Applicator plate, device, and method

Abstract

To provide a new top-engaging clip for grouped articles and a suitable device for mounting the new top-engaging carrier.SOLUTION: This invention is about an applicator plate (10) for use in a device(80) for mounting a group (110) of top-engaging clips in a weakened joined state onto a group of articles ('C'). The applicator plate (10) has an approximately planar body and multiple openings (16a- 26f) formed inside the body. Each opening (16a-26f) has a series of inner walls (16i-16x) arranged as such that each opening (16a-26f) has a polygonal shape.SELECTED DRAWING: Figure 2B

Description

[Technical field]

[0001] The present invention relates to an applicator plate for use in an apparatus for attaching one or more clips to a group of articles, and more particularly, but not by way of limitation, to an applicator plate comprising a plurality of apertures, each aperture having a series of interior walls arranged such that each aperture is polygonal in shape for forming one or more clips to the group of articles. Even more particularly, but not by way of limitation, the present invention relates to an applicator plate for attaching a set of frangibly adjoined clips to a group of articles, the applicator plate being arranged such that the weakened connections between the joined clips are broken to form a series of separate clips and a separate group of articles. Additionally, the present invention relates to an apparatus comprising the applicator plate and a method for forming a group of articles. [Background technology]

[0002] In the packaging field, it is often necessary to provide a consumer with a package that includes multiple primary product containers. The primary product containers may be held together by an upper engaging carrier such that the group of items may be selected and transported as a single unit. One such upper engaging carrier is formed from plastic and includes a series of connected rings that fit around the rimmed edges of the cans, and a group of cans may be held together using such plastic rings. Disadvantages of such plastic rings are that plastic cannot be easily printed to add marketing, branding, and promotional indicia; plastic is not easily recycled; and plastic rings have been associated with health risks to wildlife.

[0003] In order to bring about improvements in this field, in the present application a new upper engaging clip for grouped articles (which is the subject of a separate patent application) and a suitable device for mounting said new upper engaging carrier have been invented. Summary of the Invention [Means for solving the problem]

[0004] According to a first aspect, there is provided an applicator plate for use in an apparatus for applying a set of one or more upper engaging clips to a group of articles, the applicator plate having a generally planar body; and a plurality of apertures in said body, each aperture having a series of interior walls arranged such that each aperture of the plurality of apertures has a polygonal shape.

[0005] Optionally, a top surface of said generally planar body is flat.

[0006] Optionally, each opening has ten interior walls arranged such that the opening is decagonal in shape.

[0007] Optionally, the applicator plate further comprises at least one peg depending from a lower surface of said generally planar body.

[0008] Optionally, said plurality of apertures are arranged in a matrix of rows and columns, and said at least Each peg depends from a location on an edge or rim of the matrix of said openings.

[0009] Optionally, the at least one peg has a flat base and two side walls, the two side walls meeting at a first end of the peg and the two side walls meeting at a second end of the peg, between the first and second ends the two side walls curve outwardly from the first and second ends respectively, and the peg has a substantially leaf-shaped cross-section.

[0010] Optionally, said plurality of apertures comprises twenty-four apertures arranged in four columns and six rows.

[0011] Optionally, said at least one peg comprises fourteen pegs, two pegs located at each end of four columns and five pegs located at each edge of six rows.

[0012] Optionally, each peg is located adjacent two openings in the matrix.

[0013] Optionally, said applicator plate includes a series of openings or recesses through which alignment pegs of a device used with said applicator plate can pass.

[0014] According to another aspect, there is provided an apparatus for attaching a set of weakened bonded upper engaging clips to a group of articles, comprising: (i) an applicator plate as described in any of the relevant paragraphs above; (ii) a base plate for receiving a group of articles; (iii) a reciprocating element coupled to at least one of the applicator plate and the base plate, the reciprocating element operable to cause relative movement of the applicator plate and the base plate toward and away from each other.

[0015] Optionally, said apparatus comprises a top plate coupled to said reciprocating element, said reciprocating element operable to move said top plate towards said base plate.

[0016] Optionally, said applicator plate is associated with a top plate and moves with said top plate towards said base plate.

[0017] Optionally, the applicator plate is constructed and arranged to position and form a set of joined, weakened upper engaging clips on a group of articles located on the base plate, and is constructed and arranged to break the weakened connections between the joined engaging clips of the set to form a discrete number of groups of clipped articles.

[0018] Optionally, a grouping component is provided, said grouping component constructed and arranged to receive a group of items and maintain said group of items in an organized group.

[0019] Optionally, the grouping part comprises four sides, a base and an open top, and a group of cans can be placed on the base and held by the four side walls.

[0020] Optionally, said reciprocating element comprises a handle, a lever arm and a coil spring coupled together such that depression of the handle causes the coil spring to contract, lifting said applicator plate upwardly from said grouping parts.

[0021] Optionally, said apparatus further comprises drive means for moving said reciprocating element up and down.

[0022] Optionally, said applicator plate is releasably attachable to said device.

[0023] Optionally, said applicator plate may be releasably attached to said top plate.

[0024] Optionally, said top plate comprises at least one alignment peg.

