Method and system for attaching an article to a carrier

Abstract

A method for at least partially forming a package includes moving a blank and a plurality of articles in a downstream direction through a clip station. The blank can include at least a first attachment panel, a second attachment panel, and a keel portion extending from the first attachment panel to the second attachment panel. The method can further include, while moving the blank and the plurality of articles through the clip station, clipping the first attachment panel and the second attachment panel of the blank to respective articles of the plurality of articles to form a clipped assembly, and moving the plurality of articles toward each other as the clipped assembly is moved downstream, forming a keel by folding the keel portion of the blank between the articles.

Description

Related Applications

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 016,607, filed October 21, 2019.

[0002] [Incorporated by reference] U.S. Provisional Patent Application No. 63 / 016,607, filed April 28, 2020; U.S. Provisional Patent Application No. 62 / 779,689, filed December 14, 2018; U.S. Provisional Patent Application No. 62 / 783,752, filed December 21, 2018; U.S. Provisional Patent Application No. 62 / 796,830, filed January 25, 2019; U.S. Provisional Patent Application No. 62 / 797,585, filed January 28, 2019; U.S. Provisional Patent Application No. 62 / 810,015, filed February 25, 2019; U.S. Provisional Patent Application No. 62 / 820,015, filed March 6, 2019; U.S. Provisional Patent Application No. 62 / 814,412 filed on March 12, 2019, U.S. Provisional Patent Application No. 62 / 817,120 filed on May 1, 2019, U.S. Provisional Patent Application No. 62 / 841,449 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,050 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,057 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,060 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,070 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,080 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,090 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,010 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,020 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,030 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,040 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,052 filed on May 30, 2019, U.S. Provisional Patent Application No. 16 / 426,063 file No. 26,063, U.S. Patent Application No. 16 / 426,066, filed May 30, 2019, U.S. Design Patent Application No. 29 / 692,992, filed May 30, 2019, U.S. Design Patent Application No. 29 / 692,993, filed May 30, 2019, U.S. Design Patent Application No. 29 / 692,994, filed May 30, 2019, U.S. Design Patent Application No. 29 / 692,996, filed May 30, 2019, U.S. Design Patent Application No. 29 / 692,997, filed May 30, 2019 The disclosures of U.S. Patent Application No. 16 / 598,282, filed October 10, U.S. Design Patent Application No. 29 / 709,918, filed October 18, 2019, U.S. Provisional Patent Application No. 62 / 952,839, filed December 23, 2019, and U.S. Provisional Patent Application No. 62 / 956,882, filed January 3, 2020, and U.S. Patent Application No. 16 / 829,346, filed March 25, 2020, are hereby incorporated by reference for all purposes as if set forth herein in their entireties. [Technical field]

[0003] The present disclosure relates generally to a package including a carrier attached to an article and a method of forming the package. More specifically, the present disclosure relates to a method and system for forming a package, for example, by clipping a blank to the article, forming a keel from the blank between the articles, and folding the blank into the carrier. Summary of the Invention

[0004] In general, one aspect of the disclosure relates to a method of at least partially forming a package, the method including moving a blank and a plurality of articles in a downstream direction through a clip station. The blank can include at least a first attachment panel, a second attachment panel, and a keel portion extending from the first attachment panel to the second attachment panel. The method can further include clipping the first attachment panel and the second attachment panel of the blank to respective articles of the plurality of articles while moving the blank and the plurality of articles through the clip station to form a clipped assembly, and moving the plurality of articles toward one another as the clipped assembly moves in the downstream direction to form a keel by folding the keel portion of the blank between the articles.

[0005] In another aspect, the present disclosure generally relates to a system for at least partially forming a package. The system can include a clip station that receives a plurality of articles and a blank including at least a first attachment panel, a second attachment panel, and a keel portion extending from the first attachment panel to the second attachment panel. The clip station can clip the first attachment panel and the second attachment panel of the blank to respective articles of the plurality of articles to form a clipped assembly while moving the blank and the plurality of articles in a downstream direction. The system can further include a junction station that can receive the clipped assembly from the clip station. The junction station can move the plurality of articles toward each other while forming a keel by folding the keel portion of the blank between the articles as the clipped assembly moves in a downstream direction.

[0006] Additional aspects, features, and advantages of the present invention will become apparent from the following description and accompanying drawings.

[0007] Those skilled in the art will appreciate the above advantages and other benefits and advantages of various additional embodiments upon reading the following detailed description of the embodiments with reference to the following drawings, in which: It is within the scope of this disclosure that the above-mentioned aspects are provided individually and in various combinations.

[0008] According to common practice, the various features in the drawings described below are not necessarily drawn to scale. Dimensions of the various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present disclosure.

[0009] Corresponding parts are designated by corresponding reference numbers throughout the drawings. [Brief description of the drawings]

[0010] [Figure 1]FIG. 2 is a plan view of an exterior surface of a blank for forming a carrier according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 is a perspective view of a clipped assembly formed from the blank and article of FIG. 1 according to an exemplary embodiment. [Diagram 3] 2 is a perspective view of a clipped assembly formed from the blank and article of FIG. 1 according to an exemplary embodiment. [Figure 4] FIG. 4 is a perspective view of the clipped assembly of FIGS. 2 and 3 with the pair of containers removed. [Diagram 5] FIG. 4 is a perspective view of a package formed from the clipped assemblies of FIGS. 2 and 3 according to an exemplary embodiment. [Figure 6] 6 is a schematic perspective view of a system and method for folding and forming the clipped assembly of FIGS. 2 and 3 and forming the package of FIG. 5 according to an exemplary embodiment of the present disclosure. FIG. [Figure 7] FIG. 7 is a schematic perspective view of a clip station and a junction station of the system of FIG. 6. [Figure 8] FIG. 8 is a schematic perspective view of a portion of the clip station of FIGS. 6 and 7; [Figure 9] FIG. 8 is a schematic perspective view of a portion of the clip station of FIGS. 6 and 7; [Figure 10] FIG. 8 is a schematic perspective view of a portion of the clip station of FIGS. 6 and 7; [Figure 11] FIG. 8 is a schematic perspective view of a portion of the bonding station and the merging station of FIGS. 6 and 7. [Figure 12] 7 is a schematic perspective view of a portion of the junction station, folding station, and clip station of the system of FIG. 6. [Figure 13] FIG. 13 is a schematic perspective view of a portion of the folding station of FIGS. 6 and 12; [Figure 14] FIG. 13 is a schematic perspective view of a portion of the folding station of FIGS. 6 and 12; [Figure 15]A schematic perspective view of a product flow showing the formation of the clipped assembly of FIGS. 2 and 3, according to an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0011] The present disclosure generally relates to systems and methods for forming packages that can include carriers for holding containers or other articles. The containers can be used, for example, to package food and beverage products. The containers can be made from materials of a composition suitable for packaging a particular food or beverage product, the materials including, but not limited to, plastics such as glass, PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, nylon, aluminum and / or other metals, or any combination thereof. The carriers according to the present disclosure can accommodate a number of differently shaped containers. For purposes of illustration and not limitation of the scope of the present disclosure, the following detailed description describes a beverage container (e.g., an aluminum can) at least partially disposed within an embodiment of the carrier. As used herein, the terms “downward,” “bottom,” “upward,” “top,” “front,” and “rear” indicate directions determined with respect to a fully upright carrier.

