Method and apparatus for packaging, article carriers and blanks therefor - Patent application

Abstract

Aspects of the disclosure relate to an apparatus for forming an article carrier, a method for assembling a package, a package, an article carrier (290) for packaging one or more articles, and a blank (210) for forming the carrier (290). The disclosure provides an apparatus (1) for packaging an article (B) in the article carrier (290). The apparatus (1) comprises an article translation device or conveyor for moving a group of articles (B) in a downstream direction (D1) through an application section. The apparatus (1) comprises a carrier pre-forming device (10, 110) for folding and gluing a carrier blank (210) into a top-engaged carrier (290) and conveying the top-engaged carrier (290) in a downstream direction (D1) to an application section where the top-engaged carrier (290) is applied to the group of articles (B).

Description

[Technical field]

[0001] The present invention relates to an apparatus for assembling an article carrier, a method for assembling an article carrier, the article carrier itself, and blanks for forming the article carrier. More particularly, but not exclusively, the present invention relates to a method and apparatus for preforming a top-gripping type article carrier having one or more openings for receiving and holding an article. [Background technology]

[0002] In the packaging art, it is known to provide cartons for carrying multiple articles. Cartons are well known in the art and are useful for allowing a consumer to transport, store, and access a group of articles for consumption. Cost and environmental considerations require that such cartons or carriers be formed from as little material as possible and to minimize waste of the material from which they are formed. An additional consideration is the strength of the carton and its suitability for holding and transporting heavy weight articles. It is desirable that the contents of the carton do not move within the carton.

[0003] It is well known to provide top gripped article carriers in which an opening is formed in a panel of the carrier, where a tab is stamped and formed from said panel and disposed about the opening, the tab being moved out of the plane of said panel when an article is received in the opening, where said tab typically engages the article about a flange or lip of the article. The present invention seeks to provide an improvement in the field of cartons, which are typically formed from paperboard or the like. Summary of the Invention [Problem to be solved by the invention]

[0004] It is an object of the present disclosure to provide an apparatus and method for assembling packages that automates the assembly of an article carrier and the application of the article carrier to at least one article while the at least one article is continuously conveyed through a packaging machine. [Means for solving the problem]

[0005] A first aspect of the invention provides an apparatus for packaging articles in an article carrier, the apparatus comprising an article translation device or conveyor for moving a group of articles downstream through an application section, and a carrier pre-forming device for folding and gluing a carrier blank into a pre-formed top-engaged carrier and conveying the top-engaged carrier downstream to the application section where the top-engaged carrier is applied to the group of articles.

[0006] Optionally, the carrier pre-forming device comprises an internal mold and an external applicator for effecting folding of the carrier blank around the internal mold.

[0007] Optionally, the external applicator comprises at least one carrier holding device for holding the preformed apex-engaged carrier while transporting the apex-engaged carrier downstream to the application section.

[0008] Optionally, the internal mold includes a groove for receiving at least a portion of the at least one carrier holding device to allow the external applicator to slide relative to the internal mold.

[0009] Optionally, the outer applicator includes an opening on at least one end thereof for receiving an end portion of the inner mold.

[0010] Optionally, the external applicator comprises a pair of opposed side walls each with a recess in an edge thereof, the recesses being aligned to receive a static panel folding guide of the device.

[0011] Optionally, the inner mold includes openings at its ends that provide channels through which the static panel folding guides can be received, the openings being aligned with recesses in each of the edges of the opposing side walls of the outer applicator.

[0012] Optionally, the external applicator comprises a pair of opposed side walls, each of which comprises a chamfered lower edge for engaging a panel of the article carrier to effect folding of the article carrier.

[0013] Optionally, the external applicator comprises at least one opening for receiving a portion of the article during application of the top-engaging carrier to the batch of articles, The at least one opening is provided in a top wall of the external applicator.

[0014] A second aspect of the invention provides a method of packaging articles comprising translating a group of articles in a downstream direction through an application section of a packaging system, the method comprising folding and adhering a carrier blank into a preformed apex-engaging carrier, conveying the apex-engaging carrier in a downstream direction to the application section, and applying the apex-engaging carrier to the group of articles.

[0015] Optionally, the method includes folding and adhering the carrier blank around the internal mold using an external applicator to effect folding of the carrier blank around the internal mold.

[0016] Optionally, the method includes transporting the pre-formed apex-engaging carrier in an external applicator.

[0017] Optionally, the method includes applying the top engaging carrier to the group of articles using an external applicator and receiving the articles within the external applicator.

[0018] A third aspect of the invention provides a carrier forming device comprising a pair of tools including an inner tool and an outer tool. The inner tool comprises a plurality of mandrel surfaces including a pair of opposed side surfaces. The plurality of mandrel surfaces comprises at least one end surface for supporting at least two end closure flaps of the carrier in an overlapping arrangement with an end closure panel of the carrier. The outer tool comprises a pair of opposed side members for folding the opposed side surfaces of the carrier downwardly along the pair of opposed side surfaces of the inner tool into a folded position. The outer tool is structured and dimensioned such that at least one end surface of the inner tool is offset outwardly from an adjacent end of the side member of the outer tool when the side members bring the side panels of the carrier into the folded position.

[0019] A fourth aspect of the invention provides a carrier forming device comprising a pair of tools including an inner tool and an outer tool. The outer tool comprises a pair of opposed side members for folding opposed side panels of the carrier downwardly along an exterior of the inner tool into a folded position. At least one of the side members of the outer tool comprises an engagement ledge for engaging the carrier. The engagement ledge is movably connected to the side members for movement between an engaged position where the ledge is disposed inside the outer tool and a yielded position where the ledge is disposed outside the interior of the outer tool. The ledge is biased towards the engaged position when disposed in the yielded position.

[0020] In some cases, the internal tool comprises a pair of side surfaces, at least one of the side surfaces of the internal tool having a groove for receiving a ledge of the external tool, the groove extending over at least one of the side surfaces such that the ledge is movable along the groove.

[0021] Optionally, the ledge is slidably translatable within the groove.

[0022] A fifth aspect of the invention provides a carrier forming device comprising a pair of tools including an inner tool and an outer tool, the outer tool comprising a pair of opposed side members for folding opposed side panels of the carrier downwardly along the exterior of the inner tool into a folded position, the pair of opposed side members of the outer tool each comprising a recess along an edge thereof for receiving a static mechanical guide.

[0023] Optionally, the internal tool includes a channel for receiving the static guide, the channel extending between opposed side surfaces of the internal tool, the channel being aligned with a recess in a pair of opposed side members.

[0024] Optionally, the inner tool has a top surface having an edge, the top surface including a recess in the edge, the recess communicating with the channel.

[0025] A sixth aspect of the invention provides a carrier forming device comprising a pair of tools including an inner tool and an outer tool. The outer tool comprises a pair of opposed side members for folding opposed side panels of the carrier downwardly along the exterior of the inner tool into a folded position. At least one of the pair of opposed side members of the outer tool is provided with a protrusion at an end thereof, the protrusion protruding inwardly beyond the plane of the inner surface of at least one of the pair of opposed side members. The protrusion may take the form of a rib extending perpendicular to a top wall of the outer tool connecting the pair of opposed side members.

[0026] A seventh aspect of the invention provides a method of packaging articles, comprising the steps of preforming a carrier blank into a top-engaged carrier using a carrier forming device. The carrier forming device comprises a pair of tools including an inner tool and an outer tool. The method comprises the steps of disengaging the carrier from the inner tool while maintaining the carrier engaged in the outer tool. The method comprises the steps of engaging the outer tool together with the carrier to a group of articles such that the articles are connected to each other by the carrier, and removing the outer tool from the group of articles as well as from the carrier.

[0027] An eighth aspect of the invention provides an article carrier for packaging one or more articles. The article carrier comprises a top panel, a pair of side panels, and an end closure structure for closing at least one of the opposed ends of the carrier. The end closure structure comprises a plurality of end closure flaps, including a pair of side end flaps and a top end flap. The top end flap has no direct foldable connection with the pair of side end flaps. At least one of the pair of side end flaps comprises a corner panel. The top end flap is provided with a recess along at least one of its side edges. The plurality of end closure flaps are secured together to form the end closure structure, the recess of the top end closure being aligned with at least a portion of the corner panel along an imaginary axis perpendicular to the top panel.

[0028] Optionally, the recess is located on the corner panel and exposes for view a portion of the corner panel that would otherwise be hidden.

