flap fold guide 264 is configured to engage the first anchor flap 158 and the second anchor flap 160 as the blank 106 advances under the anchor flap fold guide 264. In one or more examples, the anchor flap fold guide 264 is configured to engage the third anchor flap 162 and the fourth anchor flap 164 as the blank 106 advances under the anchor flap fold guide 264. In one or more examples, the second downward fold arm 252 is configured to hold the second end flap 152, and thus the third anchor flap 162 and the fourth anchor flap 164, in a downwardly folded position orientation such that the anchor flap guide 264 can further fold the third anchor flap 162 and the fourth anchor flap 164 into the folded position.

[0159] In one or more examples, the folding machine 228 includes an upper folding wheel 266. In one or more examples, the upper folding wheel 266 is positioned above the lower folding wheel 242. The upper folding wheel 266 is configured to rotate about an upper rotation axis 268 (e.g., as shown in FIG. 15 ). In one or more examples, the upper rotation axis 268 is a horizontal axis. In one or more examples, the upper rotation axis 268 is at least approximately perpendicular, such as substantially perpendicular, to a direction of travel of the articles 102 and blanks 106 along the packaging path. In one or more examples, the upper rotation axis 268 is parallel to the lower rotation axis 244.

[0160] In one or more examples, the folder 228 further includes an upper folder arm 270. The upper folder arm 270 projects radially from the upper folder wheel 266. In one or more examples, a plurality of upper folder arms 270 project radially from the upper folder wheel 266.

[0161] The folding machine 228 also includes an upper rotary drive 330. The upper rotary drive 330 is configured to rotate the upper folding wheel 266 about an upper axis of rotation 268 in a direction of rotation (e.g., as indicated by directional arrow 304 in FIG. 15 ). Additionally or alternatively, the upper rotary drive 330 is configured to rotate the upper folding wheel 266 about the upper axis of rotation 268 in a direction of rotation (e.g., opposite directional arrow 304 in FIG. 15 ). In one or more examples, the upper rotary drive 330 is coupled to the upper folding wheel 266 by a drive shaft (not shown). The upper rotary drive 330 includes any suitable rotary drive mechanism, such as a servo motor.

[0162] In one or more examples, the rotational speed of the upper fold wheel 266 is constant. In one or more examples, the rotational speed of the upper fold wheel 266 is variable, such as variably controlled using a cam profile.

[0163] In one or more examples, the upper fold arm 270 is configured to assist the lower fold wheel 242, and, if present, the second lower fold wheel 300, in folding the second end panel 144 and / or the second end flap 152 into a folded position as the group of articles 102 and blanks 106 advance along a portion of the packaging path. In one or more examples, the rotational speed of the upper fold wheel 266 is synchronized with the flow rate of the group of articles 102 and blanks 106 such that the upper fold arm 270 properly engages the blanks 106 to fold the second end panel 144 and / or the second end flap 152 into a folded position as the group of articles 102 and blanks 106 pass under the upper fold wheel 266.

[0164] In one or more examples, the upper fold arm 270 is configured to fold the second end panel 144 upwardly into an orientation that is generally perpendicular to the main panel 108 as the upper fold wheel 266 rotates (e.g., in the direction of arrow 304) and the group of articles 102 and the blanks 106 pass beneath the upper fold wheel 266. In one or more examples, the upper fold arm 270 is configured to fold the second end flap 152 into an orientation that is generally perpendicular to the second end panel 144 in the direction of travel of the group of articles 102 and the blanks 106 as the upper fold wheel 266 rotates (e.g., in the direction of arrow 304) and the group of articles 102 and the blanks 106 pass beneath the upper fold wheel 266.

[0165] In one or more examples, the upper fold arm 270 is configured to engage the second end panel 144 from behind and / or above to fold the second end panel 144 upwardly relative to the main panel 108 into a folded position. In one or more examples, the upper fold arm 270 is configured to engage the second end flap 152 from behind and / or above to fold the second end flap 152 downwardly relative to the second end panel 144 into a folded position.

[0166] In one or more examples, the upper fold arm 270 is configured to assist the lower fold wheel 242, and, if present, the second lower fold wheel 300, in folding the first end panel 142 and / or first end flap 150 into a folded position as the group of articles 102 and blanks 106 advance along a portion of the packaging path. In one or more examples, the rotational speed of the upper fold wheel 266 is synchronized with the flow rate of the group of articles 102 and blanks 106 as they pass under the upper fold wheel 266 such that the upper fold arm 270 properly engages the blanks 106 to fold the first end panel 142 and / or first end flap 150 into a folded position.

[0167] In one or more examples, the upper fold arm 270 is configured to fold the first end panel 142 upwardly into an orientation that is generally perpendicular to the main panel 108 as the upper fold wheel 266 rotates (e.g., in a direction opposite to arrow 304) and the group of articles 102 and the blanks 106 pass beneath the upper fold wheel 266. In one or more examples, the upper fold arm 270 is configured to fold the first end flap 150, opposite the direction of travel of the group of articles 102 and the blanks 106, into an orientation that is generally perpendicular to the second end panel 144 as the upper fold wheel 266 rotates (e.g., in a direction opposite to arrow 304) and the group of articles 102 and the blanks 106 pass beneath the upper fold wheel 266.