[0012] FIG. 1 shows a plan view of an exterior surface 101 of a blank 103 used to form a carrier 105 (FIG. 5) according to a first exemplary embodiment of the present disclosure. The carrier 105 may be provided with one or more containers C as a package 110 (FIG. 5). In some embodiments, the carrier 105 and package 110 may be similar or identical to one or more of the carriers and packages disclosed in the applications incorporated by reference identified above. Generally, an embodiment of the system and method of the present disclosure may feed a series of blanks (e.g., blanks 103) and a plurality of articles (e.g., containers C) in a machine direction (e.g., as shown by arrow MD in FIG. 1 in an exemplary embodiment), clip or otherwise attach the blanks to the articles together, and continue to move the attached blanks and articles while applying adhesive and folding faces of the blanks to form a carrier (e.g., carrier 105) and package (e.g., package 110). In alternative embodiments, the blank 103 may be oriented in other directions with respect to the machine direction MD (eg, the arrow MD may be reversed in FIG. 1).

[0013] As shown in FIG. 5, the carrier 105 is sized to accommodate or support six containers C, with three containers CA1, CA2, CA3 attached to a first or left portion 106 of the carrier 105 and three containers CB1, CB2, CB3 attached to a second or right portion 108 of the carrier 105. In the illustrated embodiment, the containers CA1, CA2, CA3, CB1, CB2, CB3 may be beverage cans or any other suitable type and size of container without departing from this disclosure. The carrier 105 may be sized and shaped to hold more or less than six containers. In one embodiment, the first portion 106 and the second portion 108 of the carrier 105 each have three containers, while in other embodiments, the first portion 106 and the second portion 108 of the carrier 105 may carry more or less than three containers without departing from this disclosure.

[0014] As shown in FIG. 1, the blank 103 has a longitudinal axis L1 and a transverse axis L2. The blank 103 has a first side 107 for forming a first portion 106 of the carrier 105 and a second side 109 for forming a second portion 108 of the carrier 105. In the illustrated embodiment, the blank 103 may be moved in a system to form a package 110 (e.g., system 200, described in more detail below) having the first side 107 on the left side of the system and the second side 109 on the right side of the system, as determined when looking in the downstream machine direction as indicated by arrow MD in FIG. 1. The first side 107 and the second side 109 of the blank 103 are foldably connected at a transverse fold line 112 that forms a transverse centerline CL of the blank 103, as shown. In the illustrated embodiment, the first side 107 of the blank 103 comprises a first central panel 125a having a pair of adhesive or glue openings 127a at an interior portion thereof and a pair of surface features or areas 129a adjacent each of the adhesive openings 127a. As shown in Figures 1, 2 and 4, the surface areas 129a are represented generally by rectangles that may not be visible in the actual blank. In some embodiments, the surface features 129a may be, for example, embossed features or other at least partially raised or recessed surface configurations. In some embodiments, the surface features 129a may be omitted.

[0015] In the illustrated embodiment, the first container-retaining panel or first mounting panel 131a is foldably connected to the first central panel 125a at a transverse fold line 133a. The first mounting panel 131a includes a container-retaining portion 135a (e.g., a crown panel) defined at least partially between a pair of longitudinally spaced transverse fold lines 137a, 139a interrupted by a respective pair of longitudinally spaced cuts 141a, each of which may include one or more curved and / or angled portions. As illustrated, the longitudinally spaced cuts 141a define container-retaining tabs 148a (e.g., crown tabs) extending outwardly from the container-retaining portion 135a. Also illustrated, each diagonal cut 143a, 145a extends outwardly from each cut 141a to form a flexible retaining edge on the first mounting panel 131a for engaging the top (e.g., chime) of a respective container. In one embodiment, each pair of cuts 141 can at least partially define a clip mechanism 149a in the first mounting panel 131a for engaging a respective receptacle CA1, CA2, CA3.

[0016] 1, an inner peripheral portion 136a of the attachment panel 131a is defined between fold lines 137a, 133a, and an outer peripheral portion 138a of the attachment panel 131a is defined between fold lines 139a and a transverse fold line 157a. As shown, a bevel or first side panel 155a is foldably connected to the first attachment panel 131a at the transverse fold line 157a, and a top panel 159 (e.g., first top panel 159) is foldably connected to the first side panel 155a at the transverse fold line 161a.

[0017] In the illustrated embodiment, the second side 109 of the blank 103 includes a second central panel 125b, a second container retaining panel or second attachment panel 131b, and a second side panel 155b having associated features that are generally mirror images of the corresponding panels and flaps of the first side 107 of the blank 103. Corresponding components (e.g., panels, flaps, fold lines, cuts, etc.) are designated by corresponding reference numerals that differ with an "a" or "b" suffix, with the "a" components corresponding to the first side 107 of the blank 103 and the "b" components corresponding to the second side 109 of the blank 103. The second side 109 of the blank 103 also includes an attachment flap 177 (e.g., second top panel 177) foldably connected to the second side panel 155b at a transverse fold line 161b.

[0018] In the illustrated embodiment, the blank 103 may include a gripping or gripping mechanism including a pair of gripping flaps 163 (broadly, respective first and second handles, grips, or gripping mechanisms) foldably connected to the top panel 159 at respective fold lines 165 and at least partially defined by respective curved cuts 167. The gripping mechanism may also include a gripping opening 130 extending into the central panels 125a, 125b and the inner peripheral portions 136a, 136b. In one embodiment, the gripping opening 130 may provide clearance for the gripping flaps 163 and / or for a user's fingers when gripping the carrier 105 with the gripping mechanism. The blank 103 and carrier 105 may have different arrangements of gripping mechanisms or no gripping mechanisms without departing from this disclosure.

[0019] As shown in FIG. 1, the top end of each adhesive opening 127a is spaced from the centerline CL by a longitudinal distance D1 that is greater than the longitudinal distance D2 that the top end of each adhesive opening 127b on the second side 109 of the blank 103 is spaced from the centerline CL. In another embodiment, each of the adhesive openings 127a, 127b can be replaced by a set of four adhesive openings or any suitable number of adhesive openings that can be spaced apart along the longitudinal direction L1. For example, each set of four adhesive openings can include adhesive openings that are aligned or at least partially aligned in the longitudinal direction L1. Each of the adhesive openings in each set of adhesive openings in the first central panel 125a can be spaced apart from the transverse fold line 112 differently than each of the adhesive openings in each set of adhesive openings in the second central panel 125b.