[0025] According to yet another aspect, a method of attaching one or more upper engaging clips to a group of articles, comprising the steps of: (i) receiving a batch of articles and maintaining said batch of articles in an organized group; (ii) providing an applicator plate according to any of the relevant paragraphs above; (iii) positioning and forming the one or more upper engaging clips on the group of articles to form one or more groups of clipped together articles.

[0026] Optionally, the one or more upper engaging clips comprise a set of weakened joined upper engaging clips, and the step of arranging and forming the set of weakened joined upper engaging clips forms a discrete number of groups of clipped together articles by breaking weakened connections between the sets of joined upper engaging clips.

[0027] Optionally, the method further comprises: (i) associating a set of weakened bonded upper engagement clips with a lower surface of said applicator plate; (ii) moving the applicator plate and the weakened joined set of upper engagement clips downwardly toward the group of articles.

[0028] Within the scope of this application, it is contemplated that the various aspects, embodiments, examples, features, and alternatives described in the following paragraphs, claims, and / or in the following description and drawings may be used independently or in any combination, for example, a feature described in relation to one embodiment is applicable to all embodiments, unless the features are incompatible with each other.

[0029] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief description of the drawings]

[0030] [Figure 1]1 is a plan view of the upper surface of an applicator plate for use in an apparatus for attaching a set of joined upper engaging clips to a group of articles (e.g., cans) according to a first embodiment of the present invention. [Figure 2A] 2 is a plan view of the underside of the applicator plate of FIG. 1. [Figure 2B] FIG. 3 is a perspective view of the underside and side edge of the applicator plate of FIGS. 1 and 2. [Diagram 3] FIG. 1 is a top plan view of a set of joined top engaging clips, each top engaging clip of the set for grouping together and attaching an array of articles (e.g., a single group of 2×3 arrangement of cans). [Figure 4] FIG. 4 is a top perspective view of an apparatus for applying a set of joined upper engaging clips, such as that shown in FIG. 3, to a group of articles, the apparatus including the applicator plate of FIGS. 1-2B. [Diagram 5] FIG. 5 is a bottom perspective view of a portion of the apparatus of FIG. 4, showing a set of joined upper engaging clips on the underside of the applicator plate and a grouped arrangement of cans to which the set of clips are about to be applied to form groups between four separate 2×3's. [Figure 6A] FIG. 2 is a top perspective view of an applicator plate and a grouped arrangement of articles, with the applicator plate aligned above the group, ready to apply a set of joined upper engaging clips. [Figure 6B] FIG. 7 is a top perspective view of an applicator plate placed on top of the grouped arrangement of articles of FIG. 6, showing the applicator plate applying a set of joined upper engaging clips. [Figure 7A] FIG. 6 is a side perspective view of the apparatus of FIGS. 4 and 5 showing an applicator plate and grouped arrangement of articles, with the applicator plate aligned above the group ready to apply a set of joined upper engaging clips. [Figure 7B]FIG. 6 is a side perspective view of the device of FIGS. 4 and 5 showing an applicator plate applying a set of joined upper engaging clips; [Figure 8] FIG. 5 is a top perspective view of the apparatus of FIGS. 4, 5, 7A, and 7B, showing a grouping part for receiving a group of cans and for maintaining the group of cans as an organized group detached from the rest of the apparatus. [Figure 9] A perspective view from below of a portion of a group of cans showing the applicator plate aligned and placed on top of the group of articles and showing a joined set of clips in the process of being applied to the group. [Figure 10] FIG. 1 is a side perspective view of an apparatus according to various embodiments, showing an applicator plate and a grouped arrangement of articles, with the applicator plate aligned above the group of articles ready to attach a set of joined upper engaging clips to the group of articles. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Detailed descriptions of specific embodiments of the applicator plate, device, and method are disclosed below. It is understood that the disclosed embodiments are merely examples of how certain aspects of the invention may be implemented, and do not represent an exhaustive list of all the ways in which the invention may be embodied. As used herein, the term "exemplary" is used broadly to refer to an embodiment that serves as an example, specimen, model, or pattern. Indeed, it is understood that the applicator plate, device, and method described herein may be embodied in various alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials, or methods are not necessarily described in detail to avoid obscuring the disclosure. The specific structural and functional details described herein should not be construed as limiting the invention, but should be construed merely as a basis for the claims and as a representative basis for teaching those skilled in the art to practice the invention in various forms.

[0032] 3, there is shown a top plan view of a blank 110 forming a set of upper engaging clips 112a, 112b, 112c, 112d weakened and joined by weakened connections 22, 24. The blank 110 is intended to be attached as a single unit to a grouped arrangement of articles 88 (see, e.g., FIGS. 4, 5, 6A, 6B). Each upper engaging clip 112a, 112b, 112c, 112d of the set of clips is attached to a grouped arrangement of articles 88 (see, e.g., FIGS. 4, 5, 6A, 6B). 12c, 112d are optionally attached to the articles in a 2×3 arrangement and separated from the other upper engaging clips 112a, 112b, 112c, 112d to form four separate groups of arranged articles (not shown as such). Beneficially, in some arrangements, the apparatus 80 disclosed herein automatically breaks the weakened connections 22, 24 between the upper engaging clips 112a, 112b, 112c, 112d of a pair of weakened joined upper engaging clips 112a, 112b, 112c, 112d, thereby applying a single blank 110 to the grouped arrangement of articles 88 and forming four smaller groups of articles, each of which is connected by an upper engaging clip 112a, 112b, 112c, 112d.