[0029] Optionally, the corner panel is disposed at an oblique angle to the top end closure with a gap therebetween, and the recess provides an opening vertically aligned with the gap to allow access to the gap from above.

[0030] A ninth aspect of the invention provides an article carrier for packaging one or more articles. The article carrier comprises a top panel, a pair of side panels, and an end closure structure for closing at least one of the opposed ends of the carrier. The end closure structure comprises a plurality of end closure flaps, including a pair of side end flaps and a top end flap. The top end flap has no direct foldable connection with the pair of side end flaps. At least one of the pair of side end flaps comprises a corner panel including an upper edge. The top end flap is provided with a recessed edge along at least one of its side edges. The plurality of end closure flaps are secured together to form the end closure structure where the upper edge of the corner panel meets the recessed edge of the top end flap.

[0031] Additional features and advantages of the present invention will become apparent from the specific embodiments illustrated in the drawings and discussed below.

[0032] It is contemplated or intended that within the scope of this application, the various aspects, embodiments, examples, features, and alternatives presented in the preceding paragraphs, claims, and / or the following description and drawings may be considered or incorporated independently or in any combination thereof.

[0033] A feature or element described with or in relation to one embodiment is applicable to all embodiments, unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated or combined with any of the other embodiments disclosed herein, and a feature or element extracted from one of the aforementioned embodiments may be included in addition to or in exchange for one or more features or elements of the other aforementioned embodiments.

[0034] A feature or combination of features of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment, or a feature or combination of features of an embodiment may be omitted from that embodiment.

[0035] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief description of the drawings]

[0036] [Figure 1] 1 is an isometric view from above of a first device for forming an article carrier according to various embodiments of the present disclosure. [Diagram 2] FIG. 13 is an isometric view from above of a second device for forming an article carrier according to various embodiments of the present disclosure. [Diagram 3] 11A-11C are perspective views from above showing various stages in the assembly of the blank to the carrier; [Figure 4] 11A-11C are perspective views from above showing various stages in the assembly of the blank to the carrier; [Diagram 5] 11A-11C are perspective views from above showing various stages in the assembly of the blank to the carrier; [Figure 6] FIG. 2 is a top plan view of a blank for forming a carrier according to various embodiments of the present disclosure. [Figure 7] FIG. 7 is a top perspective view of a carrier formed from the blank of FIG. 6. [Figure 8] 3A and 3B are perspective views from below of a stage in the assembly of a blank onto a carrier using the first device of FIG. 1 and the second device of FIG. 2; [Figure 9] 3A-3C are perspective views from above of various stages in the assembly of a blank onto a carrier using the first device of FIG. 1 and the second device of FIG. 2; [Figure 10] 8 is a perspective view from above of a stage in the assembly of a package with the carrier of FIG. 7 using the second device of FIG. 2 for applying the carrier to a group of articles. [Figure 11] FIG. 11 is a top perspective view of a portion of the package of FIG. 10. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] Detailed descriptions of specific embodiments of the devices, methods, packages, blanks, and carriers are disclosed herein. It will be understood that the disclosed embodiments are merely examples of ways in which certain aspects of the invention may be implemented, and do not represent a comprehensive list of all ways in which the invention may be embodied. In this specification, the term "exemplary" is used expansively to refer to an embodiment that serves as an example, specimen, model, or pattern. Indeed, it will be understood that the devices, methods, packages, blanks, and carriers described herein may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of specific components. Well-known components, materials, or methods are not necessarily described in detail to avoid obscuring the disclosure. Any specific structural and functional details disclosed herein should not be interpreted as limitations, but merely as a basis for the claims and as a representative basis for teaching those skilled in the art to use the invention in various ways.

[0038] 6, there is shown a plan view of a blank 210 capable of forming a carton or carrier 290 as shown in FIG 7 for containing and transporting a group of primary products, such as but not limited to bottles or cans, hereafter referred to as articles (not shown). The blank 210 forms a secondary package for packaging at least one primary product container or package.

[0039] In the embodiments detailed herein, the terms "carton" and "carrier" refer to a container for engaging and carrying an article, such as a primary product container, for non-limiting purposes of illustrating various features of the present invention. It is contemplated that the teachings of the present invention may be applied to a variety of product containers, which may or may not be tapered and / or cylindrical. Exemplary containers include bottles (e.g., metal, glass, or plastic bottles), cans (e.g., aluminum cans), tin cans, pouches, packets, and the like.

[0040] The blank 210 is formed from a sheet of a suitable substrate. As used herein, the term "suitable substrate" should be understood to include any type of foldable sheet material, such as paperboard, corrugated cardboard, plastic, combinations thereof, etc. For example, it should be recognized that one or any other number of blanks may be used as long as they are suitable for providing a carrier structure, which is described in more detail below.

[0041] The packaging structure or carton 290 described herein may be formed from a sheet material, such as paperboard, which may be made or coated with materials to enhance its strength. An example of such a sheet material is the tear-resistant NATRALOCK® paperboard made by WestRock Company. It should be noted that the tear-resistant material may be provided by two or more layers to help improve the tear resistance of the package. Typically, one surface of the sheet material may have different properties than the other surface. For example, the surface of the sheet material facing outward from the finished package may be particularly smooth and may have a coating, such as a clay coating or other surface treatment, to provide good printability. On the other hand, the surface of the sheet material facing inward may be provided with a coating, layer, treatment, or otherwise prepared to provide properties such as one or more of tear resistance, good glue-ability, heat sealability, or other desirable functional properties.

[0042] In the embodiment shown, the blank 210 is configured to form a carton or carrier 290 for packaging an exemplary arrangement of exemplary items B. In the embodiment shown in Figure 6, the arrangement is a 2x3 matrix or array, with two rows of three items B provided, where items B are 500ml PET bottles (not shown).

[0043] Alternatively, blank 210 may be configured to form a carrier for packaging other types, numbers, and sizes of articles and / or for packaging articles in different arrangements or configurations.

[0044] The blank 210 shown in FIG. 6 comprises a plurality of panels 212, 214A, 214B, 216A, 216B, 218A, 218B, 220A, 220B, including a main panel 212 for forming the top wall or engagement panel of the carrier 290 (see FIGS. 7 and 11).

[0045] A first upper end panel 214A is hingedly connected to a first end of the main panel 212 by a hinge connection in the form of fold line 213A. A first lower end panel 214B is hingedly connected to the first upper end panel 214A by a hinge connection in the form of fold line 213B.

[0046] A second upper end panel 216A is hingedly connected to the second end of the main panel 212 by a hinge connection in the form of fold line 215A. A second lower end panel 216B is hingedly connected to the second upper end panel 216A by a hinge connection in the form of fold line 215B.

[0047] A first upper side panel 218A is hingedly connected to a first side of the main panel 212 by a hinge connection in the form of fold line 217A. A first lower side panel 218B is hingedly connected to the first upper side panel 218A by a hinge connection in the form of fold line 217B.

[0048] A second upper side panel 220A is hingedly connected to a second side of the main panel 212 by a hinge connection in the form of fold line 219A. A second lower side panel 220B is hingedly connected to the second upper side panel 220A by a hinge connection in the form of fold line 219B.

[0049] A first corner panel 224A is hingedly connected to a first end of the first lower side panel 218B by a hinge connection in the form of fold line 225A. A second corner panel 224B is hingedly connected to a first end of the second lower side panel 220B by a hinge connection in the form of fold line 225B.

[0050] The first fastening panel 222A / 230A is hingedly connected to the first corner panel 224A by a hinge connection in the form of a fold line 223A. The first fastening panel 222A / 230A includes a first lower fastening panel portion 222A and a first upper fastening panel portion 230A, which is hingedly connected to the first upper fastening panel portion 230A by a hinge connection in the form of a fold line 221A. The first upper fastening panel portion 230A is separated from the first upper and lower end panels 214A, 214B by a cut 233A or by a frangible or severable line. An opening A3 separates the first corner panel 224A from the first upper end panel 214A, and the opening A3 also separates the first upper fastening panel portion 230A from the first upper side panel 218A and a portion of the first lower end panel 214B.