[0020] 1, the blank 103 may include two lug notches 179 for engaging features in the system 200, as described in more detail below. In the illustrated embodiment, the lug notches 179 may extend from respective longitudinally extending leading and trailing edges of the blank 103 at the central panels 125a, 125b (e.g., centered about a centerline CL).

[0021] Any of the panels, flaps, fold lines, cuts, or other features may be other shapes, arrangements, and / or omitted from blank 103 without departing from this disclosure. Blank 103 may be sized and / or shaped to accommodate more or less than six containers without departing from this disclosure.

[0022] As shown in FIG. 1, adhesive G can be applied to one or more portions of the central panels 125a, 125b, for example across the respective surface areas 129a, 129b. Although adhesive G is shown on the outer surface 101 of the blank 103 in FIG. 1 for clarity of illustration and to illustrate the positioning of the blank 103 relative to other features, it will be understood that adhesive G is applied to at least the inner surfaces of the central panels 125a, 125b, as shown in FIG. 2. In one embodiment, adhesive G can be applied to both the inner and outer surfaces of the central panels 125a, 125b. Adhesive G can be applied in multiple beads to each of the central panels 125a, 125b, as shown in FIGS. 1 and 2, and the beads can be arranged in a row or any suitable number of rows on each of the central panels 125a, 125b. Alternatively, each of the central panels 125a, 125b can include one long bead of adhesive G.

[0023] 2, the outer surface 101 of the blank 103 can be positioned over the containers CA1, CA2, CA3, CB1, CB2, CB3 such that the container retaining portion 135a of the first mounting panel 131a covers the containers CA1, CA2, CA3, and the container retaining portion 135b of the second mounting panel 131b covers the containers CB1, CB2, CB3. When the mounting panels 131a, 131b are positioned further down over the multiple containers CA1, CA2, CA3, CB1, CB2, CB3, the container retaining portions 135a, 135b can be actuated to engage the respective containers. For example, when the first mounting panel 131a is lowered or urged downwardly over the containers CA1, CA2, CA3, the peripheral portions 136a, 136b are folded downwardly against the container retaining portion 135a so that the container retaining portion 135a can engage the tops T of the containers. This allows the container retaining portion 135a to at least partially separate from the remainder of the first mounting panel 131a at the cut 141a to form a retaining edge at the peripheral portion 136a, 138a. When the peripheral portion 136a, 138a is further folded downward, the top or top T (e.g., chime) of each container CA1, CA2, CA3 can extend at least partially through the respective opening formed by the respective cut 141a, and the retaining edge engages under the chime of the container CA1, CA2, CA3, and the blank 103 is attached (clipped) to the container CA1, CA2, CA3. Such reconfiguration of the corresponding portion of the second mounting panel 131b can be caused when the second mounting panel 131b is lowered or urged downward onto the containers CB1, CB2, CB3. In such a configuration, peripheral portions 136a, 138a of mounting panel 131a can be folded at least partially downward at respective fold lines 137a, 139a, and similarly, peripheral portions 136b, 138b of mounting panel 131b can be folded at least partially downward at respective fold lines 137b, 139b. In some embodiments, for containers having a rim with a smaller diameter than the sides of the container, peripheral portions 136a, 138a, 136b, 138b can extend diagonally from the top T to the shoulders.In some other embodiments where the container has a top with a similar diameter as the sides of the container, the perimeter portion can extend perpendicular or nearly perpendicular from the chime of the container.

[0024] As shown in FIG. 2, the first central panel 125a and the second central panel 125b can be folded at fold line 112 so that the first central panel 125a and the second central panel 125b are in at least partial face-to-face contact and so that the respective adhesive openings 127a, 127b and respective surface areas 129a, 129b in each central panel 125a, 125b are positioned to be laterally aligned but longitudinally offset due to the different relative spacing of the respective adhesive openings 127a, 127b away from the centerline CL. In this regard, as described further herein, the central panels 125a, 125b are positioned such that a portion of the first central panel 125a overlaps each of the adhesive openings 127b and a portion of the second central panel 125b overlaps each of the adhesive openings 127a to provide communication between the central panels 125a, 125b and the respective surfaces to which the respective containers CA1, CA2, CA3, CB1, CB2, CB3 may be adhered or otherwise attached. Such repositioning of the central panels 125a, 125b may cause the respective central panels 125a, 125b to fold downwardly at the respective fold lines 133a, 133b relative to the respective mounting panels 131a, 131b.

[0025] 3, when the central panels 125a, 125b are folded into face-to-face contact and adhered to the respective containers CB1, CB2, CB3 and CA1, CA2, CA3, the central panels 125a, 125b may form a keel 180 that generally extends between the rows of containers. Thus, in one embodiment, the central panels 125a, 125b may be considered the keel portion of the blank prior to folding the central panels 125a, 125b to form the keel 180.

[0026] 4, with containers CA2, CB2 removed for clarity of illustration, adhesive G can be at least partially aligned with adhesive openings 127a to adhere containers CA1, CA2, CA3 to respective exposed portions of central panel 125b through respective adhesive openings 127a. Similarly, adhesive G can be at least partially aligned with respective adhesive openings 127b to adhere containers CB1, CB2, CB3 to respective exposed portions of central panel 125a through respective adhesive openings 127b. Adhesive G can cover at least a portion of surface areas 129a, 129b such that one or more of surface areas 129a, 129b provides additional surface for adhering and / or spacing between first portion 106 and second portion 108 of carrier 105.

[0027] The attachment of containers CA1, CA2, CA3, CB1, CB2, CB3 to respective center panels 125a, 125b can provide retention and support for the respective containers in addition to or in place of the container retention and support provided by respective container retaining portions 135a, 135b, e.g., so that the containers do not detach from carrier 105 under their own weight. The adhesive G described herein can be, for example, a hot melt adhesive, a high tack adhesive, an epoxy, a polymer cement, or the like, or a combination thereof.

[0028] As shown in Figures 2, 3 and 5, the first side panel 155a can be folded upwardly at fold line 157a into a vertical or oblique arrangement with the containers CA1, CA2, CA3, CB1, CB2, CB3, and the top panel 159 can be folded at fold line 161a into at least partial face-to-face contact with at least a portion of the attachment panels 131a, 131b. Similarly, as shown in Figure 5, the second side panel 155b can be folded upwardly at fold line 157b into a vertical or oblique arrangement with the containers CA1, CA2, CA3, CB1, CB2, CB3, and the attachment flap 177 can be folded at fold line 161b into at least partial face-to-face contact with the attachment panel 131b. Such an arrangement can be maintained by a cohesive such as an adhesive. For example, adhesive can be applied to the container-retaining portions 135a, 135b and / or to the top panel 159 and the attachment flap 177 prior to folding the top panel 159 and the attachment flap 177 into face-to-face contact with the container-retaining portions 135a, 135b. In the illustrated embodiment, the top panel 159 and the attachment flap 177 are folded such that laterally extending edges of the top panel 159 and the attachment flap 177 are proximate and / or abutting one another. Alternatively, the top panel 159 and the attachment flap 177 can be spaced apart from one another or can be in at least a partial overlapping relationship.