[0168] In one or more examples, the upper fold arm 270 is configured to engage the first end panel 142 from the front and / or above to fold the first end panel 142 upwardly relative to the main panel 108 into a folded position. In one or more examples, the upper fold arm 270 is configured to engage the first end flap 150 from the front and / or above to fold the first end flap 150 downwardly relative to the second end panel 144 into a folded position.

[0169] In one or more examples, the folding machine 228 includes a second upper folding wheel 318 and a second upper folding arm 320 that projects radially from the second upper folding wheel 318. The second upper folding wheel 318 is substantially similar to the upper folding wheel 266. The second upper folding arm 320 is substantially similar to the upper folding arm 270.

[0170] In one or more examples, the packaging system 100 includes an upper protrusion 272. The upper protrusion 272 is configured to engage the top edge 246 of the article 102. The upper protrusion 272 is configured to press against the article 102 from above and to resist any movement of the article 102 and / or blank 106 due to engagement with the folding machine 228 during folding of the blank 106.

[0171] In one or more examples, the packaging system 100 includes a second upward projection 310. The second upward projection 310 is configured to engage the top end 246 of the article 102 in a spaced apart relationship from the upper projection 272. The second upward projection 310 is configured to press against the article 102 from above and to resist any movement of the article 102 and / or blank 106 due to engagement with the folding machine 228 during folding of the blank 106.

[0172] In one or more examples, the upper projection 272 is configured to engage the article 102 proximate the rear end 298 of the blank 106 and the second upper projection 310 is configured to engage the article 102 proximate the front end 296 of the blank 106. In one or more examples, the separation distance (e.g., linear displacement) between the upper projection 272 and the second upper projection 310 is adjustable to account for a variety of different sizes and / or configurations of groups of articles 102 and blanks 106.

[0173] In one or more examples, the packaging system 100 includes a post 274 projecting downwardly from the upper projection 272. Optionally, the second upper projection 310 additionally or alternatively includes a post 274 projecting therefrom. In one or more examples, the post 274 is configured to be inserted at least partially through a handle opening 132 formed in the main panel 108. The post 274 is configured to index the blank 106 during folding.

[0174] In one or more examples, the folding machine 228 includes side panel fold guides, such as a pair of side panel fold guides (not shown), configured to fold the first side panel 110 into a folded position relative to the main panel 108 and fold the second side panel 112 into a folded position relative to the main panel 108. The side panel fold guides may include or take the form of any suitable panel folding mechanism, such as a plow, a rotating plate, a rotating rod (e.g., extending downstream), or other mechanism configured to passively or actively urge (e.g., fold upwardly) the first side panel 110 and the second side panel 112 into a folded position relative to the main panel 108 as the group of articles 102 and blanks 106 advance along a portion of the packaging path.

[0175] In one or more examples, the folding machine 228 includes cover panel fold guides, such as a pair of cover panel fold guides (not shown), configured to fold the first cover panel 118 into a folded position relative to the first side panel 110 and the second cover panel 120 into a folded position relative to the second side panel 112. The cover panel fold guides may include or take the form of any suitable panel folding mechanism, such as a plow, a rotating plate, a rotating rod (e.g., extending downstream), or other mechanism configured to passively or actively urge (e.g., fold downwardly) the first cover panel 118 and the second cover panel 120 as the group of articles 102 and the blank 106 advance along a portion of the packaging path.

[0176] 17-19, which generally illustrate a portion of the packaging system 100, and more specifically, a portion of the alignment machine 230. In one or more examples, the alignment machine 230 includes a first alignment block 276 that is configured to engage with the first side panel 110 after the first side panel 110 has been folded upwardly into an orientation that is generally perpendicular to the main panel 108. In one or more examples, the alignment machine 230 includes a second alignment block 278 that is configured to engage with the second side panel 112 after the second side panel 112 has been folded upwardly into an orientation that is generally perpendicular to the main panel 108.

[0177] In one or more examples, each one of the first alignment block 276 and the second alignment block 278 includes an alignment surface 280. The alignment surface 280 is oriented at an alignment angle 284 relative to a vertical plane (e.g., as shown in FIGS. 18 and 19 ). In one or more examples, the alignment angle 284 is complementary to a predetermined angle 282 of the first side panel 110 and the second side panel 112 (e.g., as shown in FIG. 20 ).

[0178] In one or more examples, the first registration block 276 and the second registration block 278 are configured to advance with the group of articles 102 and the blank 106 as the blank 106 advances along the packaging path.