[0051] The second fastening panel 222B / 230B is hingedly connected to the second corner panel 224B by a hinge connection in the form of a fold line 223B. The second fastening panel 222B / 230B includes a second lower fastening panel portion 222B and a second upper fastening panel portion 230B, which is hingedly connected to the second upper fastening panel portion 230B by a hinge connection in the form of a fold line 221B. The second upper fastening panel portion 230B is separated from the first upper and lower end panels 214A, 214B by a cut 233B or by a frangible or severable line. An opening A3 separates the second corner panel 224B from the first upper end panel 214A, and opening A3 also separates the second upper fastening panel portion 230B from the second upper side panel 220A and a portion of the first lower end panel 214B.

[0052] A third corner panel 228A is hingedly connected to a second end of the first lower side panel 218B by a hinge connection in the form of fold line 231 A. A fourth corner panel 228B is hingedly connected to a second end of the second lower side panel 220B by a hinge connection in the form of fold line 231B.

[0053] The third fastening panel 226A / 232A is hingedly connected to the third corner panel 228A by a hinge connection in the form of a fold line 229A. The third fastening panel 226A / 232A includes a third lower fastening panel portion 226A and a third upper fastening panel portion 232A, which is hingedly connected to the third upper fastening panel portion 232A by a hinge connection in the form of a fold line 227A. The third upper fastening panel portion 232A is separated from the second upper and lower end panels 216A, 216B by a cut 235A or by a frangible or severable line. An opening A3 separates the third corner panel 228A from the second upper end panel 216A, and opening A3 also separates the third upper fastening panel portion 232A from the first upper side panel 218A and a portion of the second lower end panel 216B.

[0054] The fourth fastening panel 226B / 232B is hingedly connected to the fourth corner panel 228B by a hinge connection in the form of fold line 229B. The fourth fastening panel 226B / 232B includes a fourth lower fastening panel portion 226B and a fourth upper fastening panel portion 232B, which is hingedly connected to the fourth upper fastening panel portion 232B by a hinge connection in the form of fold line 227B. The fourth upper fastening panel portion 232B is separated from the second upper and lower end panels 216A, 216B by a cut 235B or by a frangible or severable line. An opening A3 separates the fourth corner panel 228B from the second upper end panel 216A, and opening A3 also separates the fourth upper fastening panel portion 232B from the second upper side panel 220A and a portion of the second lower end panel 216B.

[0055] The main panel 212 includes at least one item retaining structure RT1, RT2. The main panel 212 includes a plurality of item retaining structures RT1, RT2, and in particular six item retaining structures RT1, RT2 arranged in a 2×3 matrix or array.

[0056] The article retaining structures RT1, RT2 include a pair of opposed tabs 240, 242, 270, 272. The first tab 240, 270 extends from and is integral with one of the first or second side panels 218A, 220A. The second tab 242, 272 is hingedly connected to the main panel 212 by a hinge connection in the form of a fold 243. A portion of the first tab 240, 270 is stamped and formed from the second tab 242, 272, i.e., the portion of the first tab 240, 270 is formed from the material that would otherwise form the second tab 242, 272. A pair of openings A4, A5, A6, A7 define at least a portion of the opposed edges of the first and second tabs 240, 242, 270, 272. The edge or corner retention structure RT1 may include an outer or edge-most opening A5 configured to interrupt the fold lines 213A, 215A between the respective upper end panels 214A, 216A and the main panel 212. The edge-most opening A5 may include a notch or recess defining an edge portion of the edge-most opening A5 that is disposed to be collinear with said fold lines 213A, 215A.

[0057] The blank 210 may include a handle structure H, which may include at least one finger opening. The embodiment shown includes a pair of finger openings. Each finger opening may be defined, at least in part, by a handle tab 260 stamped from or defined within the main panel 212. Each handle tab 260 is hingedly connected to the main panel 212 by a hinge connection in the form of a fold 261, and the handle tabs 260 may be hinged opposite one another.

[0058] Figure 7 shows a carrier 290 formed from the blank 210 of Figure 5. The blank 210 may be preassembled into the carrier 290 as shown in Figures 3-5.

[0059] In its preformed state prior to application to a load of articles, the article carrier 290 is substantially planar and includes corner panels 224A, 224B, 228A, 228B extending between the lower side panels 218B, 220B and the lower end panels 214B, 216B. More specifically, the preassembled article carrier 290 may provide a skirt structure formed of the side panels 218A / 218B, 220A / 220B, the end panels 214A / 214B, 216A / 216B, and the corner panels 224A, 224B, 228A, 228B. Each pair of opposed upper panels (i.e., opposed upper side panels 218A, 220A and opposed upper end panels 214A, 216A) are angled relative to the main panel 212 such that each pair of opposed panels moves away from one another as they extend downwardly from the main panel 212. The opposed lower side panels 218B, 220B extend from lower edges of the upper side panels 218A, 220A, respectively. The lower side panels 218B, 220B are substantially planar and perpendicular to the main panel 212. The opposed lower end panels 214B, 216B extend from lower edges of the upper end panels 214A, 216A, respectively. The lower end panels 214B, 216B are substantially planar and perpendicular to the main panel 212. Each corner panel 224A, 224B, 228A, 228B interconnects adjacent lower side and end panels to provide a respective corner panel of the skirt structure. The corner panels 224A, 224B, 228A, 228B are substantially perpendicular to the main panel 212.

[0060] 7 and 11 show the carrier 290 after application to a group of articles B, which are omitted from FIG. 7 for illustrative purposes. The corner panels 224A, 224B, 228A, 228B have been deformed from their initial planar preformed shape and may assume a generally convex shape (when viewed from an external perspective), in which the length or area of ​​the region of the corner panels 224A, 224B, 228A, 228B in contact with the article B may increase. The maximum distance between pairs of diagonally opposed corner panels 224A / 228B, 224B / 228A increases. A portion of the corner panels 224A, 224B, 228A, 228B are displaced outwardly.

[0061] Figure 1 shows a first device 10 for forming a mandrel for preforming a carrier 290 from a blank 210. Figure 2 shows a second device 110 for application of the blank 210 to the first device 10 and / or folding the blank 210 around the first device 10 (see Figures 3 to 5, 8 and 9). Optionally, the second device 110 can be used for subsequent application of the preformed carrier 290 to a batch of articles B, as shown in Figure 10.

[0062] The first device 10 comprises a plurality of walls 12, 14, 18A, 18B, 20A, 20B. The plurality of walls 12, 14, 18A, 18B, 20A, 20B includes a top wall 12 and a first upper sidewall 18A depending from the top wall 12. The first upper sidewall 18A is connected to a first side of the top wall 12 and is inclined relative to the top wall 12. The plurality of walls 12, 14, 18A, 18B, 20A, 20B includes a second upper sidewall 20A depending from the top wall 12. The second upper sidewall 20A is connected to a second opposite side of the top wall 12 and is inclined relative to the top wall 12.

[0063] A first lower sidewall 18B is connected to the first upper sidewall 18A and may be generally perpendicular to the top wall 12.

[0064] A second lower sidewall 20B may be connected to the second upper sidewall 20A and may be generally perpendicular to the top wall 12. The second lower sidewall 20B is generally parallel to the first lower sidewall 18B.

[0065] The first device 10 includes a first end wall 14 and a second end wall 16 (see FIG. 3). The first end wall 14 is connected to a first lower side wall 18B by a first lower corner or bevel wall 22A. The first end wall 14 is connected to a second lower side wall 20B by a second lower corner or bevel wall 22B.

[0066] The second end wall 16 is connected to the first lower sidewall 18B by a third lower corner wall or bevel wall 24A. The second end wall 16 is connected to the second lower sidewall 20B by a fourth lower corner wall or bevel wall 24B (see FIG. 3).

[0067] An optional first upper corner or bevel wall 26A connects the first lower corner or bevel wall 22A to the first upper sidewall 18A. An optional second upper corner or bevel wall 26B connects the second lower corner or bevel wall 22B to the second upper sidewall 20A.

[0068] An optional third upper corner or bevel wall 28A connects the third lower corner or bevel wall 24A to the first upper sidewall 18A. An optional fourth upper corner or bevel wall (not shown) connects the fourth lower corner or bevel wall to the second upper sidewall 20A.

[0069] The first upper corner or bevel wall 26A includes a cut-out in the form of a first recess R1. The second upper corner or bevel wall 26B includes a cut-out in the form of a second recess R2. The second recess R2 aligns with the first recess R1 for receipt of a static guide or rail G2.

[0070] The third upper corner or bevel wall 28A includes a cut-out in the form of a third recess R3. The fourth upper corner or bevel wall includes a cut-out in the form of a fourth recess (not shown). The third recess R3 aligns with the fourth recess for receipt of the second static guide or rail G2.

