Packaging systems, devices, and methods for constructing article carriers

Abstract

Aspects of the present disclosure relate to a packaging system, an apparatus (10; 110) for forming an article carrier (2090; 2190) from a carrier blank (2010; 2110), and a method of forming the article carrier (2090; 2190). The apparatus (10; 110) comprises a body having a top wall (12; 112), opposing side walls (14, 16; 114, 116), and a first end wall (18). The opposing side walls (14, 16; 114, 116) and the first end wall (18) depend from the top wall (12; 112). The top wall (12; 112) defines at least one article receiving opening (A1, A2) on an inner surface thereof. The apparatus (10; 110) includes a blank alignment device (CH) for aligning a blank (2010; 2110) with respect to at least one article receiving opening (A1, A2). The blank alignment device (CH) includes a blank receiving recess defined in each of the opposing side walls (14, 16; 114, 116) and the first end wall (18). The blank receiving recess provides a support shelf (30) for the carrier blank (2010; 2110). The blank receiving recess extends from the second open end (8) of the body to the first end wall (18) such that the carrier blank (2010; 2110) is slidably receivable in the blank receiving recess.

Description

[Technical Field]

[0001] The present invention relates to packaging systems, apparatus, and methods for constructing packages or article carriers from article carrier blanks. More particularly, but not exclusively, the present invention relates to a jig or forming device for producing packages comprising an article carrier of the upper gripping type and a group of articles. [Background technology]

[0002] In the packaging art, it is known to provide cartons for carrying multiple items. Cartons are well known in the art and are useful for allowing consumers to transport, store, and access groups of items for consumption. For cost and environmental considerations, such cartons or carriers should be formed from as little material as possible and should result in as little waste material as possible when the carrier is formed. An additional consideration is the strength and suitability of the carton to hold and transport heavy weight items. It is desirable that the contents of the carton be securely secured within the carton.

[0003] It is well known to provide top-gripping article carriers where an opening is formed in a panel of the carrier, and where a tab is punched from the panel and positioned around the opening such that when an article is received in the opening, the tab is displaced out of the plane of the panel, and the tab engages the article, generally around a flange or lip of the article. Summary of the Invention [Problem to be solved by the invention]

[0004] It would be desirable to provide a method and apparatus for constructing packages from article carrier blanks that is simple, reliable and efficient.

[0005] The present invention seeks to provide improvements in the field of packaging, cartons typically formed from paperboard or the like, and machines for erecting said cartons. [Means for solving the problem]

[0006] A first aspect of the present invention provides an apparatus for forming article carriers from carrier blanks. The apparatus includes a body having a top wall, opposing side walls, and a first end wall. The opposing side walls and the first end wall depend from the top wall. The top wall defines at least one article receiving opening on an inner surface thereof. The apparatus further includes a blank alignment device for aligning a blank with respect to the at least one article receiving opening. The blank alignment device includes blank receiving recesses defined in each of the opposing side walls and the first end wall. The blank receiving recesses provide support shelves for the carrier blanks. The blank receiving recesses extend from a second open end of the body to the first end wall such that the carrier blanks are slidably receivable in the blank receiving recesses.

[0007] Optionally, the apparatus further comprises an article engagement device in the form of a guide provided by opposed side walls and a first end wall, the guide providing a plurality of surfaces facing inwardly of the body for engaging the at least one article to align the at least one article with the at least one article receiving opening.

[0008] Optionally, the body is single.

[0009] Optionally, the apparatus is configured to apply the carrier blank to the at least one article, and the article engagement device groups the at least one article together into a group and aligns the group with the at least one article receiving opening.

[0010] Optionally, the apparatus is configured to apply the carrier blank to the at least one article, and the article engagement device maintains the at least one article in a group and aligns the group with the at least one article receiving opening.

[0011] Optionally, the apparatus further comprises a stabilizing device, the stabilizing device comprising at least one stabilizing peg extending inwardly from an inner surface of the top wall.

[0012] Optionally, the apparatus further comprises at least one break extending from an inner surface of the top wall into the interior of the body, the stabilization device extending farther from the inner surface of the top wall than the at least one break.

[0013] Optionally, the apparatus further comprises at least one fold line extending from an inner surface of the top wall into the interior of the body, and the stabilizing device extends farther from the inner surface of the top wall than the at least one fold line for engaging the carrier blank prior to the at least one fold line so that the position and orientation of the carrier blank is maintained when the at least one fold line engages the carrier blank.

[0014] Optionally, the at least one article receiving opening comprises a tab receiving recess punched out of a portion of the top wall defining the at least one article receiving opening.

[0015] Optionally, the device further comprises at least one break extending from an inner surface of the top wall into the interior of the body, the tab-receiving recess being disposed adjacent the at least one break.

[0016] Optionally, the at least one fold line is linearly disposed along a boundary between an inner surface of the top wall and an inner surface of at least one of the side walls, and the tab receiving recess is collinearly disposed with respect to the at least one fold line.

[0017] Optionally, at least one article receiving opening is at least partially bottomed to provide an article end stop.

[0018] Optionally, the at least one article receiving opening is at least partially bottomed to provide an end stop to restrain movement of the body relative to an article packaged by the article carrier.

[0019] Optionally, the body comprises a panel receiving recess, the panel receiving recess being disposed between the blank alignment device and the article engaging device.

[0020] Optionally, the panel receiving recess is configured to accommodate at least one folding panel that is hinged to an article engaging panel of the article carrier.

[0021] Optionally, the apparatus is configured to form a top engaging article carrier.

[0022] A second aspect of the present invention provides an application device for applying carrier blanks to a group of articles. The application device includes a top wall having a blank-pressing top, a pair of opposed side walls, end walls, an end opening for inserting a carrier blank therethrough, a blank-receiving passage in at least each side wall, and a registration peg for insertion into the registration opening in the carrier blank. The top wall, side walls, and end walls together define an interior of the device. The registration peg extends from the blank-pressing top into the interior of the device. A first distance, which provides a blank-support shelf, defined between the blank-pressing top and the floor of the passage is greater than the operating length of the registration peg.

[0023] Optionally, the working length of a registration peg is the dimension measured between the top of the blank press and the distal or bottommost end of the registration peg.

[0024] Optionally, the device further comprises blank edge creases or ribs extending from the blank press top portion to the interior of the device, and the operating length of the registration peg is greater than a second distance defined between the blank press top portion and the leading edge of the blank panel creases or ribs.

[0025] Optionally, blank receiving passages are also provided in the end walls.