[0179] In one or more examples, the alignment machine 230 includes a drive mechanism 286 (e.g., as shown in FIG. 11 ). The drive mechanism 286 is configured to move the first alignment block 276 into engagement with the first side panel 110 as the group of articles 102 and the blanks 106 advance along the portion of the packaging path. The drive mechanism 286 is further configured to move the second alignment block 278 into engagement with the second side panel 112 as the group of articles 102 and the blanks 106 advance along the portion of the packaging path. In one or more examples, the drive mechanism 268 includes any suitable drive, such as a continuous chain or belt and a drive motor, configured to move the first alignment block 276 and the second alignment block 278.

[0180] In one or more examples, the drive mechanism 286 is further configured to move the first alignment block 276 and the second alignment block 278 with the blank 106 as the group of articles 102 and the blank 106 advance along a portion of the packaging path.

[0181] In one or more examples, the first alignment block 276 is configured to maintain the first side panel 110 at a predetermined angle 282 relative to the main panel 108 while the first cover panel 118 of the blank 106 is folded relative to the first side panel 110. In one or more examples, the second alignment block 278 is configured to maintain the second side panel 112 at a predetermined angle 282 relative to the main panel 108 while the second cover panel 120 of the blank 106 is folded relative to the second side panel 112.

[0182] In one or more examples, the packaging system 100 includes a forming machine 288. The forming machine 288 is configured to couple the first cover panel 118 and the second cover panel 120 to one another. In one or more examples, the first alignment block 276 is configured to maintain the first side panel 110 at a predetermined angle 282 relative to the main panel 108 and the second alignment block 278 is configured to maintain the second side panel 112 at the predetermined angle 282 relative to the main panel 108 while the first cover panel 118 and the second cover panel 120 are coupled to one another.

[0183] Positioning and maintaining the first and second side panels 110, 112 at the predetermined angle 282 facilitates proper alignment of the first and second cover panels 118, 120 relative to one another while folding the first and second cover panels 118, 120 in an overlapping relationship. Positioning and maintaining the first and second side panels 110, 112 at the predetermined angle 282 facilitates proper vertical alignment of the locking elements 138 and locking openings 136 of the locking structure 134 while securing the first and second cover panels 118, 120 together.

[0184] In one or more examples, the forming machine 288 includes a wheel assembly 314 and at least one punch 316 coupled to the wheel assembly 314. The wheel assembly 314 is driven by a drive shaft (not shown). A drive mechanism (not shown), such as a servo motor, is used to rotate the wheel assembly 314. The rotation of the wheel assembly 314 brings the punch 316 into contact with the composite upper panel structure 206 to form (e.g., punch) the locking structure 134 through the first cover panel 118 and the second cover panel 120. For example, the punch 316 is configured to insert and engage the locking element 138 into the locking opening 136 and, optionally, the handle opening 132.

[0185] In other examples, the forming machine 288 may include additional or alternative components and / or may operate in a different manner. In one or more examples, the forming machine 288 may include or take the form of any one of a variety of other machines or tool heads configured to secure the first cover panel 118 and the second cover panel 120 together in overlapping relationship to complete the carton 104.

[0186] In one or more examples, the alignment machine 230 includes a series (e.g., multiple) of first alignment blocks 276 configured to engage with the first side panel 110 after the first side panel 110 is folded upwardly into an orientation that is generally perpendicular to the main panel 108. In one or more examples, the alignment machine 230 includes a series (e.g., multiple) of second alignment blocks 278 configured to engage with the second side panel 112 after the second side panel 112 is folded upwardly into an orientation that is generally perpendicular to the main panel 108.

[0187] By way of example, the present disclosure is directed to a packaging method. In one or more examples, the packaging method forms blanks 106 around the articles 102 to facilitate packaging a group of articles 102 into a carton 104. In one or more examples, the packaging method is a continuous motion packaging method for continuously packaging groups of articles 102 into cartons 104. In one or more examples, the packaging method facilitates continuous processing of a plurality of blanks 106 to form (e.g., build or assemble) a plurality of finished cartons 104 filled with a plurality of groups of articles 102 (e.g., a plurality of finished packages 234). In one or more examples, the packaging method is performed using a packaging system 100.

[0188] In one or more examples, the method includes conveying the group of articles 102 and the blank 106 that is applied to the top ends 246 of the articles 102 along a packaging path. In one or more examples, the group of articles 102 and the blank 106 are conveyed along the packaging path using a conveyor 236.

[0189] In one or more examples, the method includes folding a first end panel 142 of the blank 106 relative to a main panel 108 of the blank 106 as the group of articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the first end panel 142 is folded into a folded position using a first lower folding arm 250 of the folding machine 228.

[0190] In one or more examples, the method includes folding a second end panel 144 of the blank 106 against a main panel 108 of the blank 106 after folding the first end panel 142 as the group of articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the second end panel 144 is folded into a folded position using a second lower folding arm 252 and / or an upper folding arm 270 of the folding machine 228.

[0191] In one or more examples, the method includes folding a first end flap 150 of the blank 106 against the first end panel 142 as the group of articles 102 and the blank 106 advance along a portion of the packaging path after folding the first end panel 142. In one or more examples, the first end flap 150 is folded into a folded position using an end flap fold guide 262 of the folding machine 228.