[0033] To aid in understanding the applicator plate 10, apparatus 80, and methods that are the subject of the present application, the set 110 of weakened joined upper engaging clips 112a, 112b, 112c, 112d will be further described with reference to FIG.

[0034] In the embodiments detailed herein, the terms "clip," "carton," and "carrier" refer to containers for engaging and grouping articles, such as primary product containers, for purposes of non-limitingly illustrating various features of the present invention. It is believed that the teachings of the present invention are applicable to a variety of product containers, whether or not the product containers are tapered and / or cylindrical. Examples of containers include bottles (e.g., metal bottles, glass bottles, or plastic bottles), cans (e.g., aluminum cans), tin cans, pouches, packs, and the like.

[0035] The blank 110 is formed from a sheet of suitable substrate. As used herein, "suitable substrate" will be understood to include any foldable sheet material, such as paperboard, corrugated board, cardboard, plastic, combinations thereof, etc. It should be appreciated that one or more blanks may be suitably used, for example, to provide a carrier structure, as described in more detail below.

[0036] The packaging structures or cartons described herein may be formed from a sheet material such as paperboard. The sheet material may be made of or coated with a material to increase its strength. An example of such a sheet material is tear-resistant NATRALOCK® paperboard manufactured by WestRock. The tear-resistant material may be provided in two or more layers to help increase the tear resistance of the package. Typically, one side of the sheet material may have different characteristics than the other side. For example, the side of the sheet material that faces away from the finished package may be particularly smooth and may have a coating or other surface treatment, such as a clay coating, to provide good printability. Meanwhile, the side of the sheet material that faces inward may be coated, layered, treated, or otherwise prepared to provide one or more of the following properties: tear resistance, good adhesion ability, heat sealability, or other desired functionality.

[0037] In the depicted embodiment, the blank 110 is configured to form a set of four clips 112a, 112b, 112c, 112d for grouping, joining, or otherwise joining exemplary arrangement of exemplary articles 'C'. In the depicted embodiment of FIG. 3, each of the four clips 112a, 112b, 112c, 112d holds together a grouped arrangement of six articles arranged in three rows of two. Articles 'C' are beverage cans having a rim or bordered top edge. Thus, the blank 110 is configured to be formed over a larger grouped arrangement of articles 88. In the depicted embodiment, the arrangement is a 6×4 matrix or array, and in the depicted embodiment, four columns and six rows of articles are provided for grouped arrangement 88 of twenty-four cans 'C'. In this depicted embodiment, blank 110 employs a 3×2 matrix or array of four clips 112 a, 112 b, 112 c, 112 d, with each clip weakened and connected to at least two other blanks 112 b, 112 c, 112 d, 112 a by weakened connections 22, 24 and separation apertures A9. Alternatively, blank 110 may be configured to form a carrier for packaging other types, numbers, sizes of articles and / or for packaging articles in different arrangements or configurations than those depicted herein.

[0038] Referring to FIG. 3, the blank 110 includes four upper engagement clips 112a, 112b, 112c, 112d, each having a main panel for forming the top wall or engagement panel of the clip 112a, 112b, 112c, 112d.

[0039] Each main panel includes at least one item retaining structure R1, R2, R3, R4, R5, R6. In the embodiment of Figure 3, each main panel includes a plurality of item retaining structures R1, R2, R3, R4, R5, R6, specifically six item retaining structures R1, R2, R3, R4, R5, R6 arranged in a 2x3 matrix or array.

[0040] Each of the article retention structures R1, R2, R3, R4, R5, R6 are substantially similar in construction and therefore only one article retention structure will be described in detail In alternative embodiments, the blank 110 may include two or more article retention structures having different sizes, appearances, configurations, and / or structures than those shown, and the applicator plate may be appropriately adapted to accommodate such clips.

[0041] Each article retaining structure includes an opening A1. A plurality of article engaging tabs ti, tii, tiii, tiv, tv, tvi, tvii, tviii, tix, tx (ti-tx) are disposed around the outer edge of the opening A1. Each tab ti-tx is hingedly coupled to the main panel 12 by a fold line 17. Each tab ti-tx is spaced from an adjacent adjacent tab by a cutout or recess 18. Thus, each tab ti-tx includes a first side edge 19 and a second side edge 21. Each tab ti-tx includes a free edge 23 opposite the hinged edge 17. The free edge 23 forms an engagement edge for retaining an article 'C', or at least a portion thereof, within the opening A1. In alternative embodiments, the number, size, appearance, and / or arrangement of the tabs may differ from those described herein. For example, opening A1 may not have a uniform configuration, may not be symmetrical, may have a different number of tabs, may include one or more tabs of different sizes, and / or may have an irregular shape. The applicator plate may be appropriately adapted to accommodate such clips.