[0029] Thus, the containers can be engaged by the respective attachment panels 131a, 131b and can extend below the respective container-retaining portions 135a, 135b in the assembled package 110 shown in Figure 5. In such an arrangement, containers CA1, CA2, CA3 extend below the container-retaining portions 135a in the first portion 106 of the carrier 105, containers CB1, CB2, CB3 extend below the container-retaining portions 135b in the second portion 108 of the carrier 105, and the top panel 159 and attachment flap 177 overlie respective portions of each container-retaining portion 135a, 135b. Also, a keel 180 including the first central panel 125a and the second central panel 125b is disposed between and attached to the containers CB1, CB2, CB3, CA1, CA2, CA3.

[0030] 6-15 illustrate various exemplary embodiments and components of a system and method 200 for forming a package (e.g., package 110) according to the present disclosure. In the illustrated embodiment, as shown, for example, in the product flow diagram of FIG. 15, the packaging system 200 generally provides containers C and blanks (e.g., blanks 103) at an upstream end 203 of the system 200, clips the blanks 103 to a group of containers C (e.g., containers CA1, CA2, CA3, CB1, CB2, CB3) to form a clipped assembly 182 (attaching the blanks 103 to each container C), folds portions of the blanks 103 to move the group of containers C together to form a keel (e.g., keel 180), and folds portions of the blanks 103 to form a carrier (e.g., carrier 105). The blanks 103 and containers C can be moved through the system 200 generally in a downstream machine direction MD (downstream direction) to the downstream end 205. As shown in FIG. 6, the upstream direction MU of the system 200 extends in the opposite direction to the downstream direction MD. Furthermore, the system 200 can have a horizontal transverse direction MT perpendicular to the downstream direction MD and a vertical direction MV perpendicular to the downstream direction MD. In the present application, the system 200 can have a left side SL and a right side SR determined while looking in the downstream direction MD. In one embodiment, the system 200 of the present disclosure includes a clipping station 211 that brings the blanks 103 and the containers C together to form a clipped assembly 182 (FIGS. 2-4, 9, and 11), a joining station 213 that moves the containers C together to form the keel 180, and a folding station 215 that folds the side panels and the top panel of the blanks 103 to form the carrier 105.

[0031] In the illustrated embodiment, the blanks 103 may be fed to a clip station 211 at the upstream end 203 by a carton feeder (e.g., a pick-and-place carton feeder, belt feeder, conveyor belt, or any other suitable feeder and / or conveyor), not shown, and the containers C may be fed to the clip station 211 in two streams. In one embodiment, the system may include a pair of orientation units 221 ( FIG. 6 ) that may selectively rotate individual containers C so that the containers C are fed to the clip station 211 in a predetermined orientation (e.g., to ensure that one or more universal product codes or other information on the containers C face inward and are hidden by other containers C in the package 110, and / or to ensure that the labels or other information on the containers C face outward in the resulting package 110). In the illustrated embodiment, the orienting unit 221 can receive containers C from a respective infeed conveyor (not shown) and output the containers C in a predetermined orientation onto a respective upstream conveyor 223 (FIGS. 7, 10, and 12) of the system 200, where two upstream conveyors 223 (e.g., a first upstream conveyor 223 and a second upstream conveyor 223) can move the containers C downstream in respective first and second streams along a portion of the system 200. Alternatively, the orienting assembly 221 can be omitted or bypassed such that the containers C can be fed directly to the clip station 211. Additionally, in other embodiments, the containers C can be fed to the upstream conveyor 223 in other ways.

[0032] 7 and 8, the clip station 211 may include a support plate 225 (FIGS. 7 and 8) at an upstream end of the clip station 211, an overhead assembly 227 (FIG. 8) for moving and guiding the blanks 103, and two upstream transport belts or upstream weighing belts 229 (FIGS. 7, 9, 10, and 12) on either side of the upstream conveyor 223. Although there are multiple upstream weighing belts 229 shown diagrammatically on each side of the system 200 in FIGS. 6 and 7 to illustrate that different belts may be used in the system 200, only one upstream weighing belt 229 will be included on each side of the system at a time, and the belts will be selected in a length and configuration appropriate for the size (e.g., diameter) of the containers C being packaged, as will be described in more detail below. In the illustrated embodiment, the support plate 225 is tiltable to guide the blanks 103 received from the carton feeder as they move along the support plate 225 (e.g., by one or more belts or other conveyors mounted along at least a portion of the support plate 225 and / or by sliding under gravity). A set of brushes 231 (FIG. 7) may be disposed above the blanks 103 at the upstream end of the support plate 225 to control the movement of the blanks 103. Alternatively, the brushes 231 may be omitted or mounted below the blanks 103 and replaced by other mechanisms capable of slowing or otherwise controlling the blanks 103 as they slide along the support plate 225. The support plate 225 may be omitted or otherwise arranged, shaped, positioned, or configured without departing from this disclosure.

[0033] In the illustrated embodiment, the overhead assembly 227 can include a frame plate 233 (FIGS. 7 and 8) that is mounted over at least a portion of the upstream conveyor 223. A blank flight belt or lug belt 235 can be attached to the frame plate 233 by drive wheels 237a and guide wheels 237b. Although there are multiple lug belts 235 shown diagrammatically in FIGS. 6 and 7 to illustrate that different lug belts 235 can be used with the system 200, only one lug belt 235 will be used with the system 200, and the lug belt will be selected with an appropriate length and lug spacing for the blanks to be handled by the system 200, as will be explained in more detail below. In one embodiment, the drive wheel 237a can move the lug belt 235 along the wheel in line with (e.g., at the same speed as) the upstream conveyor 223, with the bottom of the lug belt 235 moving in the downstream direction MD through the clip station 211. As shown in FIGS. 7-9, a plurality of lugs 239 are spaced along the lug belt 235 to engage the blanks 103 and move the blanks 103 in the downstream direction MD along the clipping station 211. In one embodiment, each of the lugs 239 engages the lug notch 179 on the trailing edge of one blank 103 with the lug notch 179 on the leading edge of the blank 103 adjacent and upstream of the first blank 103. In an exemplary embodiment, the lugs 239 may be sized so that the blanks 103 may abut each other or may be otherwise positioned relative to each other such that the blanks 103 may be clipped to the container C while the container C is in the product pitch configuration (e.g., each of the containers is adjacent to an adjacent upstream and downstream container, respectively, such that the containers are not spaced apart along each of the streams). In one embodiment, the support plate 225 may include slots (FIG. 8) that may accommodate the lugs 239 as the lug belt 235 moves the blanks 103 along the support plate 225 to engage the container C.