[0192] In one or more examples, the method includes folding a second end flap 152 of the blank 106 against the second end panel 144 as the group of articles 102 and the blank 106 advance along a portion of the packaging path after folding the second end panel 144. In one or more examples, the second end flap 152 is folded into a folded position using a second lower folding arm 252 and / or an upper folding arm 270 of the folding machine 228.

[0193] In one or more examples, the method includes folding the first end flap 150, followed by folding the first anchoring flap 158 and the second anchoring flap 160 as the group of articles 102 and blanks 106 advance along a portion of the packaging path. In one or more examples, the first anchoring flap 158 and the second anchoring flap 160 are folded into a folded position using anchoring flap fold guides 264 of the folding machine 228.

[0194] In one or more examples, the method includes folding the third anchoring flap 162 and the fourth anchoring flap 164 as the group of articles 102 and the blank 106 advance along a portion of the packaging path after folding the second end flap 152. In one or more examples, the third anchoring flap 162 and the fourth anchoring flap 164 are folded into a folded position using anchoring flap fold guides 264 of the folding machine 228.

[0195] In one or more examples, the method includes securing the group of articles 102 and the blank 106 while folding the first end panel 142, the second end panel 144, the first end flap 150, the second end flap 152, the first anchoring flap 158, the second anchoring flap 160, the third anchoring flap 162, and the fourth anchoring flap 164 into a folded position as the group of articles 102 and the blank 106 advance along a portion of the packaging path. In one or more examples, the group of articles 102 and the blank 106 are secured using an upward protrusion 272 of the packaging system 100.

[0196] In one or more examples, the method includes indexing the blank 106 while folding the first end panel 142, the second end panel 144, the first end flap 150, the second end flap 152, the first anchoring flap 158, the second anchoring flap 160, the third anchoring flap 162, and the fourth anchoring flap 164 into folded positions as the group of articles 102 and blank 106 advance along a portion of the packaging path. In one or more examples, the blank 106 is indexed using posts 274 of the packaging system 100.

[0197] In one or more examples, the method includes folding the first side panel 110 of the blank 106 against the main panel 108 as the group of articles 102 and the blank 106 advance along a portion of the packaging path after folding the first end flap 150 and the second end flap 152. In one or more examples, the first side panel 110 is folded into a folded position using a side panel fold guide 306 of the folding machine 228.

[0198] In one or more examples, the method includes folding the second side panel 112 of the blank 106 against the main panel 108 as the group of articles 102 and the blank 106 advance along a portion of the packaging path after folding the first end flap 150 and the second end flap 152. In one or more examples, the second side panel 112 is folded into a folded position using a side panel fold guide 306 of the folding machine 228.

[0199] In one or more examples, the method includes positioning the first side panel 110 and the second side panel 112 at a predetermined angle 282 relative to the main panel 108 after folding the first side panel 110 and the second side panel 112. In one or more examples, the first side panel 110 and the second side panel 112 are positioned using a first alignment block 276 and a second alignment block 278 of the alignment machine 230.

[0200] In one or more examples, the method includes folding a first cover panel 118 of the blank 106 relative to the first side panel 110 while maintaining the first side panel 110 at a predetermined angle 282 as the group of articles 102 and blank 106 advance along a portion of the packaging path. In one or more examples, the first cover panel 118 is folded into a folded position using a cover panel fold guide 308 of the folding machine 228.

[0201] In one or more examples, the method includes folding the second cover panel 120 of the blank 106 relative to the second side panel 112 while maintaining the second side panel 112 at a predetermined angle 282 as the group of articles 102 and blank 106 advance along a portion of the packaging path. In one or more examples, the second cover panel 120 is folded into the folded position using a cover panel fold guide 308 of the folding machine 228.

[0202] In one or more examples, the method includes securing the first cover panel 118 and the second cover panel 120 to one another in an overlapping relationship. In one or more examples, the first cover panel 118 and the second cover panel 120 are secured together using a forming machine 288.

[0203] In one or more examples, the method includes maintaining the first side panel 110 and the second side panel 112 at a predetermined angle 282 relative to the main panel 108 while securing the first cover panel 118 and the second cover panel 120 to one another. In one or more examples, the first side panel 110 and the second side panel 112 are maintained using a first alignment block 276 and a second alignment block 278 of the alignment machine 230.

[0204] In one or more examples, the blank 106 is formed from a sheet of a suitable substrate. As used herein, the term "suitable substrate" includes all manner of foldable sheet material, such as paperboard, corrugated board, cardboard, plastic, combinations thereof, etc. It will be appreciated that any number of (e.g., one or more) blanks 106 may be used, as appropriate, to provide and / or form one or more cartons 104 (e.g., carrier structures), as described in more detail below.

[0205] In one or more examples, the blank 106, and thus the carton 104, is formed from a sheet material, such as a paperboard substrate. The paperboard substrate can be, for example, a solid bleached sulfate (SBS) substrate, an uncoated natural kraft (UNC) substrate, or a coated natural kraft (CNK) substrate. The paperboard substrate can be formed from virgin fibers, recycled fibers, or a combination thereof.