[0026] A third aspect of the present invention is a method of packaging an article, comprising the steps of: Sliding a carrier blank into a blank-receiving recess in a body of the forming jig through the open end and aligning the carrier blank with the body; placing a forming tool over at least one article; lowering the forming tool relative to at least one article; engaging at least one article with an article engaging device provided by the body to align the at least one article with the carrier blank; pressing the carrier blank against at least one article; receiving at least one article in an opening in a top wall of the body; receiving at least one article in an opening of an article retaining device provided in an engagement panel of the carrier blank; folding at least one engagement tab of the article retaining device into engagement with the at least one article; folding at least one panel hinged to the engagement panel relative to the engagement panel; raising the forming fixture relative to the carrier blank and the at least one article such that the at least one article clears the top wall of the body; sliding the forming tool relative to the carrier blank and the at least one article so that the carrier blank and the at least one article pass through the open end of the body adjacent the top wall; The present invention provides a method comprising:

[0027] Further features and advantages of the present invention will become apparent from the specific embodiments illustrated in the drawings and discussed below.

[0028] Within the scope of this application, it is anticipated or intended that the various aspects, embodiments, examples, features, and alternatives presented in the preceding paragraphs, claims, and / or in the following description and drawings may be considered or interpreted independently or in any combination thereof.

[0029] Features or elements described in connection with or with respect to one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into or combined with any of the other embodiments disclosed herein, and the features or elements extracted from said one embodiment may be included in addition to or in place of one or more features or elements of said other embodiments.

[0030] Any feature or combination of features of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment. Alternatively, any feature or combination of features of an embodiment may be omitted from that embodiment.

[0031] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0032] [Figure 1] FIG. 1 is a top perspective view of a fixture for forming an upper engagement carrier according to a first embodiment of the present disclosure. [Figure 1A] FIG. 2 is a plan view of the jig of FIG. 1 from above. [Figure 1B] FIG. 2 is a cross-sectional view of the jig of FIG. 1. [Figure 1C] 2 is an alternative perspective view of the fixture of FIG. 1, including hidden (dashed) lines to show hidden features. [Figure 2A] FIG. 2 is a plan view of the jig of FIG. 1 from below. [Figure 2B] FIG. 2 is a first end view of the fixture of FIG. 1. [Figure 2C]FIG. 2 is a second end view of the fixture of FIG. 1. [Figure 2D] FIG. 2 is a side view of the jig of FIG. [Figure 3A] 2 is a second end view of the fixture of FIG. 1, including hidden (dashed) lines to show hidden features. [Figure 3B] 2 is a side view of the fixture of FIG. 1, including hidden (dashed) lines to show hidden features. [Figure 4] FIG. 10 is a top plan view of a blank for forming an upper engagement carrier according to an embodiment of the present disclosure. [Figure 5] 5 is a top perspective view of a package formed from the carrier blank of FIG. 4. [Figure 6] 6A-6C are perspective views of stages in the construction of the package of FIG. 5 using the jig of FIG. 1. [Figure 7] 6A-6C are perspective views of stages in the construction of the package of FIG. 5 using the jig of FIG. 1. [Figure 8] 6A-6C are perspective views of stages in the construction of the package of FIG. 5 using the jig of FIG. 1. [Figure 9] 6A-6C are perspective views of stages in the construction of the package of FIG. 5 using the jig of FIG. 1. [Figure 10] 10A-10C are perspective views from above of stages in the construction of an alternative package using a forming jig according to an alternative embodiment of the present disclosure. [Figure 11] FIG. 10 is a top perspective view of an alternative package formed from a carrier blank according to an alternative embodiment of the present disclosure. [Figure 12] 5 is a cross-sectional view of the fixture of FIG. 1 with the blank according to FIG. 4 covered thereon, indicated by the dashed lines. [Figure 13A] 2 is a first end view of the fixture of FIG. 1 relative to the article carrier and article during the package build stage. [Figure 13B] 2 is a first end view of the fixture of FIG. 1 relative to the article carrier and article during the package build stage. DETAILED DESCRIPTION OF THE INVENTION

[0033] Detailed descriptions of specific embodiments of packaging systems, apparatus, tools, methods, blanks, and carriers are disclosed herein. It is understood that the disclosed embodiments are merely examples of ways in which certain aspects of the invention may be practiced and do not represent a comprehensive listing of all ways in which the invention may be embodied. As used herein, the word "exemplary" is used broadly to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it is understood that the packaging systems, apparatus, tools, methods, 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 have not necessarily been described in great detail to avoid obscuring the disclosure. Any specific structural and functional details disclosed herein are not intended as limitations, but merely as representative principles for the claims and to teach those skilled in the art to variously use the invention.

[0034] Referring to Figure 4, there is shown a plan view of a blank 2010 from which a top-engaging carton or carrier 2090, as shown in Figure 5, can be formed for containing and carrying a group of primary products, hereafter referred to as Item B, as shown in Figure 5, such as, but not limited to, bottles or cans. Item B can be generally cylindrical, and Item B can have a circular cross-section, at least around the area of ​​engagement with carrier 2090. Blank 2010 forms a secondary package for packaging at least one primary product container or package. An alternative carton or carrier 2190 is shown in Figure 11. Carrier 2190 is formed from an alternative blank 2110 partially shown in Figure 10.

[0035] 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 are applicable 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.

[0036] The cartons or carriers in the drawings are shown in the form of upper engaging carriers, merely as an option. Upper engaging carriers as illustrated throughout this disclosure each have a main or primary engaging panel provided with a plurality of article retaining structures. Each structure typically includes an opening for receiving an upper portion of an article and one or more engaging teeth or tabs coupled along the periphery of the opening.

[0037] The blanks 2010; 2110 are formed from sheets of suitable substrate. As used herein, it is understood that the term "suitable substrate" includes all manner of foldable sheet material, such as paperboard, corrugated board, cardboard, plastic, combinations thereof, etc. It should be recognized that one or more blanks may be used, as appropriate, to provide, for example, the carrier structures described in more detail below.

[0038] The packaging structures or cartons described herein can be formed from sheet materials, such as paperboard, which can be made from or coated with materials to increase their 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 can be provided in two or more layers to help improve the tear resistance of the package. Typically, one surface of the sheet material can have different properties from the other surface. For example, the surface of the sheet material facing the outside of the finished package can be smooth, specifically, or can have a coating, such as a clay coating or other surface treatment, to provide good printability. Meanwhile, the surface of the sheet material facing the inside can be provided with a coating, layer, treatment, or prepared to provide properties such as one or more of tear resistance, good adhesive ability, heat sealability, or other desired functional properties.

[0039] In the illustrated embodiment, the blank 2010; 2110 is configured to form a carton or carrier 2090; 2190 for packaging an exemplary arrangement of exemplary items B. In the embodiment shown in Figure 4, the blank 2010 is designed for six items B (see Figure 5) arranged in a 2x3 matrix or array, i.e., two rows of three items B, where the items B are 350 ml beverage cans. In the embodiment shown in Figure 11, the items are arranged in a 1x4 matrix or array, i.e., one row of four items B, where the items B are 350 ml beverage cans. Alternatively, the blanks 2010; 2110 may be configured to form carriers for packaging items of other types (e.g., bottles), numbers (e.g., 2, 3, 4, 5, or 8), and sizes (e.g., 330 ml or 500 ml cans), and / or carriers for packaging items in different arrangements or configurations (e.g., 1x2, 1x3, 1x5, 2x2, 2x4).