[0071] The recesses R1, R2, R3 may form part of a channel extending between opposite sides of the first device 10, the channel being suitable for receiving a static panel forming guide G2.

[0072] The first device 10 includes a first slot S1 stamped or defined in the first lower sidewall 18B, the first slot S1 extending from a lower free edge of the first lower sidewall 18B beyond the first lower sidewall 18B into the first upper sidewall 18A. The first slot S1 terminates at the first upper sidewall 18A.

[0073] Optionally, the first device 10 includes a second slot S2 stamped or defined in the first lower sidewall 18B, the second slot S2 extending from a lower free edge of the first lower sidewall 18B beyond the first lower sidewall 18B into the first upper sidewall 18A. The second slot S2 terminates at the first upper sidewall 18A.

[0074] The first device 10 includes a third slot S3 stamped or defined in the second lower sidewall 20B, the third slot S3 extending from a lower free edge of the second lower sidewall 20B beyond the second lower sidewall 20B into the second upper sidewall 20A. The third slot S3 terminates at the second upper sidewall 20A.

[0075] Optionally, the first device 10 includes a fourth slot (not shown) stamped or defined in the second lower sidewall 20B, the fourth slot extending from a lower free edge of the second lower sidewall 20B, beyond the second lower sidewall 20B, and into the second upper sidewall 20A. The fourth slot terminates at the second upper sidewall 20A.

[0076] The cutout provides an opening O separating or spacing the first end wall 14 from the top wall 12, which may be considered to remove or omit material that would otherwise form an upper end wall connecting the first end wall 14 to the top panel 12. Similarly, a further cutout provides an opening separating or spacing the second end wall 16 from the top wall 12. The cutout may be considered to form a portion of a laterally extending channel for receiving the static panel forming guide G2. In some embodiments, the upper corner panels 26A, 26B, 28A may be omitted in such embodiments, and the opening O may be considered to extend into the opposing side of the first device 10.

[0077] The top wall 12 may include a recessed first edge defined by at least one top wall recess C1, C2. In the embodiment shown, the recessed first edge includes a pair of top wall recesses C1, C2 spaced apart from one another to define a protrusion therebetween.

[0078] Top wall 12 may include a recessed second edge defined by at least one top wall recess C3, C4. In the embodiment shown, the recessed second edge includes a pair of top wall recesses C3, C4 spaced apart from one another to define a protrusion therebetween.

[0079] 2, the second device 110 comprises a main or top wall 112 and a pair of opposed side walls 118, 120 depending from the main wall 112. Each of the pair of opposed side walls 118, 120 comprises a vertically extending rib or protrusion 118R, 120R at a respective end thereof. Each protrusion 118R, 120R provides an interior wall or surface that is arranged in a non-coplanar divergent arrangement with the interior wall or surface of an intermediate or adjacent portion of the opposed side wall 118, 120 from which it extends. In this manner, each interior surface of each side wall 118, 120 comprises a first portion that is arranged between a second portion and a third portion, the second portion and the third portion being arranged divergent with respect to each other and with respect to the first portion. Thus, the interior of the second device 110 is complementarily shaped to at least a portion of the exterior surface of the first device 10 so as to partially encase the first device. The second device 110 is adapted to be disposed about the top wall 12, upper and lower walls 18A, 20A, 18B, 20B, and portions of the corner panels 22A, 22B, 24A, 24B of the first device 10.

[0080] The top wall 112 includes at least one aperture A1, and in the embodiment shown, the top wall 112 includes a plurality of apertures A1, specifically, but not limited to, six apertures A1, each aperture A1 receiving a portion of an article B and a portion of an engagement tooth or tab 240, 242, 270, 272 when the second device 110 is used to apply the carrier 290 to one or more articles B as shown in FIG.

[0081] The second device 110 includes a first recess R5 stamped or defined in a portion of the first sidewall 118 adjacent the top wall 112, where the first recess R5 can interrupt the vertically extending rib 118R. The second device 110 includes a second recess R6 stamped or defined in a portion of the second sidewall 120 adjacent the top wall 112, where the second recess R6 can interrupt the vertically extending rib 120R. The second recess R6 is aligned with the first recess R5, i.e., the first and second recesses R5, R6 are spaced equidistant from the top wall 112. The first and second recesses R5, R6 are adapted to be aligned with the pair of recesses R1, R2, R3 in the first device, if present.

[0082] Similarly, the second device 110 includes a third recess R7 stamped or defined in a portion of the first side wall 118 adjacent to the top wall 112, said third recess R7 being located at an end of the first side wall 118 opposite the first recess R5. The second device 110 includes a fourth recess R8 (see FIG. 3) stamped or defined in a portion of the second side wall 120 adjacent to the top wall 112, said fourth recess R8 being located at an end of the second side wall 120 opposite the second recess R6. The third recess R7 is aligned with the fourth recess R8, i.e. the third and fourth recesses R7, R8 are spaced equidistant from the top wall 112. The third and fourth recesses R7, R8 are aligned with the pair of recesses R1, R2, R3 of the first device, if present.

[0083] The first side wall 118 comprises at least one carrier retaining device CL1, CL2 for retaining the carrier 290 in the second device 110 when the first device 10 is withdrawn or removed from the interior of the carrier 290. In the embodiment shown, the first side wall 118 comprises two retaining devices CL1, CL2. The or each carrier retaining device CL1, CL2 takes the form of a barb or detent extending into the interior of the second device 110. The barb or detent is located adjacent to a lower edge of the first side wall 118 and attached to the first side wall 118 so as to be displaceable laterally relative to a longitudinal or tube axis of the second device 110. The detent provides a ledge L on which an edge of one of the panels of the carrier 290 can rest. The carrier retaining devices CL1, CL2 can be resiliently biased into a rest or initial position in which the barb or detent projects beyond the inner surface of the first side wall 118 into the interior of the second device 110. The barbs or detents are attached to the first side wall by springs, which may take the form of leaf springs. The springs may be molded or formed integrally with the first side wall 118 to form a living hinge or spring. The exterior surface of the first side wall 118 may be recessed or cut away such that the carrier retaining devices CL1, CL2 do not protrude outwardly of the exterior surface of the first side wall 118 when displaced outwardly. In this manner, the carrier retaining devices CL1, CL2 and the barbs or detents may be displaced to a disengaged or open state without increasing the footprint of the second device 110. That is, the carrier retaining devices CL1, CL2 do not protrude beyond the exterior surfaces of the side walls 118, 120 of the second device 110 in the open or yielded position.

[0084] In alternative embodiments, the interior surface of the first sidewall 118 may be recessed or cut out, and the carrier retention devices CL1, CL2 may be attached to the first sidewall 118 such that the recesses may be displaced outwardly into the recesses, the recesses having a depth sufficient to accommodate the barbs or detents within the first sidewall 118 in the open state. In other embodiments, the carrier retention devices CL1, CL2 may comprise static bars or detents, and in such embodiments, the carton skirt panels 214A, 214B, 216A, 216B, 218A, 218B, 220A, 220B, 224A, 224B, 228A, 228B may deform or displace in response to receipt of the article B within the carrier 290, and such deformations may be accommodated by the carrier retention devices CL1, CL2. 1, the skirt panels 214A, 214B, 216A, 216B, 218A, 218B, 220A, 220B, 224A, 224B, 228A, 228B engaged by CL2 can be displaced inward to disengage said skirt panels 214A, 214B, 216A, 216B, 218A, 218B, 220A, 220B, 224A, 224B, 228A, 228B from the carrier holding devices CL1, CL2.

[0085] The carrier retaining devices CL1, CL2 may be positioned on the first sidewall 118 to align with the gaps or recesses between the pair of generally cylindrical articles B.

[0086] Similarly, the second side wall 120 is provided with at least one second carrier holding device CL3, CL4 for holding the carrier 290 within the second device 110, the second carrier holding devices CL3, CL4 being substantially similar to the carrier holding devices CL1, CL2 in the first side wall 118 and will not be described in further detail.

[0087] 3 to 5 show the stages of assembly of an article carrier 290 from the blank 210 shown in FIG. 6. The blank 210 is lowered onto the first device 10 and the top panel 212 of the carton blank 210 is lowered against the top wall 12 of the first device 10. The blank 210, and the subsequently formed article carrier 290, are transported in a first direction D1 on or by a conveyor (not shown). The first and second devices 10, 110 are transported in a downstream direction D1 in synchronism with the respective blank 210 or article carrier 290 over the working reach of the packaging system. Upon completion of the work assigned to them, the first and second devices 10, 110 can be returned to an upstream position on the return reach of the conveyor in order to engage the following blank 210 in the incoming stream of carton blanks 210.