[0042] Each of the recesses 18 includes a curved portion 20. In the depicted embodiment, the recesses 18 include rounded ends. That is, the curved portion 20 may be defined by a portion of the circumference of an imaginary circle. A portion of the recesses 18 may be defined by a section of a circle. Another portion of the recesses 18 may be defined by a trapezoid, which may be an isosceles trapezoid. The trapezoid has converging side edges 19, 21. Each of the tabs ti-tx may be hinged to the main panel 12 by a straight fold line 17 that tangently contacts or intersects with the rounded end 20 of an adjacent recess 18.

[0043] The curved portions 20 or rounded ends of the cutout 18 may reduce the likelihood of a tear propagating from the cutout 18 in the main panel 12 .

[0044] In the depicted embodiment, each article holding structure R1 comprises ten tabs ti to tx arranged around the outer edge of the opening A1. The article holding structures R1 define an imaginary circle. Circle C 1 is defined by each vertex of a first polygon defined by fold lines 17 of tabs ti-tx. In the depicted embodiment, the first polygon is a decagon or ten-sided polygon, although in alternative embodiments other polygons having more or fewer sides may be employed. Each of the sides 17 of the first polygon are equal in length.

[0045] The free edges 23 of the tabs ti-tx define a second polygon. The tabs ti-tx have a height defined between the free edge 23 and the hinged edge 17. In the depicted embodiment, the second polygon is a decagon or ten-sided polygon, in other embodiments other polygons having more or less sides may be employed. The second polygon has the same number of sides as the first polygon. Each of the sides of the second polygon is of equal length. In other embodiments, each side of the first polygon and / or the second polygon may not have equal length, each side may have one or more lengths, and / or the number of sides may be different than depicted.

[0046] Each of the main panels 112a, 112b, 112c, 112d includes a matrix or array of item retaining openings R1-R6 arranged in a YxZ configuration, where Y represents the number of rows of items 'C' and Z represents the number of columns of items 'C'.

[0047] In the embodiment depicted in Figure 3, the items 'C' are arranged in a 3 x 2 matrix. The width of the main panel 12 may be equal to twice the maximum width of the items 'C'. The length L of the main panel 12 may be equal to three times the maximum width of the items 'C'.

[0048] The diameter of the imaginary circle may be smaller than the maximum diameter of item 'C' and larger than the diameter of a rim, cap or flange of item 'C' (which is smaller than said maximum diameter).

[0049] Optionally, the main panel 12 may include a handle structure. The handle structure may include a first handle opening A7 and a second handle opening A8. The first handle opening A7 is located in an area cut out of the main panel 12 and centered between the four article retaining structures R1, R2, R3, R4. The second handle opening A8 is located in an area cut out of the main panel 12 and centered between the four article retaining structures R3, R4, R5, R6. The first handle opening A7 may be defined in part by a cushion tab hingedly connected to the main panels 112a, 112b, 112c, 112d by fold lines. The second handle opening A8 may be of a similar structure.

[0050] Optionally, the main panels 112a, 112b, 112c, 112d may include one or more pull tabs T1. The pull tabs T1 may be located substantially at the corners of the main panels 112a, 112b, 112c, 112d. The pull tabs T1 may be substantially triangular in shape. The pull tabs T1 may be positioned to extend the main panels 112 beyond the occupied area of ​​the packaged group of articles C1a, C2a, C1b, C2b, C1c, C2c. In this manner, a user may more easily remove the carriers or clips 112a, 112b, 112c, 112d from the group of articles C1a, C2a, C1b, C2b, C1c, C2c.

[0051] Optionally, the main panels 112a, 112b, 112c, 112d include at least a paperboard substrate and a tear resistant layer laminated together. Optionally, the main panels include an adhesive layer between the paperboard substrate and the tear resistant layer. The paperboard substrate material may be selected from any conventional paperboard, e.g., having a weight of about 10 points to about 14 points, preferably about 11 points to about 14 points. An example of such a substrate is WestRock's 12 point SBS board or CNK board. The paperboard substrate may be a bleached board. The board may be bleached or unbleached. The board may be coated on at least one side (optionally the side opposite the lamination side) with a conventional coating selected for compatibility with the printing method and board composition.

[0052] The tear resistant layer may be disposed over the uncoated side of the paperboard substrate and may be formed of a polymeric material and secured to the substrate. The tear resistant layer provides toughness to the laminate structure. Suitable tear resistant materials include, but are not limited to, tear resistant laminate sheet materials (e.g., NATRALOCK®) that may include layers of n-axis oriented films (e.g., MYLAR®, a biaxially oriented polyester, oriented nylon, cross-laminate polyolefin, high density polyolefin). The orientation and cross-laminate structure of these materials contribute to the tear resistance. Tear resistance may also be due to the chemistry of the tear resistant material, such as extruded metallocene catalyzed polyethylene (mPE).

[0053] 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, there is no need to incorporate an adhesive layer. Other suitable materials having a high level of tear resistance may be used.

[0054] The adhesive layer may be formed of a polyolefin material, such as low density polyethylene (LDPE). The adhesive layer may be disposed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

[0055] Reference is now made to Figure 4, with respect to the apparatus 80 and applicator plate 10 used to assemble the blanks 110 into carriers containing a group of articles. In Figure 4, a perspective view of the apparatus 80 is shown which is capable of accepting an input of primary products (such as, but not limited to, bottles and cans, hereinafter referred to as article 'C').