[0206] In one or more examples, the blank 106, and thus the carton 104, is formed from a sheet material, such as paperboard, which may be made from or coated with a material to increase its own strength. An example of such a sheet material is tear-resistant NATRALOCK® paperboard made by WestRock Company. In one or more examples, the tear-resistant material is provided in two or more layers to help improve the tear resistance of the carton 104.

[0207] In one or more examples, the blank 106 includes at least a paperboard substrate. The paperboard substrate material may be selected from any conventional paperboard, for example, ranging in weight from about 10 pt. and up, preferably from about 16 pt. and up to about 28 pt. (0.028 in. / about 0.7 mm). An example of such a substrate is 27 point (pt.) SBS cardboard (PrintKote®, a solid bleached sulfate board coated on one side) or CNK® cardboard (Coated Natural Kraft® - CarrierKote™, an unbleached kraft board with a clay coat on one side) manufactured by WestRock® Company. The paperboard substrate may be bleached or unbleached cardboard. The cardboard may be coated on at least one side with a conventional coating selected for compatibility with the printing method and cardboard composition, and optionally coated on the opposite side of the lamination.

[0208] In one or more examples, one surface of the sheet material has different properties than the other surface. For example, the surface of the sheet material facing away from the finished carton 104 may be particularly smooth and may have a coating, such as a clay coating or other surface treatment to provide good printability, while the surface of the sheet material facing inwardly may be provided with a coating, layer, and / or treatment or may be prepared to provide properties such as one or more of tear resistance, good adhesive ability, heat sealability, or other desired functional properties.

[0209] In one or more examples, the blank 106 may include a tear-resistant layer laminated to the paperboard layer. The blank 106 may optionally include an adhesive layer between the paperboard substrate and the tear-resistant layer. The tear-resistant layer may be placed over the uncoated side of the paperboard substrate and may be formed of a polymeric material and secured to the substrate. The tear-resistant layer imparts toughness to the laminate structure. Suitable tear-resistant materials may include, but are not limited to, tear-resistant laminate sheet materials, such as NATRALOCK®, which may include layers of n-axis oriented films, such as MYLAR®, which are biaxially oriented polyester, oriented nylon, cross-laminated polyolefin, or high density polyolefin. The orientation and cross-laminated structure of these materials contribute to the tear-resistant properties. Tear resistance may also be due to the chemistry of the tear-resistant material, such as extruded metallocene-catalyzed polyethylene (mPE).

[0210] Alternatively, in one or more examples, the tear resistant layer may be a layer of linear low density polyethylene (LLDPE). In examples where linear low density polyethylene (LLDPE) or mPE is used, it is not necessary to incorporate an adhesive layer. Other suitable materials having a high degree of tear resistance may be used. The adhesive layer may be formed of a polyolefin material, such as low density polyethylene (LDPE). The adhesive layer may be disposed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

[0211] The foregoing detailed description refers to the accompanying drawings, which show specific examples of the disclosed packaging system and method described by the present disclosure. It is understood that the disclosed examples are merely exemplary embodiments of how certain aspects of the disclosed packaging system and method can be implemented, and do not represent a comprehensive list of all the ways in which the disclosed packaging system and method can be embodied. Other examples having different structures and operations do not depart from the scope of the present disclosure. Similar numerals may refer to the same features, elements, or components in different drawings. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of specific components. Throughout the present disclosure, any one of a plurality of items may be referred to individually as an item, and a plurality of items may be referred to collectively as an item. Furthermore, as used herein, it should be understood that a feature, element, component, or step preceded by the word "a" or "an" does not exclude a plurality of features, elements, components, or steps, unless expressly suggested otherwise.

[0212] Illustrative, non-exhaustive examples of the subject matter according to the present disclosure that may be claimed are provided above. Reference to an "example" herein means that one or more features, structures, elements, components, properties, and / or operational steps described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Thus, the phrases "example," "other example," "one or more examples," and similar words throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, subject matter characterizing any one example may, but does not necessarily, include subject matter characterizing any other example. Furthermore, subject matter characterizing any one example may, but does not necessarily, be combined with subject matter characterizing any other example.

[0213] It is to be understood that not all objectives or advantages may necessarily be achieved in accordance with any particular example described herein. Thus, for example, one skilled in the art will recognize that a particular example may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein, without necessarily achieving other objectives or advantages as may be taught or suggested herein.

[0214] It should be understood that terms such as "front," "reverse," "rear," "bottom," "upper," "left," "right," "side," "end," "upper," "lower," "inward," "outward," as well as similar terms or other forms of such terms, when used to modify structures, elements, items, components, or features described herein, are relative and refer to example spatial relationships between structures, elements, items, components, or features. As such, the examples of blank 106 and carton 104 described herein and shown in the figures are not intended to be limited by the particular relative terms used to describe any structures, elements, items, components, or features thereof.