[0088] The first and second side panels 218A, 218B, 220A, 220B may be partially folded downward about the fold lines 217A, 219A relative to the top panel 212. The corner panels 224A, 224B, 228A, 228B and the fixed panels 222A / 230A, 222B / 230B, 226A / 232A, 226B / 232B are folded relative to the side panels 218A, 218B, 220A, 220B to which they are connected. The corner panels 224A, 224B, 228A, 228B and the fixed panels 222A / 230A, 222B / 230B, 226A / 232A, 226B / 232B are maintained in the folded position by the guide rails G1.

[0089] The second device 110 is lowered relative to the carton blank 210 and the first device 10, as indicated by directional arrow D2 in Figure 3. The lower edges of the first and second side walls 118, 120, including the ribs 118R, 120R, may be chamfered or otherwise shaped to facilitate engagement of the first and second side walls 118, 120 with the carton blank 210. The second device 110 is lowered relative to the carton blank 210 and the first device 10 to fold the first and second side panels 218A, 218B, 220A, 220B, the corner panels 224A, 224B, 228A, 228B, and the fastening panels 222A / 230A, 222B / 230B, 226A / 232A, 226B / 232B around the first device 10.

[0090] The carrier retaining devices CL1, CL2, CL3, CL4 may be displaced or spread outwardly such that the detents are disposed outside the interior surfaces of the side walls 118, 120 during lowering of the second device 110 around the blank 210 and the first device 10. Once the detents have cleared the lower edges of the lower side panels 218B, 220B, the carrier retaining devices CL1, CL2, CL3, CL4 may return to an unbiased or resting position in which the detents engage said lower edges of the lower side panels 218B, 220B.

[0091] The first side panels 218A, 218B of the carton blank 210 are disposed between the first side wall 118 of the second device 110 and the first upper and lower side walls 18A, 18B of the first device 10.

[0092] As best shown in FIG. 8, the second side panels 220A, 220B of the carton blank 210 are positioned between the second side wall 120 of the second device 110 and the second upper and lower side walls 20A, 20B of the first device 10.

[0093] Each corner panel 224A, 224B, 228A, 228B is disposed between a respective lower corner or bevel wall 22A, 22B, 24A, 24B and one of the vertically extending ribs 118R, 120R. The fixed panels 222A / 230A, 222B / 230B, 226A / 232A, 226B / 232B are disposed between one of the first and second end walls 14, 16 and a respective static guide G1, see FIG. 5. For illustrative purposes, only one of the static guides G1 is shown in FIGS. 3-5.

[0094] To facilitate the downward folding of the upper and lower end panels 214A, 214B, 216A, 216B, a second static guide shown in Fig. 5 effects the folding of the upper fixed panel portions 230A, 230B, 232A, 232B inwardly of the first and second devices 10, 110. The second static guide G2 is received within recesses R5, R6, R7, R8 in the second device 110 and recesses R1, R2, R3 in the first device 10. The second static guide G2 folds the upper fixed panel portions 230A, 230B, 232A, 232B into an opening or gap O in the upper end of the first device 10. Folding the upper fixed panel portions 230A, 230B, 232A, 232B inwardly prevents them from interfering with the subsequent folding of the upper and lower end panels 214A, 214B, 216A, 216B.

[0095] An adhesive or other adhesive treatment may be applied to the lower fastening panel portions 222A, 222B, 226A, 226B while the lower fastening panel portions 222A, 222B, 226A, 226B are held in a folded state between the first device 10 and the guide G1.

[0096] After the adhesive or other adhesive treatment is applied, end panel folding guides (not shown) effect the folding of the upper and lower end panels 214A, 214B, 216A, 216B relative to the engagement panel 212.

[0097] The second guide G2 is terminated or withdrawn once the upper and lower end panels 214A, 214B, 216A, 216B are fully folded around the end of the first device 10.

[0098] The end panel folding guides urge the upper and lower end panels 214A, 214B, 216A, 216B into face-contacting relationship with the lower fixed panel portions 222A, 222B, 226A, 226B, and the guide G1 leaves or is withdrawn from its position between the lower fixed panel portions 222A, 222B, 226A, 226B and the lower end panels 214B, 216B when or just before the lower end panels 214B, 216B contact the lower fixed panel portions 222A, 222B, 226A, 226B. In this manner, the lower end panels 214B, 216B may contact the lower fixed panel portions 222A, 222B, 226A, 226B without being impeded by the guide G1.

[0099] Pressure or force is applied to the outer surfaces of the lower end panels 214B, 216B to secure the bond between the lower end panels 214B, 216B and the lower fixed panel portions 222A, 222B, 226A, 226B.

[0100] In this manner, the carrier 290 is pre-formed around the first device 10 , which acts as a mandrel or mold to form the article carrier 290 .

[0101] 8 and 9 show portions of the first and second devices 10, 110 arranged around a preformed article carrier 290. Each of the opposing ends of the article carrier 290 projects outwardly of the end of the second device 110. The corner panels 224A, 224B, 228A, 228B are disposed between the corner walls 22A, 22B, 24A, 24B of the first device 10 and the ribs 118R, 120R of the second device 110. The side panels 218A, 218B, 220A, 220B are disposed between the side walls 18A, 18B, 20A, 20B of the first device and the side walls 118, 120 of the second device 110.

[0102] As best shown in FIG. 8, the lower end panels 214B, 216B may partially overlap the ribs 118R, 120R of the second device 110, and a portion of the ribs may be disposed between the lower end panels 214B, 216B and the adjacent corner panels 224A, 224B, 228A, 228B.

[0103] To allow withdrawal of the article carrier 290 from within the second device 110, the upper end panels 214A, 216A are provided with recessed or shaped end walls to avoid interference therewith. The recesses R have the effect of creating an opening through which the ribs 118R, 120R can be withdrawn, see FIG.

[0104] Once the article carrier 290 is formed, the first device 10 is removed from the interior of the article carrier 290 while the second device 110 remains disposed about the exterior of the article carrier 290. This may be achieved by raising the second device 110 relative to the first device 10, whereupon the article carrier 290 is raised relative to the first device 10 so as to disengage it from the first device 10. The carrier retention devices CL1, CL2 of the second device 110 clip or secure the article carrier 290 therein.

[0105] When the second device 110 and the preformed carrier 290 are raised relative to the first device 10, the detents of the carrier holding devices CL1, CL2 slide along grooves or slots S1, S2, S3, S4 in the side walls 18A / 18B, 20A, 20B of the first device 10.

[0106] The first device 10 may be configured such that a portion of the lower sidewalls 18B, 20B extend below the lower side panels 218B, 220B of the article carrier 290 and extend below or beyond the lower ends of the sidewalls 118, 120 of the second device 110. This may facilitate handling of the first device 10 when placed with the article carrier 290.

[0107] After the second device 110 and the carrier 290 are separated from the first device 10, the article carrier 290 and the second device 110 are transported to the application station of the apparatus 1 and lowered onto the group of articles B vertically aligned below them. The articles B are received in each one of the article holding structures RT1, RT2. A portion of the article B passes through an opening A1 in the top wall 112 of the second device 110, as shown in FIG. 10. The tabs 240, 242, 270, 272 engage the article B below a flange or protrusion of the article B. The second device 110 can then be raised, as shown by the directional arrow D3, to separate the second device from the package formed from the article carrier 290 and the group of articles B. In this way, the second device 110 is used to form the article carrier 290 and to apply the article carrier 290 to the group of articles B.

[0108] The blank 210 includes at least one paperboard substrate. The paperboard substrate material may be selected from any conventional paperboard, for example ranging in weight from about 10 pt., preferably from about 16 pt. to about 28 pt. (0.028" / about 0.7 mm). Examples of such substrates are 27 pt. SBS board (solid bleached sulfate board coated on one side, trade name PrintKote®) or CNK® board (Coated Natural Kraft® - unbleached kraft board with a clay coating on one side, trade name CarrierKote™), manufactured by WestRock® Company, 21 pt. SBS board or CNK® board, and E-flute or F-flute corrugated board. The paperboard substrate may be bleached or unbleached board. The board may be coated on at least one side, optionally the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and board composition.