[0056] The apparatus 80 is for applying a set of joined upper engaging clips 110 to a group of articles 88 (e.g., cans 'C'). The apparatus includes an applicator plate 10 (see Figs. 1, 2A, 2B) which will be described in more detail below. The apparatus 80 is used with a grouping part 86 (see Figs. 5, 6B, 7B, and 8) which is constructed and arranged to receive the group of articles 88 and maintain the group of articles 88 in an organized group. Optionally, the grouping part 86 is a third packaging carton which may optionally be formed from corrugated cardboard and which may be removed from the apparatus together with the clipped cans. Alternatively, the grouping part may be a tray which is used to collect individual cans 'C' from a can product production line (not shown) into a set 88 of cans 'C'. The apparatus includes a reciprocating element 84 and a base plate 78. Optionally, a reciprocating element 84 is coupled to the applicator plate 10, appropriately positioned relative to the base plate 78, and operable to move the applicator plate 10 downwardly toward the base plate 78 and upwardly away from the base plate 78.

[0057] The applicator plate 10 is constructed and arranged to form a set of weakened joined upper engaging clips 110 on a collection of articles 88 located on, in or within the grouping piece 86. The applicator plate 10 is also constructed and arranged to break the weakened connections 22, 24 between the sets of joined engaging clips 112a, 112b, 112c, 112d to form a discrete number of groups of clipped together articles. In this depicted arrangement, four separate groups of six articles are formed, each clipped together in a 2 by 3 arrangement.

[0058] As shown in Figures 5, 6B, 7B and 8, the grouping part 86 comprises four sides, a base and an open top. The grouped arrangement of articles 88 can be placed on the base and held by the four side walls. In another embodiment, it is contemplated that the grouping part 86 can take on various structures, configurations and forms suitable for easily arranging the group of articles 88 and for maintaining the articles 88 as an organized group. In this way, when the device 80 is operational and the applicator plate 10 is lowered to the top of the article 'C' and positioned on the article 'C', the article 'C' is immobile and does not move, and the relative position of the article 'C' does not vary, allowing the applicator plate 10 to position and / or form the set of upper gripping clips 110 connected in a weakened state.

[0059] The reciprocating element 84 comprises a handle 'H', a lever arm 98 and a coil spring 90 coupled together such that movement of the handle 'H' expands or contracts the spring 90 to lift the top plate 82 and (connected thereto) the applicator plate 10 upwardly from or downwardly towards the base plate 78. The handle 'H' may be coupled to a lower end of the coil spring 90 by one or more handle arms 92a, 92b. The upper end of the coil spring 90 may be coupled to a first end of a lever arm 98. The lever arm 98 may pivot about a central fulcrum. The second end of the lever arm 98 may be coupled to a rod 96. The rod 96 may be coupled to the top plate 82. The applicator plate 10 may be releasably attached to the device 80. Optionally, the applicator plate 10 may be releasably attached to the top plate 82. Thus, if clips with a different arrangement of openings or sets of weakened connected clips are used to group a plurality of articles in an arrangement different from that shown in Figure 3, an applicator plate with a matching configuration or similarly shaped openings would be required, but the new applicator plate can replace the original applicator plate 10 without having to replace the entire apparatus 80. Applicator plate 10 may also be referred to as an "applicator mold" since it is a component constructed and arranged to mould or form the upper gripping clips onto a group of articles 88.

[0060] The device 80 may include drive means for raising and lowering the reciprocating element 82, thereby avoiding (and making unnecessary) manual articulation using a handle. Such an arrangement may incorporate motors, pistons, and / or other suitable electromechanical components to facilitate automated raising and lowering of the applicator plate 10. However, in the operation shown here, the device is manually operated.

[0061] 1, 2A and 2B, an applicator plate 10 that may optionally be utilized in apparatus 80 to apply the weakened bonded set of upper engaging clips 110 to a group of articles 88. Applicator plate 10 has a generally planar body with a plurality of apertures 16a-24f formed therein. Optionally, apertures 16a-24f are arranged in a matrix that matches the arrangement of apertures A1 in set 110 of upper engaging clips. Thus, in this embodiment, when used with upper engaging clip 110 as shown in Figures 3 and 4, applicator plate 10 includes a 4 column by 6 row arrangement of openings 16a, 16b, 16c, 16d, 16e, 16f, 18a, 18b, 18c, 18d, 18e, 18f, 20a, 20b, 20c, 20d, 20e, 20f, 26a, 26b, 26c, 26d, 26e, 26f (collectively referred to herein as 16a-26f). In alternative embodiments or arrangements, applicator plate 10 may have a different number and / or arrangement of articles.

[0062] Each opening (16a to 26f) in the applicator plate 10 is 0. Each opening 16a-26f includes a series of interior walls arranged such that each opening 16a-26f has a shape, size, configuration, and relative position to cooperate with the arrangement of item retaining structures R1, R2, R3, R4, R5, R6. Thus, in this optional arrangement depicted, each opening 16a-26f has a polygonal cross-sectional shape. Optionally, each opening 16a-26f has ten equally sized and equally angularly spaced interior walls 16i-16x arranged such that each opening 16a-26f is decagonal.