[0040] FIG. 4 shows a blank 2010 with an engagement panel 2012 that forms part of the carrier 2090 shown in FIG.

[0041] Blank 2010 includes a first end panel 2014 hinged to a first end of main panel 2012 by a hinge connection in the form of fold line 2013. Fold line 2013 is linear. Blank 2010 includes a second end panel 2016 hinged to a second end of main panel 2012 by a hinge connection in the form of fold line 2015. Fold line 2015 is linear.

[0042] The blank 2010 includes a first side panel 2018 hinged to a first side of the main panel 2012 by a hinge connection in the form of a fold line 2017. The fold line 2017 is linear. The blank 2010 includes a second side panel 2020 hinged to a second side of the main panel 2012 by a hinge connection in the form of a fold line 2019. The fold line 2019 is linear.

[0043] The main panel 2012 includes four corner regions 2012A, each substantially identical in structure. The corner regions 2012A will be described in further detail with reference to the first corner region 2012A. The first corner region 2012A is defined, at least in part, by a splayed pair of fold lines 2013A, 2017A. The pair of fold lines 2013A, 2017A includes the first fold line 2013A oriented substantially perpendicular to the second fold line 2017A.

[0044] Each of the pair of fold lines 2013A, 2017A is substantially collinear with a respective one of the fold lines 2013, 2017 that hinge the first side panel 2018 and the first end panel 2014 to the main panel 2012.

[0045] The first corner region 2012A may comprise a beveled, chamfered, or chamfered corner that defines the free edge of the main panel 2012, ie, the free edge is not hinged to another panel.

[0046] The main panel 2012 of the blank 2010 includes at least one item retention structure RT1, RT2. The main panel 2012 includes a plurality of item retention structures RT1, RT2, specifically six item retention structures RT1, RT2 arranged in a 2x3 matrix or array. Each of the item retention structures RT1, RT2 includes an opening or aperture A3, A4.

[0047] The blank 2010 includes four first item retention structures RT1. The first item retention structures RT1 are positioned adjacent to the edges of the main panel 2012. The blank 2010 includes two second item retention structures RT2. The second item retention structures RT2 are positioned between a first pair of first item retention structures RT1 positioned adjacent to the first edge of the main panel 2012 and a second pair of first item retention structures RT1 positioned adjacent to the second edge of the main panel 2012. The second item retention structures RT2 are also referred to herein as intermediate item retention structures RT2. The first item retention structures RT1 are also referred to herein as end item retention structures RT1.

[0048] The first item retaining structure RT1 includes an item receiving opening defined in part by an opening A3.

[0049] The first article retaining structure RT1 includes a plurality of engagement teeth or tabs 2050A, 2050B, 2052A, 2052C disposed around the opening A3.

[0050] A plurality of tines 2050A, 2050B, 2052A, 2052C are hinged to the main panel 2012 by fold lines.

[0051] The first tab 2050A may be hinged to the main panel 2012 via one of the side panels 2018, 2020. The first tab 2050A extends from and is integral with said side panel 2018, 2020. The first tab 2050A includes a pair of side edges defined by a slit 2051 extending outward from the opening A3. The slit 2051 may be linear. The slits 2051 may be arranged to extend toward each other.

[0052] The second tab 2050B may be hinged to the main panel 2012 via one of the end panels 2014, 2016. The second tab 2050B includes a pair of side edges defined by cuts 2051 extending outward from the opening A3. The cuts 2051 may be linear. The cuts 2051 may be arranged to extend from one another.

[0053] Each pair of radial cuts 2051 in the first tab 2050A and second tab 2050B extends to a fold line 2013, 2015, 2017, 2019 that hinges the side or end panels 2018, 2020, 2014, 2016 to the engagement panel 2012.

[0054] The first tab 2050A and the second tab 2050B sever a respective one of the fold lines 2013, 2015, 2017, 2019 that hinge the engagement panel 2012 to the side or end panel 2018, 2020, 2014, 2016 through which the first tab 2050A and the second tab 2050B extend or from which the first tab 2050A and the second tab 2050B extend, i.e., the first tab 2050A and the second tab 2050B are integral with one of the side or end panels 2018, 2020, 2014, 2016.

[0055] The plurality of tines 2050A, 2050B, 2052A, 2052C includes a third tine 2052A and a fourth tine 2052C that are hingedly connected to the main panel 2012 by fold lines. The fold lines may be defined by a plurality of cuts 2055, 2057. The plurality of cuts 2055, 2057 may define or approximate a circle.

[0056] The plurality of teeth 2050A, 2050B, 2052A, 2052C includes third teeth 2052A disposed around a portion of the opening A3. Each of the plurality of third teeth 2052A includes an engagement edge E1 opposite the hinge edge. The engagement edge E1 is defined by a linear portion of the cut that defines the opening A3. Each engagement edge E1 defines a portion of a polygon. The illustrated embodiment includes seven third teeth 2052A. Each third tooth 2052A includes a pair of side edges defined by cuts 2053 that extend radially outward from each vertex of the polygon. The cuts 2053 extend from each vertex between adjacent pairs of linear portions of the cut that define the opening A3. The cuts 2053 are divergently disposed relative to one another and define an angle therebetween, which may be approximately 22.5°.

[0057] The plurality of tines 2050A, 2050B, 2052A, 2052C are disposed around a portion of the opening A3, including a fourth tine 2052C, also referred to herein as a partial tab or tine 2052C. The illustrated embodiment includes four fourth tines 2052C. The fourth tines 2052C are provided on opposite sides of one of the first tab 2050A or the second tab 2050B, such that a partial tine 2052C is provided on each side of each of the first tab 2050A and the second tab 2050B. The first tab 2050A and the second tab 2050B and the associated pair of partial tines 2052C occupy an angular width equal to three full tines 2052A, 2050B, which may be 67.5°. The first tab 2050A and the second tab 2050B can occupy approximately 39.5°, and each partial tooth 2052C can occupy approximately 14°.

[0058] Each pair of radial cuts 2051 in the abutment tabs 2050A, 2050B extends to fold lines 2013, 2015, 2017, 2019 that hinge the side or end panels 2018, 2020, 2014, 2016 to the engagement panel 2012.

[0059] The first tab 2050A and the second tab 2050B sever a respective one of the fold lines 2013, 2015, 2017, 2019 that hinge the engagement panel 2012 to the side or end panel 2018, 2020, 2014, 2016 through which the first tab 2050A and the second tab 2050B extend or from which the first tab 2050A and the second tab 2050B extend, i.e., the first tab 2050A and the second tab 2050B are integral with one of the side or end panels 2018, 2020, 2014, 2016.