[0034] As shown in FIGS. 7-9, the overhead assembly 227 can include two pressing units 241 mounted on either side of the frame plate 233. In the illustrated embodiment, each pressing unit 241 can include a guide belt 243 attached to the frame plate 233 by a drive wheel 245a and a guide wheel 245b. Additionally, each pressing unit 241 can include one or more guide bars 247 attached to the frame plate 233 by adjustable brackets 249 (FIGS. 7, 8). In the illustrated embodiment, the guide bars 247 can press downwardly a lower portion of the guide belt 243, while the lower portion of the guide belt 243 is moving in the downstream direction MD. In one embodiment, the pressing units 241 can help hold the blank 103 against the top T of the container C. In some embodiments where it is desirable to maintain the orientation of the container C (e.g., the orientation set by the optional orientation unit 221) as it moves through the clip station 211, the downward pressure of the pressing unit 241 on the container C (e.g., against the upstream conveyor 223 supporting the container C from below) can help prevent the container C from rotating as it moves in the downstream direction MD. In other embodiments, the pressing unit 241 can be configured to help hold the blank 103 against the top T of the container C without regard to preventing the container from rotating, or the pressing unit 241 can be omitted. In one embodiment, the drive wheel 245a can move the guide belt 243 along the wheel in time (e.g., at the same speed) as the lug belt 235 and the upstream conveyor 223, with the bottom of the guide belt 243 moving in the downstream direction MD through the clip station 211.

[0035] As shown at least in FIGS. 8-10, further, the overhead assembly 227 can include two outer clip guides 251a, two inner clip guides 251b, and two tension guides 251c for clipping the blank 103 to the container C as the blank 103 and the container C move through the clip station 211. In the illustrated embodiment, the clip guides 251a, 251b, 251c can be attached to the frame plate 233 (e.g., via the adjustable bracket 249) and / or other mechanisms of the system. As shown at least in FIGS. 8-10, the clip guides 251a, 251b, 251c may be mounted on the blank 103 and have an inclined upstream end or inclined surface 252 that engages (e.g., contacts) each portion of the blank 103 downwardly and gradually extrudes it as the blank 103 moves downstream at the clip station 211. In the illustrated embodiment, the outer clip guide 251a can be spaced outwardly (e.g., in the transverse direction MT) from the inner clip guide 251b and the tension guide 251c such that the outer clip guide 251a engages the outer portions of the blank 103 (e.g., the outer peripheral portions 138a, 138b, the side panels 155a, 155b, and / or the top panel 159, 177). The inner clip guide 251b can be attached to the inside (e.g., immediately inside) of the two streams of the container C of the respective upstream conveyors 223 (FIG. 10) for engaging the inner portions of the blank 103 (e.g., the inner peripheral portions 136a, 136b and / or the central panels 125a, 125b). The inner clip guide 251b can first engage the inner peripheral portions 136a, 136b to apply tension to the inner portion of the blank 103 such that the outer clip guide 251a biases the outer portion of the blank downwardly, thereby enabling the chimes of the container C to engage at least partially with the outer peripheral portions 138a, 138b.In one embodiment, the outer clip guide 251a can engage to press the outer peripheral portions 138a, 138b downward against the container retaining portions 135a, 135b, and fold the outer peripheral portions 138a, 138b downward along the transverse fold lines 139a, 139b to engage the chimes of the top T of the container C with the respective retaining edges formed in the outer peripheral portions 138a, 138b by the cuts 141a, 141b. In some embodiments, the pressing unit 241 (FIG. 9) can help hold the blank 103 in place (e.g., by pressing the container retaining portions 135a, 135b of the blank against the top T of the container C) while the clip guide engages the blank to clip it to the container.

[0036] In the illustrated embodiment, the tension guides 251c can be attached to the outer portions of the blank 103 (e.g., adjacent to where the outer peripheral portions 138a, 138b are clipped to the chimes of the container C) outside (e.g., immediately outside) the two streams of containers C on each upstream conveyor 223 to hold the outer peripheral portions 138a, 138b in clip engagement with the container C such that the inner clip guides 251b further press the inner peripheral portions 136a, 136b downward to engage the chimes of the container C ( FIG. 10 ). In one embodiment, the inner clip guide 251b can press the inner peripheral portion 136a, 136b downward against the container retaining portion 135a, 135b, folding the inner peripheral portion 136a, 136b downward along the transverse fold lines 137a, 137b, and engaging the chimes of the top T of the container C with the respective retaining edges formed in the inner peripheral portion 136a, 136b by the cuts 141a, 141b. Thus, the blank 103 can be clipped to the container C (e.g., containers CA1, CA2, CA3, CB1, CB2, CB3 of Figures 2-5) by the clip station 211 to form the clipped assembly 182 as the container C and blank 103 move in the downstream direction MD by the upstream conveyor 223 and the lug belt 235. Any portion of the overhead assembly 211 can be omitted or arranged, shaped, positioned, or configured in other manners without departing from this disclosure.

[0037] In the illustrated embodiment, two or more initial plows 253 (FIGS. 9, 10, and 12) can be positioned at the downstream end of the clip station 211 for engaging the top panels 159, 177 and / or side panels 155a, 155b of the blank 103 and gradually folding the top panels 159, 177 and side panels 155a, 155b upwardly along at least the transverse fold lines 157a, 157b. In one embodiment, each of the initial plows 253 can be a vertical plate extending along the downstream direction MD on either side of the upstream conveyor 223 and can have an inclined upstream end 254. In an exemplary embodiment, the initial plows 253 can be spaced apart in the transverse direction MT to engage the top panels 159, 177 (e.g., adjacent the fold lines 161a, 161b) and / or the side panels 155a, 155b (e.g., adjacent the fold lines 157a, 157b). The inclined upstream end 254 of the initial plow 253 may push the top panel 159, 177 and / or the side panel 155a, 155b upward so that the top panel 159, 177 or the side panel 155a, 155b and the top panel 159, 177 may be at least partially vertical as the clipped assembly 182 moves in the downstream direction MD (e.g., by the upstream conveyor 223). As the clipped assembly 182 advances in the downstream direction MD, the top panel 159, 177 and / or the side panel 155a, 155b may engage an inner surface of the initial plow 253 (e.g., the surface facing the upstream conveyor 223), thereby holding the top panel 159, 177 and the side panel 155a, 155b in an at least partially vertical position (FIG. 10).