[0109] The blank 210 may include a tear resistant layer laminated to the paperboard layer. The blank 210 may optionally include an adhesive layer between the paperboard substrate and the tear resistant layer. The tear resistant layer may be disposed on the uncoated side of the paperboard substrate and may be formed of a polymeric material and secured to the substrate. The tear resistant layer provides toughness to the laminate structure. Suitable tear resistant materials may include, but are not limited to, tear resistant layer laminate sheet materials, such as NATRALOCK®, which may include layers of n-axially 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 the materials contribute to the tear resistance properties. Tear resistance may also be due to the chemistry of the tear resistant material, such as extruded metallocene catalyzed polyethylene (mPE).

[0110] Alternatively, the tear resistant layer may be a layer of linear low density polyethylene (LLDPE). In embodiments where linear low density polyethylene (LLDPE) or mPE is used, the incorporation of an adhesive layer is not required. Other suitable materials having a high level of tear resistance may also be used.

[0111] The adhesive layer may be formed of a polyolefin material, such as low density polyethylene (LDPE). The adhesive layer may be disposed between a substrate and a tear resistant layer to secure the tear resistant layer to the substrate.

[0112] The present disclosure provides a top-engaging type carrier having an improved article retention structure or article top-engaging device.

[0113] The embodiment provides an item retaining structure RT1, RT2 in the main, top or engagement panel 212 having a plurality of tabs 240, 242, 270, 272 and at least one item retaining opening A4, A5.

[0114] The article carrier 290 comprises at least one top panel or engagement panel 212 and a skirt structure surrounding and extending from the at least one engagement panel 212, the skirt structure comprising a plurality of panels 214A, 214B, 216A, 216B, 218A, 218B, 220A, 220B, 224A, 224B, 228A, 228B for surrounding a portion of at least one article B.

[0115] In some embodiments, one or both of the longitudinal and lateral dimensions decrease after loading the carrier 290 with articles. In some embodiments, one of the longitudinal and lateral dimensions may decrease and the other of the longitudinal and lateral dimensions may increase after loading the carrier 290 with articles. In other embodiments, the diagonal dimension or diagonal distance between the diagonally opposed corner panels increases after loading, and in such embodiments, one or both of the longitudinal and lateral dimensions may also change. The change in the size or shape of the skirt structure has the effect of increasing the circumferential tension of the skirt structure after application to the articles so as to tightly bunch or restrain the articles in the group of articles B. The increased circumferential tension may create an upward force on the carrier 290 such that the engagement teeth or tabs 240, 242, 270, 272 are pressed tightly against the underside of an article feature such as an end closure, cap, or neck flange.

[0116] In some embodiments, the tilt angle or shape of the upper side panels 218A, 220A may change in response to receipt of an article B within the carrier 290.

[0117] In some embodiments, the angle or shape of the upper end panels 214A, 216A may change in response to receipt of an article B within the carrier 290.

[0118] The article carrier 290 may automatically disengage from the second device 110, from the carrier retaining devices CL1, CL2, upon receipt of an article B into the article carrier 290. In other embodiments, the carrier retaining devices CL1, CL2 may release the carrier 290 when the second device 110 is moved upward relative to the article carrier 290 and the article B received therein. The engagement force between the article carrier 290 and the article B may be greater than the engagement force of the carrier retaining devices CL1, CL2 with the article carrier 290, such that the detents are displaced outwardly relative to the panel of the carrier 290 with which they engage, without disengaging the article carrier 290 from the article B when the second device 110 is moved upward. It will be appreciated that the detents may be shaped to encourage either outward displacement of the detents or inward displacement of the panel with which they engage (panels 218B, 220B in the illustrated embodiment) when the second device 110 is raised upward relative to the carrier 290.

[0119] The detents may be shaped to encourage either outward displacement of the detents or inward displacement of the panel that the detents engage (panels 218B, 220B in the embodiment shown) when the second device 110 is lowered downward relative to the carrier 290.

[0120] The present disclosure provides an apparatus 1 for packaging articles B in an article carrier 290. The apparatus 1 comprises an article translation device or conveyor for moving the batch of articles B in a downstream direction D1 through an application section. The apparatus 1 comprises a carrier pre-forming device 10, 110 for folding and gluing a carrier blank 210 into a top-engaged carrier 290 and for conveying the top-engaged carrier 290 in the downstream direction D1 to the application section where the top-engaged carrier 290 is applied to the batch of articles B.

[0121] The present disclosure provides a method of packaging a batch of articles B, comprising translating the batch of articles B in a downstream direction D1 through a packaging section. The method comprises folding and adhering a carrier blank 210 into a top-engaged carrier 290, conveying the top-engaged carrier 290 in the downstream direction D1 to an application section, and applying the top-engaged carrier 290 to the batch of articles B.

[0122] The method may include folding and adhering the carrier blank 210 around the internal mold 10 using an external applicator 110 to effect folding of the carrier blank 210 around the internal mold 10 .

[0123] The method may include the step of transporting the top engagement carrier 290 using the external applicator 110 .

[0124] The method may include applying the top engagement carrier 290 to the group of articles B using the external applicator 110 and may include receiving the group of articles B into the external applicator 110.

[0125] The present disclosure provides a carrier forming device 10 / 110 comprising a pair of tools 10, 110 including an inner tool 10 and an outer tool 110. The inner tool 10 comprises a plurality of mandrel surfaces 12, 14, 16, 18A, 18B, 20A, 20B, 22A, 22B, 24A, 24B including a pair of opposing side surfaces 18B, 20B and at least one end surface 14, 16 for supporting at least two end closure flaps 222A, 222B, 226A, 226B of the carrier 290 in overlapping arrangement with end closure panels 214B, 216B of the carrier 290. The external tool 110 comprises a pair of opposed side members 118, 120 for folding opposed side panels 218B, 220B of the carrier 290 downwardly along the side surfaces 18B, 20B of the internal tool 10 into a folded position. The external tool 110 is structured and dimensioned such that at least one end surface 14, 16 of the internal tool 10 is offset outwardly from an adjacent end of the side members 118, 120 of the external tool 110 when the side members 118, 120 bring the side panels 218B, 220B of the carrier 290 into the folded position.

[0126] The present disclosure provides a carrier forming device 10 / 110 comprising a pair of tools 10, 110 including an internal tool 10 and an external tool 110. The external tool 110 comprises a pair of opposed side members 118, 120 for folding opposed side panels 218B, 220B of the carrier 290 downwardly along the exterior of the internal tool 10 into a folded position. At least one of the side members 118, 120 of the external tool 110 comprises an engagement ledge L (see FIG. 2) for engaging the carrier 290. The engagement ledge L is movably connected to the external member 110 for movement between an engagement position where the ledge L is disposed inside the external tool 110 and a yield position where the ledge L is disposed outside the interior of the external tool 110. The ledge L is biased, biased or encouraged towards the engagement position when disposed in the yield position.

[0127] The internal tool 10 may comprise a pair of side surfaces 18A / 18B, 20A / 20B, where at least one of the side surfaces 18A / 18B, 20A / 20B of the internal tool 10 has a groove S1, S2, S3 for receiving a ledge L of the external tool 110. The groove S1, S2, S3 extends over at least one of the side surfaces 18A / 18B, 20A / 20B such that the ledge L is movable or slidably translatable along or within the groove S1, S2, S3.

[0128] The present disclosure provides a carrier forming device 10 / 110 comprising a pair of tools 10, 110 including an inner tool 10 and an outer tool 110. The outer tool 110 comprises a pair of opposed side members 118, 120 for folding opposed side panels 218A / 218B, 220A / 220B of the carrier 290 downwardly into a folded position along the exterior of the inner tool 10. The side members 118, 120 of the outer tool 110 each include a recess R5, R6, R7, R8 along its edge for receiving a static mechanical guide G2.

[0129] The internal tool 10 may have a channel or opening O (in the illustrated embodiment in the form of a void) for receiving the static guide G2, the channel or opening O extending between the opposing side walls 18A / 18B, 20A / 20B of the internal tool 10.

[0130] The internal tool 10 has a top surface 12 having an edge along which the top end flaps 214A / 214B, 216A / 216B of the carrier 290 are folded, the top surface 12 having recesses C1, C2, C3, C4 along the edge, the recesses C1, C2, C3, C4 communicating with channels or openings O.