[0060] The first and second tabs 2050A, 2050B are defined by a pair of radial cuts 2051, the radial cuts 2051 of the first and second tabs 2050A, 2050B being longer than at least one of the radial cuts 2053 defining the first tooth 2052A. The pair of radial cuts 2051 extend beyond the perimeter of the third and fourth engagement teeth 2052A, 2052C, i.e., beyond the peripheral fold that defines the outer edges of the plurality of third and fourth engagement teeth 2052A, 2052C, the peripheral fold being defined by the plurality of cuts 2055, 2057.

[0061] The first item retaining structure RT1 may include a plurality of first peripheral cuts 2057. Each of the plurality of first peripheral cuts 2057 is aligned with one of the radial cuts 2053 such that said one, or a notional extension thereof, bisects a respective one of the plurality of first peripheral cuts 2057.

[0062] Each of the plurality of first peripheral cuts 2057 is spaced from one of the radial cuts 2053 that bisects it so as to define a connecting notch or bridge portion between pairs of adjacently disposed teeth 2050A, 2050B, 2052A, 2052C.

[0063] Each of the plurality of first peripheral cuts 2057 may be linear in shape.

[0064] The first item retaining structure RT1 may include a plurality of second peripheral cuts 2055. Each of the plurality of second peripheral cuts 2055 is disposed between and spaced apart from a pair of the plurality of first peripheral cuts 2057 so as to define a pair of interlocking notches or bridge portions between each of the third tines 2052A and fourth tines 2052C and the main panel 2012. The pairs of interlocking notches or bridge portions provide a hinged or foldable connection between each of the third tines 2052A and fourth tines 2052C and the main panel 2012.

[0065] Each of the plurality of second peripheral cuts 2055 may be linear in shape. In alternative embodiments, each of the plurality of first peripheral cuts 2057 may be arcuate or curved. In alternative embodiments, each of the plurality of second peripheral cuts 2055 may be arcuate or curved.

[0066] Each of the second item holding structures RT2 is substantially similar in structure and will therefore be described in detail with reference to the first of the second item holding structures RT2 positioned adjacent to the first of the first item holding structures RT1 as shown in FIG.

[0067] The second item retaining structure RT2 includes an item receiving opening defined in part by an opening A4. The second item retaining structure RT2 includes a plurality of engagement teeth or engagement tabs 2050A, 2052A, 2052C disposed around the opening A4.

[0068] The plurality of tines 2050A, 2052A, 2052C are hinged to the main panel 2012 by fold lines. Each of the second article retaining structures RT2 is substantially similar in structure to the first article retaining structure RT1, except that the second tab 2050B, along with its associated pair of fourth tines 2052C, is omitted and replaced with three third tines 2052A. The second article retaining structure RT2 in the illustrated embodiment includes thirteen third tines 2052A.

[0069] The fold lines 2013, 2015, 2017, 2019 that hinge the side or end panels 2018, 2020, 2014, 2016 to the engagement panel 2012 may include a plurality of spaced apart cuts that are collinear with one another. The plurality of spaced apart cuts may include two, three, or more discrete cuts. The plurality of spaced apart cuts may include two, three, or more discrete cuts each having a different length.

[0070] The blank 2010 forms an article carrier 2090 for packaging a group of articles B, as shown in FIG.

[0071] The first tab 2050A and the second tab 2050B fold out of the plane of the main panel 2012 when item B is received in the item retaining structures RT1, RT2, and the first tab 2050A and the second tab 2050B, which are integral with one of the side or end panels 2018, 2020, 2014, 2016, can encourage or initiate folding of the side or end panel 2018, 2020, 2014, 2016 relative to the main panel 2012.

[0072] In some embodiments, the first tab 2050A and the second tab 2050B can form abutment tabs 2050A, 2050B, and the inner surfaces of the abutment tabs 2050A, 2050B can contact an outer surface, such as an edge or end seam, of the item B. The abutment tabs 2050A, 2050B, when provided, do not support or suspend the item B.

[0073] The third tooth 2052A and the fourth tooth 2052C form engagement teeth 2052A, 2052C whose edges E1 engage beneath a protrusion or flange provided by item B, which may be provided at an edge or end joint of item B. The engagement teeth 2052A, 2052C support or suspend item B when it is being transported or when item B is not supported at its base.

[0074] The main panel 2012 includes a handle structure. The handle structure may include at least one handle opening. In the illustrated embodiment, the blank 2010 includes two handle openings. Each handle opening is defined in or punched from an area of ​​the main panel 2012 centered between four openings A3, A4 arranged in two adjacent pairs of openings A3, A4. The handle openings are defined by pairs of handle tabs 2064 hinged to the main panel 2012 by respective hinge connections in the form of fold lines 2063. The fold lines may be positioned adjacent to each other or perpendicular to each other. The pairs of handle tabs 2064 are separated from each other by cuts or severance lines.

[0075] The handle opening may be substantially square or diamond shaped. The handle opening may provide a receiving element for receiving a retention or stabilizing pin or lug 28 of the forming jig 10.

[0076] The blank 2010 may include at least one stabilizing device. In the illustrated embodiment, the blank 2010 includes two stabilizing devices, each provided by one of the handle openings. Each stabilizing device includes an opening in the main panel 2012. Each stabilizing device is configured to receive an abutment peg or dog 28 of the packaging machine.

[0077] The openings forming at least a portion of the stabilizing device can be non-circular in shape and can be substantially square or diamond shaped. The opening or openings in the main panel 2012 that provide the stabilizing device can be defined by punching at least one tab out of the panel in which it is formed and hinged.

[0078] Looking at the construction of carrier 2090 from blank 2010, blank 1010 can be formed into assembled carrier 2090 as shown in Figure 5. Figures 1-3B show an apparatus or fixture 10 for forming blank 2010 into article carrier 2090 for a group of articles B.

[0079] The fixture 10 includes a top wall 12 and a pair of opposed side walls 14, 16 depending from the top wall 12. A first end wall 18 depends from the top wall 12 and extends between the pair of opposed side walls 14, 16. The second end 8 of the fixture 10 is open. The top wall 12 includes orifices or openings A1, A2 in its inner surface. The orifices A1, A2 can extend through the top wall 12 to its outer surface to define openings therethrough. The orifices A1, A2 can be at least partially bottomed. In the illustrated embodiment, the top wall 12 includes six openings A1, A2 arranged in a 2x3 matrix or array. The openings A1, A2 include four endmost openings A2 and a pair of intermediate openings A1 disposed therebetween. The extreme opening A2 may be partially bottomed and define an end stop 24 that prevents or inhibits an item B from passing through the top wall 12. The intermediate opening A1 may define an opening A1 through the top wall 12.