[0038] As shown in Figures 7, 9, 10 and 12, the upstream weigh belts 229 are partially disposed below the overhead assembly 227 on each side of the containers C transported on the upstream conveyor 223. In the illustrated embodiment, each of the upstream weigh belts 229 can be mounted on a drive wheel 257a and a guide wheel 257b. The upstream weigh belts 229 can be driven by the wheels 257a, 257b to move the innermost (e.g., closest to the upstream conveyor 223) length of the upstream weigh belt 229 in the downstream direction MD in line with the lug belt 235 and the guide belt 243. In one embodiment, each of the upstream weigh belts 229 can include wedge-shaped lugs or projections 259 (some of the projections 259 are shown diagrammatically along a portion of the length of the belt 229) spaced apart along the belt such that each projection 259 engages two adjacent containers C. The protrusions 259 may have a curved, triangular, or other profile to engage a portion of a side of the cylindrical container C, and in an exemplary embodiment may be spaced apart to engage each container C between two of the protrusions 259 when the containers C are in a product pitch configuration (e.g., in contact with and engaged with each other in each of the streams of containers). In one embodiment, the upstream weighing belt 229 may align with the clip mechanisms 149a, 149b of the blanks 103 to help move the containers C in the downstream direction MD as the blanks 103 are positioned and moved by the lugs 239 of the lug belt 235. The upstream weighing belt 229 may be omitted or may be otherwise arranged, shaped, positioned, or configured without departing from this disclosure.

[0039] In the illustrated embodiment, the lug belt 235 and the upstream weigh belt 229 can be aligned (e.g., such that a container C moved by the upstream weigh belt 229 is aligned with the clip mechanisms 149a, 149b of the blank 103 moved by the lug belt 235) using lug belt timing preset stops 255a (FIG. 7) and weigh belt timing preset stops 256a (FIGS. 7, 10, and 12). In one embodiment, the lug belt timing preset stops 255a can include slide locks or pins 255b that are slidable within grooves in brackets 255c that are attached to the frame plate 233. Similarly, the weigh belt timing preset stops 256a can include slide locks or pins 256b that are slidable within grooves in brackets 256c. When not in use, the pins 255b, 256b can be locked out of the way of the lug belt 235 and the upstream weigh belt 229. When aligning the belts, the lug belt 235 can be moved to align the lug 239 with the pin 255b and the pin 255b can be advanced to engage the lug 239. Similarly, each of the upstream metering belts 229 can be moved to align the protrusion 259 with the pin 256b and advanced to engage the protrusion 259. In an exemplary embodiment, the positions of the timing preset stops 255a, 256a can be predetermined such that the lug belt 235 and the upstream metering belt 229 are aligned when the pins 255b, 256b engage the lug 239 and the protrusion 259, respectively. After alignment, the pins 255b, 256b can be locked in a non-engaged position for operation of the system 200. The timing preset stops 255a, 256a can be omitted or can be arranged, shaped, positioned, or configured without departing from this disclosure.

[0040] In the illustrated embodiment, aspects of system 200 can be adjusted and / or replaced to configure system 200 to form packages having containers with different diameters, heights, volumes, etc. For example, the diameters of different containers can include about 53 mm, about 58 mm, and about 66 mm, or the containers can have any suitable diameter. Further, aspects of system 200 can be adjusted and exchanged to configure system 200 to form packages having different blanks. For example, system 200 can be configured to form any of the packages shown and described in the applications incorporated by reference above. The blanks can be different in size or form to accommodate different container sizes (e.g., configured to accommodate containers in an arrangement such as 2×2, 2×4, 2×6, etc.). Further, the blanks can have different keel depths. For example, the carrier can have a deeper keel to accommodate larger and / or heavier containers, or a shallower keel for substrate efficiency. Additionally, packages sold to consumers can have a deeper keel for a stronger connection to the container, for example, than packages for only transporting and storing containers for individual sale. In some embodiments, the keel depth can be in the range of, for example, about 40 mm to about 70 mm. Alternatively, the keel can have any suitable depth. Different keel depths can result in the size of the central panel (e.g., central panels 125a, 125b in blank 103) in the longitudinal direction L1 such that a deeper keel results in a longer blank in the longitudinal direction L1 and a shallower keel results in a shorter blank in the longitudinal direction L1.

[0041] In one embodiment, the configuration of the clip station 211 (similar to other configurations of the system 200) can be adjusted to accommodate different blanks and containers. For example, the position of the overhead assembly 227 can be adjusted in the vertical direction MV for different container heights. In an exemplary embodiment, the overhead assembly 227 can be attached to the frame of the system 200 that has a motor or other mechanism (not shown) capable of moving the overhead assembly in the vertical direction MV. In another example, the lug belt 235 can be adjusted or replaced to accommodate different blank widths in the lateral direction L2 (e.g., for different formats and / or different container diameters). In one embodiment, the lugs 239 can be fixed to the belt 235 at the intervals required for a particular blank, and the belt 235 can be selected in length such that all the lugs 239 are spaced apart along the lug belt 235 by the required intervals. Several different belt lengths for the lug belt 235 are schematically shown in FIGS. 6 and 7. In one embodiment, when the lug belt 235 is changed to one having a different length, one or more guide wheels 237b can be adjusted to apply appropriate tension to the lug belt 235. In another example, the pressing unit 241, the clip guides 251a, 251b, 251c, the upstream metering belt 229, and / or the initial plow 253 can be adjusted in the lateral direction MT for different container diameters and / or different keel depths. In a further example, the upstream metering belt 229 can be adjusted and / or replaced to accommodate different container diameters. In one embodiment, the spacing between the protrusions 259 can be adjusted for a particular container diameter, and the length of the upstream metering belt 229 can be selected such that all the protrusions 259 are appropriately spaced from adjacent protrusions 259 along the upstream metering belt 229. Different belt lengths of the upstream metering belt 229 are schematically shown in FIGS. 6 and 7. In one embodiment, when changing the upstream metering belt 229 to one having a different length, one or more guide wheels 257b can be adjusted to apply appropriate tension to the upstream metering belt 229.In a further example, the position of the two lanes or streams of containers C can be adjusted in the lateral direction MT (e.g., the position of containers C can be adjusted on the upstream conveyor 223 and / or the position of the upstream conveyor 223 can be adjusted) so that containers C line up with the mounting panels 131a, 131b of the different blanks. In one embodiment, carriers having different keel depths can have different sized keel portions (e.g., central panels 125a, 125b) in the unfolded blanks, which may result in adjustments to the position of the upstream conveyor 223 and / or other aspects of the system to align the lanes of containers with the mounting panels 131a, 131b.

[0042] Any portion of the clip station 211 may be omitted or may be otherwise arranged, shaped, positioned, or configured without departing from this disclosure.