[0131] The present disclosure provides a carrier forming device 10 / 110 comprising a pair of tools 10, 110 including an inner tool 10 and an outer tool 110. The outer tool 110 comprises a pair of opposed side members 118, 120 for folding opposed side panels 218A / 218B, 220A / 220B of the carrier 290 downwardly into a folded position along the exterior of the inner tool 10. At least one of the side members 118, 120 of the outer tool 110 is provided with a projection 118R, 120R at an end thereof, which projects inwardly beyond the plane of the inner surface of at least one of said side members 118, 120.

[0132] The present disclosure provides a method of packaging articles, comprising preforming a carrier blank 210 into a top-engaged carrier 290 using a carrier forming device 10 / 110 comprising a pair of tools 10, 110 including an internal tool 10 and an external tool 110. The method comprises disengaging the carrier 290 from the internal tool 10 while maintaining the carrier 290 engaged with the external tool 110. The method comprises engaging the external tool 110 together with the carrier 290 to the group of articles B such that the group of articles B are connected to each other by the carrier 290, and removing the external tool 110 from the group of articles B as well as from the carrier 290.

[0133] The present disclosure provides an article carrier 290 comprising a top panel 212, a pair of side panels 218A / 218B, 220A / 220B, and an end closure structure for closing at least one of the opposed ends of the carrier 290. The end closure structure comprises a plurality of end closure flaps, including a pair of side end flaps 222A / 224A, 222B / 224B, 226A / 228A, 226B / 228B, and a top end flap 214A / 214B, 216A / 216B. The top end flap 214A / 214B, 216A / 216B does not have a direct foldable connection with the pair of side end flaps 222A / 224A, 222B / 224B, 226A / 228A, 226B / 228B. At least one of the pair of side end flaps 222A / 224A, 222B / 224B, 226A / 228A, 226B / 228B comprises a corner panel 226A, 226B, 228A, 228B. The top end flap 214A / 214B, 216A / 216B is provided with a recess R along at least one of its side edges. The end closure flaps are secured together to form an end closure structure, with the recess R of the top end closure 214A / 214B, 216A / 216B aligned with at least a portion of the corner panel 226A, 226B, 228A, 228B along an imaginary axis A perpendicular to the top panel 12, as best shown in FIG. The recesses R are disposed above or on the corner panels 226A, 226B, 228A, 228B and expose for view portions of the corner panels 226A, 226B, 228A, 228B that would otherwise be hidden. The corner panels 226A, 226B, 228A, 228B may be disposed at an oblique angle to the top end closures 214A / 214B, 216A / 216B and may have a gap or void therebetween, with the recesses R providing an opening that is vertically aligned with the gap or void to allow access to the gap or void from above.

[0134] The present disclosure provides an article carrier 290 comprising a top panel 212, a pair of side panels 218A / 218B, 220A / 220B, and an end closure structure for closing at least one of the opposed ends of the carrier 290. The end closure structure comprises a plurality of end closure flaps, including a pair of side end flaps 222A / 224A, 222B / 224B, 226A / 228A, 226B / 228B, and a top end flap 214A / 214B, 216A / 216B. The top end flap 214A / 214B, 216A / 216B does not have a direct foldable connection with the pair of side end flaps 222A / 224A, 222B / 224B, 226A / 228A, 226B / 228B. At least one of the pair of side end flaps 222A / 224A, 222B / 224B, 226A / 228A, 226B / 228B comprises a corner panel 226A, 226B, 228A, 228B including an upper edge. The top end flap 214A / 214B, 216A / 216B is provided with a recessed edge R along one of its side edges. The end closure flaps are secured together to form an end closure structure in which the upper edges of the corner panels 226A, 226B, 228A, 228B meet, meet or intersect with the recessed edge R of the top end flap 214A / 214B, 216A / 216B.

[0135] It will be understood that various modifications can be made within the scope of the invention, for example, the size and shape of the panels and openings can be adjusted to accommodate articles of different sizes or shapes, more or fewer articles, and / or articles arranged in various array configurations.

[0136] It will be appreciated that references herein to directions such as "top," "bottom," "base," "front," "back," "end," "side," "inner," "outer," "above," and "below" do not necessarily limit each panel to such an orientation, but may merely serve to distinguish those panels from one another.

[0137] As used herein, the terms "hinge connection" and "crease" refer to any type of line that defines a hinge feature of the blank that facilitates folding of portions of the blank relative to one another or otherwise indicates an optimal panel folding location for the blank. Any reference to a "hinge connection" should not be construed as necessarily referring to only a single crease, and in fact, a hinge connection may be formed from two or more creases, where each of the two or more creases may be straight / linear in shape or curved / curved in shape. When straight creases form a hinged connection, they may be disposed parallel to one another or at a slight angle relative to one another. When curvilinear creases form a hinge connection, they may intersect with one another to define a shaped panel within the area enclosed by the curvilinear creases. A typical example of such a hinge connection may include a pair of arched or bowed creases that intersect at two points to define an oval panel between them. In some cases, the hinge connection is formed from one or more straight creases and one or more curved creases. A typical example of such a hinge connection may include a combination of a straight crease and an arched or bowed crease, where the creases meet at two points to define a half-moon shaped panel therebetween.

[0138] As used herein, the term "crease" may mean one of the following: a score line, an embossed line, a debossed line, a perforation line, a short slit line, a half-cut line, a single half-cut, an interrupted cut, an aligned slit line, a score line, and any combination of the foregoing options.

[0139] It should be understood that the hinge connections and folds may each include elements formed in the blank substrate, including perforations, perforation lines, short slit lines, half-cut lines, single half-cuts, cuts, interrupted cuts, slits, scores, embossed lines, debossed lines, any combination thereof, and the like. The elements may be sized and positioned to provide the desired functionality. For example, perforation lines may be sized or designed with a degree of weakness to define creases and / or cut lines. Perforation lines may be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with less effort.

[0140] The phrase "in registry with" as used herein refers to the alignment of two or more elements in an assembled carton, such as an opening formed in a first of two overlapping panels and a second opening formed in a second of two overlapping panels. The elements that are in registry 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 registry 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. [Explanation of symbols]

[0141] 1 device 10 First device, inner mold, carrier forming device, inner tool 12 top wall, top panel, mandrel surface, top surface 14 first end wall, mandrel surface, end surface 16 second end wall, mandrel surface, end surface 18A First Upper Sidewall, Mandrel Surface 18B first lower sidewall, mandrel surface, side surface 20A Second upper sidewall, mandrel surface 20B second lower sidewall, mandrel surface, side surface 22A First Lower Corner Wall or Bevel Wall, Mandrel Surface, Corner Panel 22B Second lower corner wall or bevel wall, mandrel surface, corner panel 24A 3rd Lower Corner Wall or Bevel Wall, Mandrel Surface, Corner Panel 24B 4th lower corner wall or bevel wall, mandrel surface, corner panel 26A First upper corner wall or bevel wall, upper corner panel 26B Second upper corner wall or bevel wall, upper corner panel 28A Third upper corner wall or bevel wall, upper corner panel 110 Second device, external applicator, carrier forming device, external tool, external member 112 Main wall, top wall 118 First side wall, side member 118R Rib, protrusion 120 Second side wall, side member 120R Rib, protrusion 210 Blanks, Carton Blanks, Carrier Blanks 212 Main Panel, Top Panel, Engagement Panel 213A Fold 213B Fold 214A First upper end panel, skirt panel, top end flap, top end closure 214B first lower end panel, skirt panel, end closure panel, top end flap, top end closure 215A Fold 215B Fold 216A Second upper end panel, skirt panel, top end flap, top end closure 216B second lower end panel, skirt panel, end closure panel, top end flap, top end closure 217A Fold 217B Fold 218A First upper side panel, skirt panel 218B First lower side panel, skirt panel 219A Fold 219B Fold 220A Second upper side panel, skirt panel 220B Second lower side panel, skirt panel 221A Fold 221B Fold 222A First fastening panel, first lower fastening panel portion, end closure flap, side end flap 222B second fastening panel, second lower fastening panel portion, end closure flap, side end flap 223A Fold 223B Fold 224A First corner panel, skirt panel, side end flap 224B Second corner panel, skirt panel, side end flap 225A Fold 225B Fold 226A third fastening panel, third lower fastening panel portion, end closure flap, corner panel, side end flap 226B fourth fastening panel, fourth lower fastening panel portion, end closure flap, corner panel, side end flap 227A Fold 227B Fold 228A Third corner panel, skirt panel, side end flap 228B Fourth corner panel, skirt panel, side end flap 229A Fold 229B Fold 230A First Fixing Panel, First Upper Fixing Panel Portion 230B second fixed panel, second upper fixed panel portion 231A Fold 231B Fold 232A Third fixed panel, third upper fixed panel portion 232B Fourth fixed panel, fourth upper fixed panel portion 233A Break 233B Break 235A Break 235B Break 240 First Tab 242 Second Tab 243 crease 260 Handle tab 261 crease 270 First Tab 272 Second Tab 290 Carrier, article carrier, top-engaging carrier A Virtual axis A1 opening A3 opening A4 opening, article holding opening A5 opening, article holding opening A6 opening A7 opening B Goods C1 Top wall recess C2 Top wall recess C3 Top wall recess C4 Top wall recess CL1 Carrier Retention Device CL2 Carrier Retention Device CL3 Second carrier holding device CL4 Second carrier holding device D1 First direction, downstream D2 Directional Arrow D3 Directional Arrow G1 guide rail, static guide G2 Second static guide or rail, static panel forming guide, static mechanical guide H Handle structure Ledge O opening, void R recess R1 First recess R2 Second recess R3 Third recess R5 First recess R6 Second recess R7 3rd recess R8 4th recess RT1 Article holding structure RT2 Article holding structure S1 First slot, groove S2 Second slot, groove S3 3rd slot, groove