[0080] Each of the pair of opposed side walls 14, 16 includes a blank-receiving recess in the form of a passage CH extending from the open end 8 to the closed end defined by the end wall 18. The passage CH in the first side wall 14 is opposite the passage CH in the second side wall 16. The passage CH is located adjacent to the top wall 12. The first end wall 18 includes a blank-receiving recess in the form of a passage CH extending across the first end wall 18 between the passage CH in the first side wall 14 and the passage CH in the second side wall 16. The passage CH, referring to FIG. 2C , defines a ledge 30 against which the blank 2010 can rest when received in the blank-receiving recess. The blank-receiving recess aligns the blank 2010 with respect to the fixture 10.

[0081] The jig 10 includes at least one stabilizing peg 28 extending from the top wall 12 into the interior of the jig 10. The illustrated embodiment includes a pair of stabilizing pegs 28 extending from the top wall 12 into the interior of the jig 10. Each of the stabilizing pegs 28 has a generally pyramidal shape. The stabilizing pegs 28 maintain or hold the blank 2010 in place when applying the blank to the article B, specifically when the side and end panels 2018, 2020, 2014, 2016 fold relative to the main panel 2012, and the stabilizing pegs 28 prevent or reduce slippage of the blank 2010 relative to the jig 10 and / or article B when the folded side and end panels 2018, 2020, 2014, 2016 disengage from the blank-receiving recesses.

[0082] Orifices A1, A2 include or define an interior wall; that is, a portion of top wall 12 provides the hole wall. The hole wall is interrupted or includes a recess 26 that is shaped to receive one of first tab 2050A and second tab 2050B when folded outwardly from the plane of main panel 2012. Recess 26 may define the shape of a trapezoidal prism. First tab 2050A and second tab 2050B can be folded into recess 26 outside the hole wall of orifice A1, A2.

[0083] The end stops 24 may be positioned to prevent or inhibit insertion of item B beyond or past the recess 26 such that the free edges of the first tab 2050A and the second tab 2050B (the free edges being defined by portions of the openings A1, A2) are prevented or inhibited from engaging with item B below the flange protrusion.

[0084] The jig 10 includes at least one fold guide, die, or cut 16b, 18b, 14b, 8b extending from the top wall 12. The fold guide 16b, 18b, 14b contacts one of the side or end panels 2018, 2020, 2014, 2016 for folding the side or end panels 2018, 2020, 2014, 2016 relative to the main panel 2012 for that side or end of the group of articles B.

[0085] The fixture 10 includes an article grouping device in the form of a plurality of surfaces 20, 22 that partially surrounds the article B. The plurality of surfaces 20, 22 includes a pair of opposed surfaces 20 provided by a portion of the pair of opposed side walls 14, 16 and an end surface 22 provided by the first end wall 18. In the illustrated embodiment, the end surface 22 includes a non-linear shape and may be curved or contoured to complement the cylindrical wall of the article B. In other embodiments, the first end wall 18 may be linear or planar in shape.

[0086] First end wall 18 includes opening H, which may provide a viewing window to allow an operator to monitor the interior of jig 10 during use to ensure accurate alignment of blank 2010 and / or to inspect the positioning of blank 2010 and jig relative to item B. Opening H may also allow an operator to inspect the engagement of blank 2010 with item B prior to removal of jig 10. In some embodiments, opening H may be used by an operator as a handle to facilitate handling of jig 10.

[0087] Referring to FIG. 1B, a stabilizing peg 28 extends a first distance L1 from a lower or inner surface Ls of the top wall 12 of the fixture 10.

[0088] The passageway CH includes a ledge 30 defining an upwardly facing surface, or a surface that faces toward the lower or inner surface Ls of the top wall 12. The surface of the ledge 30 is spaced a second distance L2 from the lower or inner surface Ls of the top wall 12. The second distance L2 is greater than the first distance L1.

[0089] The lowermost or front edge or surface of break lines 8b, 16b, 18b is spaced a third distance L3 from the lower or inner surface Ls of top wall 12. Third distance L3 is less than first distance L1.

[0090] The stabilizing peg 28 extends a fourth distance L4 beyond or below the lowermost or front edge or surface of the break lines 8b, 16b, 18b.

[0091] The upwardly facing surface of the ledge 30 provided by the passage CH is spaced a fifth distance L5 from the lowermost, innermost edge of the stabilizing peg 28. The fifth distance L5 defines a clearance for insertion of the blank 2010 without interference from the stabilizing peg 28.

[0092] The article grouping devices take the form of protrusions or ribs extending from the side walls 14, 16 and end wall 18 into the interior of the fixture 10. The protrusions or ribs are spaced a sixth distance L6 from the ledge 30 of the aisle CH. The side walls 14, 16 have a thickness L7, as shown in FIG. 3A. The protrusions or ribs have a thickness L8, which is greater than thickness L7. A gap, void, or recess G is defined by the inner surfaces of the side walls 14, 16 and the inner surface 20 of each of the protrusions or ridges, with the inner surface 20 of the protrusions or ridges being offset inwardly a ninth distance L9 from the inner surface of the side walls 14, 16 from which the protrusions or ridges extend.

[0093] The inner surfaces of the pair of opposed side walls 14, 16 are spaced apart a tenth distance L10. The inner surfaces 20 of the opposed protrusions or ridges are spaced apart an eleventh distance L11. The tenth distance L10 is greater than the eleventh distance L11. In this manner, an area or gap G is provided inside the fixture 10 to accommodate the side walls 2018, 2020 of the article carrier 2090 when folded around the sides of the article grouping, as best shown in Figures 13A and 13B.

[0094] 6-9 illustrate use of the jig 10 to form an article carrier 2090 from a blank 2010. FIG. 6 illustrates a stage of construction in which the blank 2010 is inserted into the jig 10, and the blank 2010, in a flat configuration, is slid into the aisle CH through the second open end 8 of the jig 10, as indicated by directional arrow D1. Side panels 2018, 2020 rest against the ledges 30 of the aisle CH on each of the opposing side walls 14, 16 of the jig 10. When fully inserted, one of the end panels 2014, 2016 of the blank 2010 rests against the ledge 30 of the aisle CH on the first end wall 18 of the jig 10. FIG. 12 illustrates the blank 2010 in a fully inserted position relative to the jig 10 (the position of the blank 2010 is indicated by dashed lines), with cross sections of the side walls 14, 16 and end wall 18 removed for illustrative purposes. Figure 12 shows how the break lines 8b, 14b, 16b, 18b align with the side and end panels 2018, 2020, 2014, 2016 and their respective hinge connections 2017, 2019, 2013, 2015. Figure 12 also shows how the abutment tabs 2050A, 2050B align with the recesses 26 in the orifices A1, A2.