[0043] As shown in FIGS. 6, 7, 11, and 12, the clip - retained assembly 182 formed at the clip station 211 passes through the merging station 213. As shown in FIGS. 6 - 8, 10, and 11, the clip - retained assembly 182 can pass through the keel - bonding unit 261 at the downstream end of the clip station 211 and the upstream end of the merging station 213. In one embodiment, the keel - bonding unit 261 can apply beads of any suitable number of adhesives G1 (FIG. 11) for adhering the central panels 125a, 125b to their respective containers C via the adhesive openings 127a, 127b and / or to each other. Generally, the merging station 213 can guide the containers C towards each other (e.g., towards the centerline of the system 200) in the clip - retained assembly 182 while the central panels 125a, 125b are bent downwardly between the containers C to form the keel 180. As shown in FIG. 12, the containers C can move from the upstream conveyor 223 to the downstream conveyor 263, and a portion thereof extends between the upstream conveyors 223. Also, as shown in FIGS. 7, 11, and 12, the merging station 213 can include two merging guides 265 angled so as to be spaced apart in the transverse direction MT by a greater distance at the upstream end of the merging station 213 than at its downstream end. Thus, the merging guides 265 engage the containers C of the blank 103 (e.g., in the side panels 155a, 155b and / or the top panels 159, 177) and the clip - retained assembly 182, gradually biasing the containers C towards each other and biasing the containers C from the upstream conveyor 223 to the downstream conveyor 263 as the clip - retained assembly 182 moves in the downstream direction by the conveyors 223, 263.

[0044] In one embodiment, the keel bonding unit 261 can be adjusted in the vertical direction MV (e.g., to accommodate different container heights) and / or the lateral direction MT to apply adhesive beads to the center panels 125a, 125b as needed for different blanks 103. Additionally, the merge guide 265 can be adjusted in the lateral direction MT (e.g., to accommodate different container diameters and / or keel depths). Any portion of the merge station 213 can be omitted or otherwise arranged, shaped, positioned, or configured without departing from this disclosure.

[0045] As shown in Figures 6 and 12-14, the clipped assembly 182 with the formed keel 180 can pass from the junction station 213 to the folding station 215. As shown in Figures 6, 7, and 14, the clipped assembly can pass under a crown panel bonding unit 267 at the upstream end of the folding station 215. In one embodiment, the crown panel bonding unit 267 can apply any suitable number of beads of adhesive G2 (Figures 11 and 12) to the container-retaining portions 135a, 135b (e.g., crown panels) of the blank 103 to bond the top panels 159, 177 to either or both of the container-retaining portions 135a, 135b. Generally, the folding station 215 can further fold the top panels 159, 177 of the blank 103 onto the container-retaining portions 135a, 135b. In the illustrated embodiment, the folding station 215 can include two downstream conveying belts or downstream weighing belts 269, a first top plow 271a, a second top plow 271b, and a lower plow 271c. The downstream weighing belt 269 can be similar or identical to the upstream weighing belt 229 and can help move the containers C of the clipped assemblies 182 in the downstream direction MD through the folding station 215. For example, the downstream weighing belt 269 can be attached to a drive wheel 257a and a guide wheel 257b and can include a timing preset stop 256a (FIG. 13) that is similar or identical to the timing preset stop 256a associated with the upstream weighing belt 229 and can be configured to set the downstream weighing belt 269 in cooperation with the lug belt 235 and the upstream weighing belt 229. Similar to the upstream weighing belt 229, the downstream weighing belt 269 can include protrusions 259 (some of the protrusions 259 are shown diagrammatically along a portion of the length of the belt 269 in FIGS. 6 and 12-14). In one embodiment, the downstream weighing belt 269 can apply a compressive force (e.g., in the lateral direction MT) to at least some of the containers C at the folding station 215 to help adhere the containers C to their respective central panels 125a, 125b with adhesive beads G1.

[0046] As shown in FIGS. 12 to 14, the top plows 271a, 271b can include horizontal (e.g., generally or substantially horizontal) plates that at least partially extend over the downstream conveyor 263. The top plows 271a, 271b engage respective angled edges 273a, 273b of the blank 103 to bend the top panels 159, 177 (e.g., along the lateral fold lines 161a, 161b) over the crown panels 135a, 135b as the clip-attached assembly 182 is moved in the downstream direction MD by the downstream metering belt 269 and the downstream conveyor 263. In the illustrated embodiment, the angled edge 273a is longer than the angled edge 273b, and the downstream end of the first top plow 271a extends further beyond the downstream conveyor 261 than the downstream end of the second top plow 271b, because the top panel 159 is larger (e.g., in the longitudinal direction L1) than the top panel 177. In other embodiments, the top plows 271a, 271b can be alternatively configured for blanks having different top panel configurations.

[0047] In the illustrated embodiment, the bottom plow 271c can be disposed at least partially downstream and spaced from the top plows 271a, 271b. As shown in FIGS. 12 to 14, the bottom plow 271c engages the respective top panels 177, 159 and gradually presses the respective top panels 177, 159 against the crown panels 135b, 135a having an adhesive bead G2 therebetween to fix the top panels 177, 159 in a predetermined position of the now-closed carrier 105 as the downstream conveyor 263 and the downstream metering belt 269 move the container C and the attached carrier 105 in the machine direction MD. It can have an inclined upstream end 273c and an inclined surface 274 (FIG. 13).

[0048] In one embodiment, the plows 271a, 271b, 271c are adjustable in the vertical direction MV and the lateral direction MT (e.g., to accommodate containers C of different heights and diameters). Also, the downstream weighing belt 269 can be adjusted in a similar or identical manner to the upstream weighing belt 229. Because the keel 180 is formed before the clipped assembly 182 moves to the folding station 215, the depth of the keel 180 (and the dimension of the central panels 125a, 125b in the longitudinal direction L1) can have little or no effect on the adjustments to the plows 271a, 271b, 271c and / or the downstream weighing belt 269. Any portion of the folding station 215 can be omitted or otherwise arranged, shaped, positioned, or configured without departing from this disclosure.

[0049] As shown in Figs. 6 and 13, the system 200 can include a compression belt 281 disposed on the downstream conveyor 263 downstream from the folding station 215. In the illustrated embodiment, the compression belt 281 can be driven on wheels such that a length of the bottom of the belt moves in the downstream direction MD in contact with the top panels 159, 177 of the carrier 105 as the packages 110 move in the downstream direction MD on the downstream conveyor 263. In one embodiment, the compression belt 281 can press the top panels 159, 177 of the carrier 105 downward (e.g., against the support of the downstream conveyor 263) to facilitate bonding of the top panels 159, 177 to the crown panels 135a, 135b. In the illustrated embodiment, the compression belt 281 can be adjusted in the vertical direction MV, for example, to accommodate containers C having different heights. The compression belt 281 can be omitted or can be arranged, shaped, positioned, or configured without departing from this disclosure.