[0063] The top surface 12 of the generally planar body of the applicator plate 10 is optionally flat and optionally a smooth surface. In another arrangement, the top surface 12 may include attachment means for coupling the applicator plate 10 to a top plate 82 of a reciprocating part 84. In some arrangements, the applicator plate 10 also functions as the top plate 82 and is directly coupled to the reciprocating part 84.

[0064] Applicator plate 10 may also include at least one alignment peg (herein simply referred to as "peg") 28a, 28b, 28c, 28d, 30a, 30b, 30c, 30d, 30e, 32a, 32b, 32c, 32d, 32e depending from underside 14 of the generally planar body. This is best illustrated in Figures 2A and 2B. Optionally, at least one peg 28a-32e has a flat base 'b' and side walls S1, S2. At least one peg 28a-32e is symmetrical. The two side walls S1, S2 meet at a first end of at least one peg 28a-32e. The two side walls S1, S2 meet at a second end of the at least one peg 28a-32e, and between the first and second ends the two side walls S1, S2 curve outwardly away from the first and second ends, respectively. Optionally, at least one peg 28a-32e has a substantially leaf-shaped cross-section.

[0065] As described above, the plurality of openings 16a-26f are arranged in a matrix of rows and columns. Each of the four columns of openings 16, 18, 20, 26 includes six rows of openings a, b, c, d, e, f. The openings 16a, 18a, 20a, 26a define a first end of the matrix of openings 16a-26f, the openings 16a, 16b, 16c, 16d, 16e, 16f define a first edge of the matrix of openings 16a-26f, the openings 16f, 18f, 20f, 26f define a second end of the matrix of openings 16a-26f, and the openings 26a, 26b, 26c, 26d, 26e, 26f define a second edge of the matrix of openings 16a-26f.

[0066] At least one peg 28a-32e depends or depends from the lower surface 14. The pegs 28a-32e may be positioned at positions along the first and second ends of the matrix of openings 16a-26f. The pegs 28a-32e may be positioned at positions along the first and second edges of the matrix of openings 16a-26f. Optionally, each peg 28a-32e is positioned adjacent to two openings 16a-26f of the matrix. Each peg 28a-32e may be shaped to fit into a gap between the lower edges of the two inner walls of one opening and the lower edges of the two inner walls of another adjacent opening. For example, peg 28b, located along the first end of the matrix of openings 16a-26f, fits between the lower edges of the inner walls 16i, 16ii of opening 16a and the lower edges of the inner walls 18ix, 18viii of opening 18a (see FIG. 2A).

[0067] In the depicted arrangement, each peg 28a-32e comprises fourteen pegs 28a-32e. The arrangement of fourteen pegs 28-32e comprises two pegs 28a, 28b; 28c, 28d at each end of the four rows of apertures, and five pegs 30a, 30b, 30c, 30d, 30e, 32a, 32b, 32c, 32d, 32e at each of the first and second edges of the matrix of apertures 16a-26f. The applicator plate may be constructed from a single member, with one or more pegs 28a-32e. It may be made from the above parts and may even be formed from a number of optionally cooperating parts, for example having a modular construction.

[0068] The shape, size and location of the alignment pegs 28a-32e allow the pegs to fit closely between two adjacent articles in the group of articles 88 (see Figures 6B and 9). Thus, when the applicator plate 10 is lowered onto the group of articles 88, the pegs 28a-32e will be located in the gap between the two adjacent articles (e.g., in Figure 9, peg 28c is located between articles C3f and C4f). The pegs 28a-32e located around the periphery of the group of articles 88 cooperate to ensure that each article 88 is held securely by the grouping piece 86 at its bottom end, and that each article 88 is held in the correct position while being carefully aligned with the applicator plate 10 into which it is introduced.

[0069] The construction of the upper engaging clips and grouped articles from the blank 110 may then be carried out in the following manner. First, a group of articles 88 is received and, optionally, maintained as an organized group of articles. This may be achieved with the aid of grouping components 86. The applicator plate 10 is provided with and associated with the weakened joint upper engaging clip set 110 and the top plate 82, as described above. More specifically, the weakened joint upper engaging clip set 110 is associated with the lower surface 14 of the applicator plate 10. The weakened joint upper engaging clip set 110 is associated with the lower surface 14 of the applicator plate 10 by vacuum, temporary mechanical attachment, or other suitable means. The applicator plate 10 and its associated set of weakened joined upper engaging clips 110 are then lowered towards the group of articles 88 by actuation of the reciprocating element 84 of the apparatus 80, the pegs 28a-32e are then positioned around the articles to ensure proper alignment between the applicator plate 10, clips 110 and the group of articles 88, and the set of weakened joined upper engaging clips 110 are then positioned and pressed onto and formed into the group of articles 88. In pressing and forming the upper engaging clips 110 onto the group of articles, the weakened connections 24 between the joined upper engaging clips 112a, 112b, 112c, 112d are broken, thereby automatically forming a discrete number of groups of articles clipped together. Alternatively, the set of weakened joined upper engaging clips 110 may be placed directly on top of the grouped arrangement of articles, and the lower surface 14 of the applicator plate 10 may be associated with the set of weakened joined upper engaging clips 110 only when the applicator plate 10 moves downward onto the group of articles 88.