[0215] As used herein, the terms "hinge connection" and "fold line" refer to any manner of line that defines a hinge feature of a blank, facilitates folding portions of a blank relative to one another, or indicates the optimal location for folding a panel of the blank. Any reference to a "hinge connection" should not be construed as necessarily referring to only a single fold line, and in fact a hinge connection may be formed from two or more fold lines, each of which may be either straight / rectilinear or curved / curved in shape. Straight fold lines may be placed parallel to one another when forming a hinge connection, or may be slightly angled relative to one another. Curved fold lines may intersect with one another when forming a hinge connection to define a molded panel within the area enclosed by the curved fold lines. A typical example of such a hinge connection may include a pair of arched or bowed fold lines that intersect at two points to define an elliptical panel therebetween. A hinge connection may be formed from one or more linear fold lines and one or more curvilinear fold lines. A typical example of such a hinge connection may comprise a combination of a linear fold line and an arched or bowed fold line that intersect at two points to define a half-moon shaped panel therebetween.

[0216] As used herein, the term "fold line" may refer to one of the following: a perforation line, an embossed line, a debossed line, a perforation line, a short slit line, a half-cut line, a single half-cut, an intermittent cut, a line of aligned slits, a perforation line, and any combination of these options.

[0217] It should be understood that the hinge connections and fold lines may each include elements formed in the blank substrate, including perforations, perforation lines, short slit lines, half-cut lines, single half-cuts, cuts, intermittent cuts, slits, perforations, embossed lines, debossed lines, any combination thereof, and the like. The elements may be sized and arranged to provide the desired functionality. For example, perforation lines may be sized or designed with a degree of weakness to define fold and / or cut lines. Perforation lines may be designed to facilitate folding while resisting tearing, to facilitate folding while facilitating tearing with greater effort, or to facilitate tearing with less effort.

[0218] As used herein, the phrase "in registration with" and similar phrases or variations of such phrases refer to the alignment of two or more elements in an erected carton, such as an opening formed in a first of two overlapping panels and a second opening formed in a second of the two overlapping panels. The elements that are in registration with each other may be aligned with each other in the thickness direction of the overlapping panels. For example, when an opening in a first panel is "in registration with" a second opening in a second panel that is placed in an overlapping arrangement with the first panel, an edge of the opening may extend along at least a portion of an edge of the second opening and may be aligned with the second opening in the thickness direction of the first and second panels.

[0219] As used herein, the terms "rotate," "rotating," "rotation," and similar terms refer to movement of a body about an axis, including situations in which the axis extends through the center of mass of the body (e.g., rotating), situations in which the axis extends through the body but not through the center of mass of the body (e.g., swiveling or pivoting), and situations in which the axis does not extend through the body (e.g., orbiting).

[0220] Conditional language such as "can" or "may," among others, unless expressly stated otherwise, is understood to be used broadly in the context to convey that particular examples include certain features, elements, and / or steps, while other examples do not. Thus, such conditional language is not intended to imply that features, elements, and / or steps are somehow required for one or more examples in general, or that one or more examples necessarily include logic for determining, with or without user input, or logic for prompting, whether those features, elements, and / or steps will be included in or performed in any particular example.

[0221] Unless otherwise indicated, terms such as "first," "second," "third," etc. are used herein merely as labels and are not intended to confer any order, status, or hierarchical requirement on the items to which they refer. Moreover, a reference to, for example, a "second" item does not require or exclude the presence of, for example, a "first" item or a lower-numbered item, and / or, for example, a "third" or a higher-numbered item.

[0222] Those skilled in the art will appreciate that not all elements described and illustrated in Figures 1-20 need be included in every example, and elements described herein are not necessarily depicted in each illustrated example. Unless expressly stated otherwise, the schematic illustrations of the examples depicted in Figures 1-20 are not meant to imply architectural limitations with respect to the illustrated example. Furthermore, while one illustrated structure is shown, it will be understood that the structure may be modified where appropriate. Also, modifications, additions, and / or omissions may be made to the illustrated structure.

[0223] Furthermore, references throughout this specification to features, advantages, or similar terms as used herein do not imply that all of the features and advantages that may be realized in the examples disclosed herein should be or are in any single example. Rather, the terms referring to features and advantages are to be understood to mean that the particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar terms as used throughout this disclosure can, but do not necessarily, refer to the same example.