[0095] A group of articles B is received within the jig 10; in some embodiments, the group of articles B is received by sliding the jig 10 over the group of articles, as indicated by directional arrow D2 in FIG. 7, so that articles B pass through the open end 8 of the jig 10. In other embodiments, articles B may be received by lowering the jig 10 over articles B, so that articles B pass through openings defined in part by side walls 14, 16 and end wall 18. In yet other embodiments, articles B may be received by a combination of lowering and sliding the jig over articles B. As articles B are received, the blank 2010 rests against the top ends of articles B, and the jig 10 rests against the blank 2010, allowing end portions of the stabilizing pegs 28 to pass through openings in the main panel 2012. The break lines 8b, 14b, 16b, 18b can rest against the side and end panels 2018, 2020, 2014, 2016.

[0096] The operator can push the jig 10 downward, as indicated by directional arrow D3 in FIG. 8 , to cause the side and end panels 2018, 2020, 2014, 2016 to fold relative to the main panel 2012. In doing so, item B is received in a respective one of the item retention structures RT1, RT2, and the teeth or tabs 2050A, 2050B, 2052A, 2052C fold outwardly of the main panel 2012. The engaging teeth 2052A, 2052C engage item B beneath the flanges or protrusions. The abutment tabs 2050A, 2050B fold along with the side or end panels 2018, 2020, 2014, 2016 from which they extend and abut against the side walls of item B. The abutment tabs 2050A, 2050B can abut against the side walls or edges of the flanges or protrusions of item B. 13A shows the jig 10 being pushed down over the item B so that the top end of the item B is received in the openings or orifices A1, A2 in the top wall 12. The top end of the item B may abut against the end stops 24.

[0097] To extract the article carrier 2090 and article B from the fixture 10, the fixture 10 is raised or lifted relative to the formed package and article B from the article carrier 2090, as indicated by directional arrow D4 in FIG. 13B. The stabilizing pegs 28 move away from the main panel 2012 to allow the fixture 10 to slide relative to the package, as indicated by directional arrow D5 in FIG. 9. The package slides out through the open end 8 of the fixture 10. The gap G between the article grouping device and the aisle CH provides space to receive the side walls 2018, 2020 of the article carrier 2090 and provides tolerance for separating the package from the fixture 10 as it slides through the open end 8.

[0098] Referring now to Figure 10, an alternative forming jig is shown for use with an alternative blank for forming a top-engaging carton or carrier according to another embodiment of the present disclosure. In the illustrated embodiment, where possible, like reference numerals are used to designate like parts, but with the addition of the prefix "100"; "2100" to indicate that these features belong to the jig and article carrier or secondary package of Figure 10. Because the embodiment of Figure 10 shares many common features with the embodiments of Figures 1-9 and 12-13B, only the differences from that embodiment will be described in more detail.

[0099] The blank 2110 is adapted to receive groups or items B in a 1x4 matrix or array arrangement, and the fixtures 110 are similarly arranged.

[0100] The present disclosure provides an apparatus or tool 10; 110 for forming an article carrier 2090; 2190 from a carrier blank 2010; 2110, the apparatus 10; 110 comprising a body having a top wall 12; 112, opposing side walls 14, 16; 114, 116, and a first end wall 18, the opposing side walls 14, 16; 114, 116 and the first end wall 18 depending from the top wall 12; 112 defining at least one article receiving opening A1, A2 on its inner surface. The apparatus 10; 110 defining at least one break line 8b, 14b, 16b, 18b extending into the apparatus 10; 110. The apparatus 10; 110 includes a blank alignment device CH for aligning a blank 2010; 2110 with at least one article receiving opening A1, A2 and at least one break line 8b, 14b, 16b, 18b. The blank alignment device CH includes a blank receiving recess defined in each of the opposed side walls 14, 16; 114, 116 and the first end wall 18. The blank receiving recess provides a support shelf 30 for the carrier blank 2010; 2110. The blank receiving recess extends from the second open end 8 of the body to the first end wall 18 such that the carrier blank 2010; 2110 is slidably receivable in the blank receiving recess.

[0101] The apparatus or fixture 10; 110 may include an article engagement device in the form of a guide provided by opposed side walls and a first end wall. The guide provides an inwardly facing surface 20, 22 of the body for engaging at least one article B to align the at least one article B with the at least one article receiving opening A1, A2 and the at least one break line 8b, 14b, 16b, 18b. In some embodiments, the apparatus 10; 110 may be configured to apply a carrier blank 2010; 2110 to multiple articles B; in such embodiments, the article engagement device may group the articles B together, or at least maintain the grouping of the articles B, and align the group with the at least one article receiving opening A1, A2 and the at least one break line 8b, 14b, 16b, 18b.

[0102] The apparatus or jig 10; 110 may include a stabilizing device which may take the form of a stabilizing peg 28 extending inwardly from the inner surface of the top wall 12; 112. The stabilizing device extends further from the inner surface of the top wall 12; 112 than the at least one fold break 8b, 14b, 16b, 18b to engage the carrier blank 2010; 2110 before the at least one fold break 8b, 14b, 16b, 18b so that the position and orientation of the carrier blank 2010; 2110 is maintained when the at least one fold break 8b, 14b, 16b, 18b engages the carrier blank 2010; 2110.

[0103] At least one article receiving opening A1, A2 may include a tab receiving recess 26 punched out of a portion of the top wall 12, 112 defining the at least one article receiving opening A1, A2. The tab receiving recess 26 may be positioned adjacent to at least one break line 8b, 14b, 16b, 18b. The tab receiving recess 26 may be positioned collinearly with at least one break line 8b, 14b, 16b, 18b.

[0104] At least one of the article receiving openings A1, A2 may be at least partially bottomed to provide an end stop 24 to prevent or inhibit movement of the body relative to the article B packaged by the article carrier 2090; 2190.

[0105] The body may include a panel receiving recess G disposed between the blank alignment device and the article engaging device. The panel receiving recess G is configured to accommodate at least one folding panel 2014, 2016, 2018, 2020; 2114, 2118 hinged to the article engaging panel 2012 of the article carrier 2090; 2190.

[0106] The article carrier 2090; 2190 may be an upper engaging article carrier.

[0107] The present disclosure also provides an application device or fixture 10; 110 comprising a top wall 12; 112 having a blank-pressing top Ls, a pair of opposed side walls 14, 16, an end wall 18, end openings for inserting a carrier blank 2010; 2110 therethrough, blank-receiving passages CH in at least each of the side walls 14; 16 and optionally in the end wall 18, and registration pegs 28 for insertion into registration openings in the carrier blank 2010; 2110. A distance L2 between the blank-pressing top Ls and the floor of the passage, providing a blank-support shelf 30, is greater than an operating length L1 of the registration pegs 28, where the operating length L1 is the dimension measured between the blank-pressing top Ls and the distal or lowermost end or tip of the registration pegs 28.

[0108] The operating length L1 can be greater than the distance L3 between the blank pressing top portion Ls and the bottom or front edge of the blank panel bend or ridge 8b, 14b, 16b, 18b.