[0070] The apparatus facilitates relative movement of the blank 110, the applicator plate, and the group of articles in an aligned state. Optionally, the blank 110 and the applicator plate 10 are lowered relative to the group of articles 88 such that each of the plurality of openings 16a-26f of the applicator plate 10 and each of the article retaining structures R1, R2, R3, R4, R5, R6 of each of the upper engaging clips 112a, 112b, 112c, 112d of the blank 110 are aligned with each of the articles 'C' of the group of articles 88. Additionally, the applicator plate 10 is aligned with the weakened and joined set of upper engaging clips 110 such that the inner walls 16i-16x of each of the polygonal openings 16a-26f are aligned with the fold lines 17 of the corresponding article retaining structures R1, R2, R3, R4, R5, R6 of the upper engaging clips 112a, 112b, 112c.

[0071] Relative movement between the group of articles 88, the applicator plate 10, and the blank 110 causes the top of each article 'C' to pass through the main panel of each of the top engagement clips 112a, 112b, 112c, 112d. As the applicator plate 10 moves downward against the top article 'C', the tabs ti-tx of each of the article retention structures R1, R2, R3, R4, R5, R6 fold out of the plane of the main panel and engage under the edge or flange of the article 'C'. The depth of the applicator plate 10 is sufficient to allow the tabs ti-tx of each of the article retention structures R1, R2, R3, R4, R5, R6 to fold into full engagement with the respective article 'C'. In this manner, the tabs ti-tx grip or retain the article 'C' and inhibit or prevent the article 'C' from unintentionally separating from the main panel of each of the upper engagement clips 112a, 112b, 112c, 112d. Although the apparatus 80 provides a movable top plate 82 which holds the applicator plate 10 and blanks 110 and moves downwardly towards the stack 88, it will be appreciated that in an alternative arrangement, the base plate 78 which houses the stack 88 may move upwardly towards the top plate 82 which holds the applicator plate 10 and blanks 110. In yet another alternative arrangement not depicted, both the top plate 82 and base plate 78 may move towards each other.

[0072] Another optional feature of the top engaging clips 112a, 112b, 112c, 112d is that the main panels are each defined by a perimeter to which no other portion of the top engaging clips 112a, 112b, 112c, 112d is connected. That is, the top engaging clips 112a, 112b, 112c, 112d are not connected to other panels (such as, but not limited to, side or end wall panels that extend laterally of the articles in other carriers). Thus, the perimeter of the main panel 12 is defined entirely by a free edge, a cut edge, or an edge without a hinge structure. The perimeter of the main panel may be folded at an angle relative to the remainder of the main panel by folding over the polygonal arrangement of tabs ti-tx of the article retention structures R1, R2, R3, R4, R5, R6 and engaging under the edge or flange of the article 'C'. Thus, the weakened connections 22, 24 are broken and the weakened joined set of upper engaging clips 110 automatically separates into four separate upper engaging clips 112a, 112b, 112c, 112d, thereby forming four separate groups of articles.

[0073] Referring now to Figure 10, an alternative embodiment of the present invention is illustrated. In the depicted second embodiment, like numerals have been used to indicate like parts wherever possible, except that the numerals have been prefixed with "200" to indicate that each feature belongs to the second embodiment. Since this alternative embodiment shares many features with the first embodiment, only the differences from the embodiment depicted in Figures 1-9 will be described in detail.

[0074] In Figure 10, the apparatus 280 again comprises a top plate 282 which moves downwardly towards a group of articles 288 held in a grouping component 286 on a base plate 278. However, in this arrangement, the top plate 282 comprises a series of pegs 228a-232e and the applicator plate 210 comprises a series of recesses or openings through which the series of pegs 228a-232e can pass. In this manner, the pegs 228a-232e ensure that the group of articles 288 and the applicator plate 210 are both accurately positioned and held in position as the top plate 282 moves downwardly towards the group of articles 288. The pegs may be removable to accommodate different articles, different sizes of groups of articles, and / or different configurations of groups of articles.

[0075] It will be understood that various modifications are possible within the scope of the invention, for example, the size and shape of each panel and opening may be adjusted to accommodate items of various sizes or shapes. In another embodiment of the invention, it is contemplated that the set of weakened joined clips may be replaced with a single clip for a single group of items.

[0076] As used herein, the terms "top," "bottom," and "front" refer to It will be recognized that directional references such as "ont," "back," "end," "edge, side," "inner," "outer," "upper," and "lower" do not necessarily limit each panel to such an orientation, but may merely be to distinguish these panels from one another.

[0077] As used herein, the terms "hinged connection" and "fold line" refer to any line that defines a hinge feature of the blank and facilitates folding one portion of the blank relative to another portion or otherwise indicates an optimal panel folding location for the blank. Typically, the fold line is a score line, an embossed line, or a debossed line. References to a hinge connection or fold line should not be construed as necessarily referring to only a single fold line. Indeed, it is contemplated that a hinge connection could be formed from any one or more of a short slit, a line of weakness, or a fold line without departing from the scope of the present invention.