[0224] The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. Those skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other cases, additional features and advantages may be recognized in a particular example that may not be present in all examples. Moreover, while various examples of the packaging system 100 and method have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims. [Explanation of symbols]

[0225] 100 Packaging System 102 Goods 104 cartons 106 Blank 108 Main Panel 110 First Side Panel 112 Second Side Panel 114, 116 Fold lines 118 First cover panel, upper cover panel 120 Second cover panel 122, 124 Fold lines 126 Retention structure 128 Retention opening 130 Retention tab 132 Handle opening 134 Locking structure 136 Locking opening 138 Locking element 140 Insert Tab 140A 1st Insert Tab 140B Second Insert Tab 142 First End Panel 144 Second End Panel 146, 148 Fold lines 150 First End Flap 152 Second end flap 154, 156 Fold lines 158 First Mooring Flap 160 Second Mooring Flap 162 3rd Mooring Flap 164 4th Mooring Flap 166 Receiving 168 Insertion part 170 Receiving Tab 170A 1st receiving tab 170B Second receiving tab 170C 3rd receiving tab 172, 174 Fold lines 176 First Gap 178 Second cutting line 180, 182, 184, 186, 188, 190 Fold lines 192A 1st hinged panel 192B 3rd hinged panel 192C Fifth hinged panel 192D 7th hinged panel 194A Second Hinged Panel 194B 4th hinged panel 194C 6th hinged panel 194D 8th hinged panel 196, 200 fold lines 202A opening 202B opening 206 Cover Panel Structure 208 End closed structure 210 Side closure structure 212 First Station 214 Second Station 216 Third Station 218 Fourth Station 220 Infeed Conveyor 222 Grouping Conveyor 224 Applicable Machines 226 Assembly Conveyor 228 Folding Machine 230 Alignment Machine 232 Discharge Conveyor 234 Completed Package 236 Conveyor 242 Downward folding wheel 244 Lower Rotation Axis 246 Top 248 Direction of travel 250 First downward folding arm 252 Second downward folding arm 254 Lower Rotation Drive 256 Cam Orbit 258 Cam Follower 262 End fold guide, end flap fold guide 264 Mooring flap guide, mooring flap folding guide 266 Upward folding wheel 268 Upper Rotation Axis 270 Upward folding arm 272 Upper process 274 Pillars 276 First Alignment Block 278 Second Alignment Block 280 Alignment Surface 282 Prescribed angle 284 Alignment Angle 286 Drive Mechanism 288 Forming Machine 290 Direction of rotation 292 Lateral process 294 Lateral protrusion drive part 296 Front end 298 Rear end 300 Second Down Fold Wheel 302 Second Cam Track 304 Direction of rotation 306 Side panel folding guide 310 Second upward projection 314 Wheel Assembly 316 Punch 318 Second Upward Folding Wheel 320 Second upward folding arm 322 Substantially circular areas 324 Downward Sloping Area 326 Upward Sloping Area 328 Pivot axis 330 Upper Rotary Drive

Claims

1. 1. A system for forming a carton around an article, comprising: a conveyor configured to transport a group of articles and a blank to be applied to upper ends of the articles along a wrapping path; 1. A folding machine, comprising: folding a first end panel of the blank against a main panel of the blank as the group of articles and the blank advance along the packaging path; folding a second end panel of the blank against the main panel of the blank after the first end panel has been folded as the group of articles and the blank advance along the packaging path; folding a first end flap of the blank against the first end panel after the first end panel has been folded as the group of articles and the blank advance along the packaging path; folding a second end flap of the blank against the second end panel after the second end panel has been folded as the group of articles and the blank advance along the packaging path; folding a first side panel of the blank against the main panel after the first end flap and the second end flap have been folded as the group of articles and the blank advance along the packaging path; folding a second side panel of the blank against the main panel after the first end flap and the second end flap have been folded as the group of articles and the blank advance along the packaging path; folding a first cover panel of the blank against the first side panel after the first side panel has been folded as the group of articles and the blank advance along the packaging path; and folding a second cover panel of the blank against the second side panel after the second side panel is folded as the group of articles and the blank advance along the packaging path; A folding machine comprising: an alignment machine configured to position the first and second side panels at a predetermined angle relative to the main panel while the first and second cover panels are folded; A system comprising:

2. a conveyor configured to transport a group of articles and a blank to be applied to upper ends of the articles along a wrapping path; A folding machine; Equipped with The folding machine includes: folding a first end panel of the blank against a main panel of the blank as the group of articles and the blank advance along the packaging path; and folding a second end panel of the blank against the main panel of the blank after the first end panel is folded as the group of articles and the blank advance along the packaging path. A packaging system comprising:

3. The folding machine includes: folding a first end flap of the blank against the first end panel after the first end panel has been folded as the group of articles and the blank advance along the packaging path; and folding a second end flap of the blank against the second end panel after the second end panel is folded as the group of articles and the blank advance along the packaging path. The packaging system of claim 2 further comprising:

4. The folding machine includes: a lower folding wheel configured to rotate about a lower axis of rotation; a first downward folding arm projecting radially from the downward folding wheel; a second downward folding arm projecting radially from the downward folding wheel; a lower rotation drive configured to rotate the lower folding wheel about the lower rotation axis; Equipped with the first downward fold arm is configured to fold the first end panel upwardly into an orientation that is generally perpendicular to the main panel of the blank as the downward fold wheel rotates and the group of articles and the blank pass over the downward fold wheel; The second downward folding arm includes: as the downward folding wheel rotates and the group of articles and the blank pass over the downward folding wheel, folding the second end panel upwardly into an orientation that is generally perpendicular to the main panel; and as the lower fold wheel rotates and the group of articles and the blank pass over the lower fold wheel, folding the second end flap into an orientation that is generally perpendicular to the second end panel in a direction of advancement of the group of articles and the blank. The packaging system of claim 3 .