[0109] In this manner, the registration pegs 28 are short enough so that they do not engage with the carrier blank 2010; 2110 when the carrier blank 2010; 2110 is received in the application device 10; 110. The registration pegs 28 are not inserted into or received in the registration or finger openings of the blank 2010; 2110 (or even come into contact with the blank 2010; 2110) when the blank 2010; 2110 is received in the application device 10; 110. This avoids or reduces displacement, deformation, or removal of the blank 2010; 2110 by the registration pegs 28 during insertion of the blank 2010; 2110 into the application device 10; 110. Thus, the blank 2010; 2110 maintains its precise registered position within the application device 10; 110.

[0110] While the registration pegs 28 are inserted into the registration openings of the blanks 2010; 2110 in the process of lowering the application device 10; 110 over the group of articles B, the blanks 2010; 2110 are supported from below by the top or upper ends of the articles B. As a result, deformation of the blanks 2010; 2110 can be reduced during the process of inserting the registration pegs 28. When the registration pegs 28 are inserted, horizontal movement of the blanks 2010; 2110 relative to the application device 10; 110, i.e., movement in the plane of the blanks 2010; 2110, is restricted.

[0111] Each applicator or jig 10, 110 may be used with a selected number of articles that is less than the number of articles for which the jig 10, 110 is designed. For example, the jig 10 may be used to apply a blank having four article retention structures RT1, RT2 arranged in a 2×2 matrix or array. To do so, the blank having the four article retention structures may be inserted all the way into the jig 10 until the blank abuts the end wall 18. Next, a group of four articles in the 2×2 configuration is introduced into the jig 10 in position below the blank. The jig 10 is then lowered to apply the blank to the group of four articles. One of the pins 28 closer to the open end of the jig 10 can be removed from the jig 10 prior to such a blank application process, depending on the blank design. In a similar manner, the jig 110 may be used to apply blanks having two or three article retention structures arranged in a 1×2 or 1×3 matrix or array.

[0112] The present disclosure provides a method of packaging an article, comprising: Sliding the carrier blank 2010; 2110 into the blank-receiving recess in the body of the forming tool 10; 110 through the open end and aligning the carrier blank 2010; 2110 with the body; placing a forming jig 10; 110 over at least one article B; lowering the forming jig 10; 110 onto at least one article B; Engaging at least one article B with an article engaging device 20 / 22 provided by the main body to align the at least one article B with the carrier blank 2010; 2110; pressing a carrier blank 2010; 2110 onto at least one article B; receiving at least one article B at an opening A1, A2 in the top wall 12; 112 of the body; receiving at least one article B in the openings A3, A4 of the article retaining devices RT1, RT2 provided in the engagement panel 2012 of the carrier blank 2010; 2110; folding at least one engagement tab 2050A, 2050B of the article retaining device RT1, RT2 into engagement with at least one article B; folding at least one panel 2014, 2016, 2018, 2020 hinged to the engagement panel 2012 relative to the engagement panel 2012; Raising the forming jig 10;110 relative to the carrier blank 2010;2110 and the at least one article B so that the at least one article B clears the top wall 12;112 of the body; sliding the forming jig 10; 110 relative to the carrier blank 2010; 2110 and the at least one article B so that the carrier blank 2010; 2110 and the at least one article B pass through the open end 8 of the body adjacent the top wall 12, 112; The present invention provides a method comprising:

[0113] The blank 2010; 2110 includes at least a paperboard substrate. The paperboard substrate material can be selected from any conventional paperboard, for example, ranging in weight from about 10 pt. or more, preferably from about 16 pt. or more, up to about 28 pt. (0.0287 in. / about 0.7 mm). Examples of such substrates are 27-point (pt.) SBS cardboard (a solid bleached sulfate paperboard coated on one side under the trade name PrintKote®) manufactured by WestRock® Company, or CNK® cardboard (Coated Natural Kraft® - an unbleached kraft paperboard with a clay coating on one side under the trade name CarrierKote™). The paperboard substrate can be bleached or unbleached cardboard. The cardboard may be coated on at least one side, optionally on the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and cardboard composition.

[0114] The blank 2010; 2110 may include a tear-resistant layer laminated to the paperboard layer. The blank 2010; 2110 optionally includes an adhesive layer between the paperboard substrate and the tear-resistant layer. The tear-resistant layer may be disposed over the uncoated side of the paperboard substrate, formed from 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®, a biaxially oriented polyester, oriented nylon, cross-laminated polyolefins, or high-density polyolefins. The orientation and cross-laminated structure of these materials contribute to their tear-resistant properties. Tear resistance may also be due to the chemistry of the tear-resistant material, such as extruded metallocene-catalyzed polyethylene (mPE).

[0115] 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, it is not necessary to incorporate an adhesive layer. Other suitable materials with a high degree of tear resistance may also be used.

[0116] The adhesive layer may be formed from 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.

[0117] It will be appreciated that various modifications can be made within the scope of the present invention. For example, the size and shape of the panels and openings may be adjusted to accommodate articles of different sizes or shapes. In some embodiments, a machine tool may be used to press the fixture against article B, and the machine tool may press two or more fixtures against separate groups of articles simultaneously.

[0118] It will be appreciated that, as used herein, references to directions such as "top," "bottom," "base," "front," "rear," "edge," "side," "inward," "outward," "above," and "below" do not necessarily limit each panel to such orientation, but may merely serve to distinguish these panels from one another.

[0119] As used herein, the terms "hinge" and "fold line" refer to any manner of line that defines a hinge feature in a blank, facilitates folding portions of a blank relative to one another, or indicates the optimal location for folding a panel about the blank. References to a "hinge" should not necessarily be construed as referring only to a single fold line; in fact, a hinge may be formed from two or more fold lines, each of which may be either straight or curved in shape. Linear fold lines may be positioned parallel to one another when forming a hinge connection, or may be slightly oblique to one another. Curved fold lines may intersect with one another when forming a hinge connection to define a molded panel within the area encompassed by the curved fold lines. A typical example of such a hinge connection may include a pair of arched or arcuate fold lines that intersect at two points to define an elliptical panel therebetween. The 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.

[0120] 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 interrupted cut, a line of aligned slits, a perforation line, and any combination of these options.

[0121] 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-cut lines, cuts, interrupted cuts, slits, perforations, embossed lines, debossed lines, any combination thereof, etc. 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.