[0078] As used herein, the term "severance line" refers to any line that facilitates separation of portions of a substrate from one another or indicates an optimal separation location. A severance line may be a line of weakness or otherwise weakened, a tear line, a cut line, or a slit.

[0079] It should be understood that the hinge connection, cut line, and fold line may each include elements formed in the blank substrate, such as perforations, short slit lines, half cut lines, single half cuts, cut lines, interrupted cut lines, slits, scores, any combination thereof, etc. These elements may be sized and positioned to provide the desired functionality. For example, the perforations may be sized or designed to be weakened to the extent that they define the fold and / or cut lines. The perforations may be designed to be easily folded and tear resistant, to be easily folded and easily broken with more force, or to be easily broken with little force.

Claims

1. An applicator plate configured to apply a blank to a group of articles and assemble the blank into an upper engaging carrier that packages the group of articles, A substantially planar body; a plurality of openings formed in the body as an array of openings in rows or columns, or in a matrix of one or more rows and one or more columns, each of the plurality of openings corresponding to a respective article of the group of articles to which the upper engagement carrier is to be applied; an alignment peg depending from a lower surface of the generally planar body; An applicator plate, wherein the alignment peg is positioned at an end or side of the array of openings and adjacent to at least one of the plurality of openings for alignment of the applicator plate with at least one article of the group of articles when applying the upper engagement carrier to the group of articles.

2. The applicator plate of claim 1 , wherein an upper surface of the generally planar body is flat.

3. 2. The applicator plate of claim 1, wherein each opening has ten interior walls arranged such that the opening is decagonal in shape.

4. The applicator plate of claim 1 , wherein each aperture of the plurality of apertures has a series of interior walls arranged such that each aperture has a polygonal shape.

5. 2. The applicator plate of claim 1, wherein the plurality of apertures are arranged in a matrix of rows and columns, and the alignment pegs depend from the lower surface of the body at locations to ends or edges of the matrix of apertures.

6. 6. The applicator plate of claim 5, wherein the alignment peg has a flat base and two side walls, the two side walls meeting at a first end of the peg and a second end of the peg, and between the first end and the second end, the two side walls extend outwardly from the first end and the second end so as to diverge from the first end and the second end, respectively.

7. 7. The applicator plate of claim 6, wherein the plurality of apertures comprises twenty-four apertures arranged in four columns and six rows, or six columns and four rows.

8. 8. The applicator plate of claim 7, comprising fourteen alignment pegs, two alignment pegs at each end of said matrix of openings and five alignment pegs at each edge of said matrix of openings.

9. 9. The applicator plate of claim 8, wherein each alignment peg is located adjacent two openings in the matrix.

10. an applicator plate configured to apply the upper engaging carrier to the group of articles, A substantially planar body; a plurality of openings formed in the body and arranged in rows or columns, or in a matrix of one or more rows and one or more columns, each of the plurality of openings corresponding to a respective article of the group of articles to which the upper engagement carrier is to be applied; An applicator plate comprising a series of alignment openings or recesses disposed within the body, wherein alignment pegs of a device used with the applicator plate are configured to pass through the series of openings or recesses.

11. 1. An apparatus for attaching an upper engagement carrier to a group of articles, comprising: An applicator plate according to any one of claims 1 to 10; a base plate configured to receive a group of articles; an apparatus comprising: a reciprocating element coupled to at least one of the applicator plate and the base plate, the reciprocating element operable to cause relative movement between the applicator plate and the base plate so that the applicator plate and the base plate move toward and away from each other.

12. The apparatus of claim 11 , wherein the apparatus comprises a top plate coupled to the reciprocating element, the reciprocating element operable to move the top plate toward the base plate.

13. 13. The apparatus of claim 12, wherein the applicator plate is coupled to or adjacent to the top plate and configured to move with the top plate toward the base plate via the reciprocating element.

14. 14. The apparatus of claim 13, wherein the applicator plate is constructed and arranged to align and form a set of weakened joined upper engagement carriers on a plurality of articles positioned on the base plate, and to break the weakened connections between each of the joined sets of upper engagement carriers to form a discrete number of groups of articles clipped together.

15. 13. The apparatus of claim 12, further comprising a grouping component, said grouping component constructed and arranged to receive said group of articles and maintain said group of articles in an organized group.

16. 16. The apparatus of claim 15, wherein the grouping part comprises four sides, a base, and an open top, and the group of articles can be placed on the base and held by the four side walls.

17. 17. The device of claim 15 or 16, wherein the reciprocating element comprises a handle, a lever arm and a coil spring coupled together such that depression of the handle causes the coil spring to contract and lift the applicator plate upwardly from the grouping parts.

18. 20. The apparatus of claim 17, further comprising drive means for moving the reciprocating element up and down.

19. A device according to any one of claims 11 to 18, wherein the applicator plate is releasably attachable to the device.

20. The apparatus of claim 12 , wherein the top plate comprises at least one alignment peg.

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