Claims

1. 1. An apparatus for packaging articles in an article carrier, comprising: an article translating device for moving the group of articles downstream through the application section; a carrier pre-forming device for folding and gluing a carrier blank into a pre-formed apex-engaged carrier and transporting the apex-engaged carrier downstream to the application section where the apex-engaged carrier is applied to the batch of articles; An apparatus comprising:

2. The apparatus of claim 1 , wherein the carrier pre-forming device comprises an internal mold and an external applicator for effecting folding of the carrier blank around the internal mold.

3. The apparatus of claim 2 , wherein the external applicator comprises at least one carrier holding device for holding the preformed apex-engaged carrier while transporting the apex-engaged carrier downstream to the application section.

4. The apparatus of claim 3 , wherein the internal mold comprises a groove for receiving at least a portion of the at least one carrier holding device to allow the external applicator to slide relative to the internal mold.

5. The apparatus of claim 2 , wherein the outer applicator includes an opening in at least one end thereof for receiving an end portion of the inner mold.

6. 3. The apparatus of claim 2, wherein the external applicator comprises a pair of opposed side walls each having a recess in an edge thereof, the recesses aligned to receive a static panel folding guide.

7. The apparatus of claim 6 , wherein the inner mold includes an opening at an end thereof, the opening providing a channel capable of receiving the static panel folding guide.

8. 3. The apparatus of claim 2, wherein the external applicator comprises a pair of opposing side walls, each of the side walls comprising a chamfered lower edge for engaging a panel of the article carrier to effect folding of the article carrier.

9. The apparatus of claim 2 , wherein the external applicator comprises at least one opening for receiving a portion of an article during application of the top engaging carrier to the group of articles.

10. 1. A method of packaging articles, comprising translating a group of articles in a downstream direction through an application section of a packaging system, comprising: folding and gluing a carrier blank into a preformed top-engaging carrier; conveying the top engagement carrier in the downstream direction to the application section; applying the top engaging carrier to the batch of articles; A method comprising:

11. The method of claim 10, comprising folding and adhering the carrier blank around an internal mold using an external applicator to effect folding of the carrier blank around the internal mold.

12. The method of claim 11 , comprising transporting the preformed apex-engaging carrier within the external applicator.

13. The method of claim 11 , comprising the steps of applying the top engaging carrier to the group of articles using the external applicator, and receiving the articles within the external applicator.

14. A carrier forming device comprising a pair of tools including an inner tool and an outer tool, the internal tool comprises a plurality of mandrel surfaces including a pair of opposing side surfaces and at least one end surface for supporting at least two end closure flaps of a carrier in overlapping arrangement with an end closure panel of the carrier; the outer tool having a pair of opposed side members for folding opposed side panels of the carrier downwardly along the pair of opposed side surfaces of the inner tool into a folded position; A carrier forming device, wherein the outer tool is structured and dimensioned such that the at least one end surface of the inner tool is offset outwardly from the adjacent end of the side member of the outer tool when the side member brings the side panel of the carrier into the folded position.

15. A carrier forming device comprising a pair of tools including an inner tool and an outer tool, the outer tool includes a pair of opposed side members for folding opposed side panels of a carrier downwardly along an exterior of the inner tool into a folded position; at least one of the side members of the external tool includes an engagement ledge for engaging the carrier; the engagement ledge is movably connected to the side member for movement between an engaged position where the engagement ledge is disposed within the interior of the external tool and a yielded position where the engagement ledge is disposed outside the interior of the external tool; A carrier forming device, wherein the engagement ledge is biased towards the engagement position when disposed in the yielding position.

16. 16. The carrier formation device of claim 15, wherein the internal tool comprises a pair of side surfaces, at least one of the side surfaces of the internal tool having a groove for receiving the engagement ledge of the external tool, the groove extending over the at least one of the side surfaces such that the engagement ledge is movable along the groove.

17. 17. The carrier formation device of claim 16, wherein the engagement ledge is slidably translatable within the groove.

18. A carrier forming device comprising a pair of tools including an inner tool and an outer tool, the outer tool includes a pair of opposed side members for folding opposed side panels of a carrier downwardly along an exterior of the inner tool into a folded position; A carrier forming device, wherein the pair of opposing side members of the external tool each include a recess along an edge thereof for receiving a static mechanical guide.

19. 20. The carrier formation device of claim 18, wherein the internal tool includes a channel for receiving the static mechanical guide, the channel extending between opposed side surfaces of the internal tool.

20. 20. The carrier formation device of claim 19, wherein the internal tool has a top surface with an edge, the top surface including a recess in the edge, the recess communicating with the channel.

21. A carrier forming device comprising a pair of tools including an inner tool and an outer tool, the outer tool includes a pair of opposed side members for folding opposed side panels of a carrier downwardly along an exterior of the inner tool into a folded position; At least one of the pair of opposing side members of the external tool is provided with a protrusion at an end thereof; A carrier forming device, wherein the projection projects inwardly beyond the plane of the inner surface of the at least one of the pair of opposed side members.

22. 1. A method of packaging an article, comprising: preforming a carrier blank into a top-engaging carrier using a carrier forming device comprising a pair of tools including an inner tool and an outer tool, disengaging the carrier from the inner tool while maintaining the carrier engaged with the outer tool; engaging the external tool together with the carrier with the group of articles such that the group of articles are connected to each other by the carrier; removing the external tool from the group of articles as well as from the carrier; A method comprising:

23. 1. An article carrier for packaging one or more articles, comprising: the article carrier comprising a top panel, a pair of side panels, and an end closure structure for closing at least one of the opposed ends of the article carrier; the end closure structure comprises a plurality of end closure flaps including a pair of side end flaps and a top end flap; the top end flap has no direct foldable connection with the pair of side end flaps, at least one of the pair of side end flaps comprising a corner panel; the top end flap being recessed along at least one of its side edges; the plurality of end closure flaps are secured together to form the end closure structure; The article carrier, wherein the recess in the top end closure is aligned with at least a portion of the corner panel along an imaginary axis perpendicular to the top panel.

24. 24. The article carrier of claim 23, wherein the recess is disposed over the corner panel and exposes for viewing a portion of the corner panel that would otherwise be hidden.

25. 24. The article carrier of claim 23, wherein the corner panel is positioned at an oblique angle to the top end closure with a gap therebetween, and the recess provides an opening vertically aligned with the gap to allow access to the gap from above.

26. 1. An article carrier for packaging one or more articles, comprising: the article carrier comprising a top panel, a pair of side panels, and an end closure structure for closing at least one of the opposed ends of the article carrier; the end closure structure comprises a plurality of end closure flaps including a pair of side end flaps and a top end flap; the top end flap has no direct foldable connection with the pair of side end flaps, at least one of the pair of side end flaps comprising a corner panel including an upper edge; said top end flap being provided with a recessed edge along at least one of its side edges; the plurality of end closure flaps are secured together to form the end closure structure where the upper edges of the corner panels meet the recessed edge of the top end flap.

Images