[0122] As used herein, the phrase "in registration with" 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 the two overlapping panels. Elements that are registered 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 "aligned" with a second opening in a second panel that is positioned in an overlapping arrangement with the first panel, an edge of the opening may extend along at least a portion of the edge of the second opening and be aligned with the second opening in the thickness direction of the first and second panels. [Explanation of symbols]

[0123] 8 Second open end 8b, 14b, 16b, 18b Folding guide, die, broken wire, ridge 10 Forming jigs, equipment, and application devices 12 Upper wall 14 First side wall 16 Second side wall 18 First End Wall 20 Surface, inner surface, article grouping device, article engagement device 22 End Surface, Article Grouping Device, Article Engagement Device 24 End stop 26 Tab receiving recess 28 Retaining or stabilizing pins or lugs, abutment pegs, dogs, registering pegs, stabilizing pegs 30 Blank support shelf 110 Apparatus, forming jig, application device 112 Upper Wall 114, 116 side wall 2010 Blank, career blank 2012 Main panel, engagement panel 2012A First Corner Area 2013 Folding Lines 2013A First fold line 2014 First End Panel 2015 Folding Lines 2016 Second End Panel 2017 Folding Lines 2017A Second fold line 2018 First Side Panel 2019 Fold Lines 2020 Second Side Panel 2050A Engagement tooth, engagement tab, first tab, abutment tab 2050B Engagement tooth, engagement tab, second tab, abutment tab 2052A Engagement tooth, engagement tab, third engagement tooth 2052C Engagement tooth, engagement tab, fourth engagement tooth, partial tab, partial tooth 2051, 2053, 2055, 2057 Breaks 2063 fold line 2064 Handle tab 2090 Carrier, article carrier 2110 Blank, Carrier Blank 2190 Goods Carrier A1, A2 orifice, item receiving opening B Goods A3, A4 opening, opening CH Blank receiving passage, blank alignment device D1 Blank sliding direction D2 Direction in which the jig slides relative to the group of articles D3 Direction to push the jig downward D4 Direction to lift the jig D5 Direction in which the jig slides against the package E1 Engagement edge Gap, void, panel receiving recess H opening L1 First distance, operating length L2 Second distance L3 Third distance L4 Fourth distance L5 Fifth distance L6 6th distance L7 Thickness L8 Thickness L9 9th Distance L10 10th distance L11 11th distance Ls bottom surface, inner surface, blank pressing top RT1, RT2 Article holding structure

Claims

1. 1. An apparatus for forming article carriers from carrier blanks, the apparatus comprising: a body having a top wall, opposing side walls, and a first end wall, the opposing side walls and the first end wall depending from the top wall, the top wall defining at least one article receiving opening in an interior surface thereof; the apparatus further comprising a blank alignment device for aligning a blank with respect to the at least one article receiving opening, the blank alignment device comprising a blank receiving recess defined in at least each of the opposing side walls, the blank receiving recess providing a support shelf for a carrier blank, the blank receiving recess extending from a second open end of the body toward the first end wall such that a carrier blank is slidably receivable in the blank receiving recess.

2. 10. The apparatus of claim 1, further comprising an article engagement device in the form of a guide provided by the opposing side walls and the first end wall, the guide providing an inwardly facing surface of the body for engaging the at least one article to align the at least one article with the at least one article receiving opening.

3. The device of claim 2 , wherein the body is unitary.

4. 3. The apparatus of claim 2, wherein the apparatus is configured to apply a carrier blank to at least one article, and the article engagement device groups the at least one article together into a group and aligns the group with the at least one article receiving opening.

5. The apparatus of claim 2, wherein the apparatus is configured to apply a carrier blank to at least one article, and the article engagement device maintains the at least one article in a group and aligns the group with the at least one article receiving opening.

6. The apparatus of claim 1 , further comprising a stabilizing device, the stabilizing device comprising a stabilizing peg extending inwardly from the inner surface of the top wall.

7. 7. The device of claim 6, further comprising at least one break extending from the inner surface of the top wall into the interior of the body, the stabilizing peg extending farther from the inner surface of the top wall than the at least one break.

8. 8. The apparatus of claim 7, wherein the stabilizing pegs extend farther from the inner surface of the top wall than the at least one fold break for engaging the carrier blank prior to the at least one fold break so that the position and orientation of the carrier blank is maintained when the at least one fold break engages the carrier blank.

9. The device of claim 1 , wherein the at least one article receiving opening comprises a tab receiving recess punched out of a portion of the top wall defining the at least one article receiving opening.

10. The device of claim 9 , wherein the tab-receiving recess is located adjacent to at least one break line.

11. 10. The device of claim 9, further comprising at least one break extending from the inner surface of the top wall into the interior of the body, the at least one break extending linearly in a direction along the inner surface of the top wall, and the tab receiving recess being aligned in line with the at least one break.

12. The apparatus of claim 1 , wherein the at least one article receiving opening is at least partially bottomed to provide an article end stop.

13. The apparatus of claim 1 , wherein the at least one article receiving opening is at least partially bottomed to provide an end stop to restrain movement of the body relative to at least one article packaged by the article carrier.

14. The apparatus of claim 1 , wherein the body comprises a panel-receiving recess disposed between the blank-alignment device and the article-engaging device.

15. 15. The apparatus of claim 14, wherein the panel receiving recess is configured to accommodate at least one folding panel hinged to an article engaging panel of an article carrier.

16. The apparatus of claim 1 configured to form an upper engaging article carrier.

17. 1. An application device for applying carrier blanks to a group of articles, the application device comprising: a top wall having a blank pressing top portion; a pair of opposing side walls; end walls; an end opening for insertion of a carrier blank therethrough; a blank receiving passage in at least each side wall; and a registration peg for insertion into a registration opening in the carrier blank, the top wall, the opposing side walls, and the end walls together defining an interior of the application device, the registration peg extending from the blank pressing top portion into the interior of the application device and providing a blank support shelf, and a first distance defined between the blank pressing top portion and a floor of the blank receiving passage that is greater than an operating length of the registration peg.

18. 18. The application device of claim 17, wherein the working length of the registration peg is the dimension measured between the top of the blank press and a distal end of the registration peg.

19. 18. The application device of claim 17, further comprising a blanking panel break or ridge extending from the blank pressing top portion into the interior of the application device, and the working length is greater than a second distance defined between the blank pressing top portion and a leading edge of the blanking panel break or ridge.

20. 18. The application device of claim 17, wherein the blank-receiving passage is further provided in the end wall.

21. 1. A method of packaging at least one item, comprising: sliding a carrier blank through an open end of a forming tool into a blank-receiving recess in the forming tool to align the carrier blank with the forming tool; placing the forming tool over at least one article; lowering the forming tool relative to the at least one article; A method comprising:

22. 22. The method of claim 21, wherein the step of positioning the forming tool over at least one article comprises engaging the at least one article with the forming tool to align the at least one article with the carrier blank.

23. 22. The method of claim 21, wherein the step of lowering the forming jig includes pressing the carrier blank against the at least one article, receiving the at least one article in an opening in the forming jig, and receiving the at least one article in an opening in an article holding device provided on the carrier blank.

24. 22. The method of claim 21, further comprising the steps of: raising the forming tool relative to the carrier blank and the at least one article; and sliding the forming tool relative to the carrier blank and the at least one article so that the carrier blank and the at least one article pass through an open end of the forming tool.

Images