5. the folding machine further comprising an end flap fold guide positioned above the lower fold wheel; 5. The packaging system of claim 4, wherein the end flap fold guide is configured to fold the first end flap into an orientation that is generally perpendicular to the first end panel, opposite the direction of advancement of the group of articles and the blank as the blank advances under the end flap fold guide.

6. the folding machine further comprising an anchoring flap fold guide positioned below the end flap fold guide; The mooring flap folding guide portion is folding a first anchor flap and a second anchor flap of the blank as the blank advances under the anchor flap fold guide into an orientation that is generally parallel to the main panel, opposite the direction of advancement of the group of articles and the blank; and as the blank advances under the anchor flap fold guide, a third anchor flap and a fourth anchor flap of the blank are folded in a direction of advancement of the group of articles and the blank into an orientation that is generally parallel to the main panel. The packaging system of claim 5 .

7. The packaging system of claim 4 , wherein the first and second downward fold arms are angularly offset from one another.

8. The first downward folding arm is fixed to the downward folding wheel, the second downward folding arm is configured to pivot about a pivot axis relative to the downward folding wheel; The packaging system of claim 4 , wherein the second downfold arm is radially movable relative to the downfold wheel.

9. The folding machine includes: a cam track positioned adjacent to the downfold wheel; a cam follower coupled to the second downward folding arm and engaged with the cam track; Further equipped with 9. The packaging system of claim 8, wherein the second downward fold arm is configured to pivot about the pivot axis and move radially relative to the downward fold wheel as the cam follower moves along the cam track.

10. The folding machine includes: an upper folding wheel configured to rotate about an upper axis of rotation; an upper folding arm projecting radially from the upper folding wheel; an upper rotation drive configured to rotate the upper folding wheel about the upper rotation axis; Further equipped with The upper folding arm includes: as the upward fold wheel rotates and the group of articles and the blank pass under the upward fold wheel, folding the second end panel upwardly to an orientation that is generally perpendicular to the main panel; and as the upper fold wheel rotates and the group of articles and the blank pass under the upper fold wheel, folding the second end flap into an orientation that is generally perpendicular to the second end panel in the direction of advancement of the group of articles and the blank. The packaging system of claim 4 .

11. a protrusion configured to engage the top end of the article; and a post projecting downwardly from the projection and configured to be inserted at least partially through a handle opening formed in the main panel; The packaging system of claim 2 further comprising:

12. a conveyor configured to transport a group of articles and blanks to be folded around said articles along a wrapping path; an alignment machine configured to position a first side panel and a second side panel of the blank at a predetermined angle relative to a main panel of the blank as the group of articles and the blank advance along the packaging path; A packaging system comprising:

13. The alignment machine includes: a first alignment block configured to engage the first side panel after the first side panel is folded upwardly into an orientation that is generally perpendicular to the main panel; and a second alignment block configured to engage the second side panel after the second side panel is folded upwardly to an orientation that is generally perpendicular to the main panel; and The packaging system of claim 12 .

14. each one of the first alignment block and the second alignment block includes an alignment surface oriented at an alignment angle relative to a vertical plane; 14. The packaging system of claim 13, wherein the alignment angle is complementary to the predetermined angle of the first and second side panels.

15. 14. The packaging system of claim 13, wherein the first registration block and the second registration block are configured to advance with the group of articles and the blank as the blank advances along the packaging path.

16. The alignment machine includes: moving the first registration block into engagement with the first side panel as the group of articles and the blank advance along the packaging path; and moving the second registration block into engagement with the second side panel as the group of articles and the blank advance along the packaging path.

20. The packaging system of claim 15, further comprising a drive mechanism configured to:

17. 17. The packaging system of claim 16, wherein the drive mechanism is further configured to move the first registration block and the second registration block with the blank as the group of articles and the blank advance along the packaging path.

18. the first alignment block is configured to maintain the first side panel at the predetermined angle relative to the main panel while a first cover panel of the blank is folded relative to the first side panel; 16. The packaging system of claim 15, wherein the second alignment block is configured to maintain the second side panel at the predetermined angle relative to the main panel while a second cover panel of the blank is folded against the second side panel.

19. a forming machine configured to bond the first cover panel and the second cover panel to one another; 20. The packaging system of claim 18, wherein the first alignment block is configured to maintain the first side panel at the predetermined angle relative to the main panel and the second alignment block is configured to maintain the second side panel at the predetermined angle relative to the main panel while the first cover panel and the second cover panel are coupled together.

20. The alignment machine includes: a series of first alignment blocks configured to engage the first side panel after the first side panel is folded upwardly into an orientation that is generally perpendicular to the main panel; and a series of second alignment blocks configured to engage the second side panel after the second side panel is folded upwardly into an orientation that is generally perpendicular to the main panel; and The packaging system of claim 12 .

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