[0050] In an exemplary embodiment, the formed packages 110 may be moved downstream from the compression belt 281 on a downstream conveyor 263 for further processing (e.g., positioning the packages 110, loading the packages into cartons, etc.) and / or for storage and / or shipping. System 200 may be configured in other manners without departing from this disclosure. For example, in one embodiment, the upstream conveyor 223 and / or the downstream conveyor 263 may be replaced with a single wide conveyor extending along the system 200.

[0051] In operation, in an exemplary embodiment, a package 110 may be formed within the system 200 (e.g., as shown diagrammatically in the product flow of FIG. 15). For example, a blank 103 may be fed to a support plate 225 and slid down the support plate 225 to a clip station 211 (FIGS. 7-10). In one exemplary embodiment, the blank 103 may be moved along at least a portion of the support plate 225 by one or more belts or other conveyors mounted along at least a portion of the support plate 225. A leading end (e.g., downstream end) of the blank 103 may engage a lug belt 235 such that one of the lugs 239 engages a lug notch 179 on the leading end of the blank 103. As the blank 103 continues to move across the support plate 225, the lug belt 235 engages the blank and serves to move the blank in a downstream direction MD. The trailing lugs 239 of the lug belt 235 can engage the lug notches 179 on the trailing (e.g., upstream) end of the blank 103, and the lug belt 235 and lugs 239 can move the blank 103 in the downstream direction MD at the same speed as the container C moves on the upstream conveyor 223 of the first and second streams / lanes. In some embodiments, the blank does not include a lug notch, and the lugs 239 can engage the leading and / or trailing ends of the blank. In one embodiment, the lugs 239 are positioned on the lug belt 235 such that the clip features 149a, 149b of the blank 103 are aligned with the top T of the container C when the container C is engaged between the protrusions 259 of the upstream weighing belt 229. As shown in Figure 7, the lug belts 235 can move the blank 103 over the downstream end of the support plate 225 so that the container retaining portions (crown panels) 135a, 135b rest on the top T of the container C and the guide belts 243 engage the blank 103 (Figure 9). The guide belts 243 and guide bars 247 can press downwardly on the container C below the crown panels 135a, 135b and the blank 103 to hold the blank 103 in contact with the container C and prevent the container C from rotating as the guide belts 243, blank 103 and container C move in the downstream direction MD.As shown in Figures 7, 9 and 10, the top panels 159, 177, side panels 155a, 155b, and / or outer peripheral portions 138a, 138b of the blank 103 can engage with the outer clip guide 251a as the blank 103 and container C are moved in the downstream direction MD by at least the respective lug belts 235 and upstream weighing belt 229, and the inclined upstream end 252 of the outer clip guide 251a can press the outer portions of the blank 103 downward against the remainder of the blank 103.

[0052] At least as shown in FIGS. 9 and 10, the inner clip guide 251b engages the inner peripheral portions 136a, 136b and / or the central panels 125a, 125b of the blank 103, applies tension to the inner portion of the blank 103, and the outer clip guide 251a engages the top panels 159, 177, the side panels 155a, 155b and / or the outer peripheral portions 138a, 138b of the blank 103, bends the outer peripheral portions 138a, 138b downward relative to the crown panels 135a, 135b, and forms retaining ends at the outer peripheral portions 138a, 138b with cuts 141a, 141b. The downward pressure of the outer clip guide 251a on the blank can engage (e.g., forcefully) the retaining ends of the outer peripheral portions 138a, 138b under the chime of the container C. Thereafter, the tension guide 251c can engage the outer portion of the blank 103. The inner clip guide 251b can gradually press the inner peripheral portions 136a, 136b and / or the central panels 125a, 125b of the blank downward relative to the crown panels 135a, 135b, while the outer clip guide 251a and subsequently the tension guide 251c can engage (e.g., press downward) the outer portion of the blank to help hold the outer peripheral portions 138a, 138b engaged with the chime of the container. Thereby, the retaining ends are formed at the inner peripheral portions 136a, 136b at the cuts 141a, 141b and can be forced to engage under the chime of the container C by the inner clip guide 251b. In one embodiment, with the retaining ends at the peripheral portions 136a, 138a, 136b, 138b engaged with the chime of the container C, the blank 103 is clipped (e.g., attached, or installed) to the container C to form the clipped assembly 182 (FIGS. 2 and 9-11). The upstream metering belt 229, the upstream conveyor 223, and the lug belt 235 can continue to move the clipped assembly 182 in the downstream direction MD.

[0053] As shown in Figures 7, 9, and 10, as the blank 103 moves in the downstream direction MD, the top panels 159, 177 and / or the side panels 155a, 155b engage the initial plow 253 and are folded upward into a vertical (e.g., generally or substantially vertical) direction. The clipped assembly 182 can then pass under the keel bonding unit 261, as shown at least in Figures 7, 10, and 11. The keel bonding unit 261 can apply a bead of adhesive G1 to the central panels 125a, 125b such that the bead of adhesive G1 on the central panel 125a aligns with the respective adhesive openings 127b of the central panel 125b when the keel 180 is formed at the merging station 213, and the bead of adhesive G1 on the central panel 125b aligns with the respective adhesive openings 127a of the central panel 125a when the keel 180 is formed.

[0054] 7 and 12, the clipped assembly 182 may travel on the upstream conveyor 223 through the merge station 213, whereupon the merge guide 265 may gradually urge the containers C inwardly from the upstream conveyor 223 to the downstream conveyor 263 while the conveyors 223, 263 move the containers C in the downstream direction MD. As the containers C approach each other, the central panels 125a, 125b may fold downwardly between the containers C and into face-to-face contact with each other to form the keel 180 (e.g., FIGS. 7 and 12). At the formed keel 180 (e.g., as described above with respect to FIG. 4), the bead of adhesive G1 on central panel 125a can engage a container C clipped to attachment panel 131b via adhesive opening 127b in central panel 125b, and the bead of adhesive G1 on central panel 125b can engage a container C clipped to attachment panel 131a via adhesive opening 127a in central panel 125a. In some embodiments, the bead of adhesive G1 can also bond the central panels 125a, 125b together.

[0055] As the clipped assembly 182 with the formed keel 180 moves in the downstream direction MD on the downstream conveyor 263 from the junction station 213 to the folding station 215, the crown panel bonding unit 267 can apply a bead of adhesive G2 (e.g., as shown in FIGS. 7, 12, and 14) to the crown panels 135a, 135b. As the clipped assembly 182 moves to the folding station 215, the downstream metering belt 269 can engage the containers C (e.g., with each of the containers engaged between the two protrusions 259) and push the containers C together (e.g., in the lateral direction MT) to move the clipped assembly 182 in the downstream direction MD to facilitate bonding of the bead of adhesive G1 between the containers C and the central panels 125a, 125b. As shown in Figures 12-14, as the clipped assembly 182 moves in the downstream direction MD, the top plows 271a, 271b can fold the top panels 159, 177 onto the crown panels 135a, 135b. The lower plow 271c can then press the top panels 159, 177 downward onto the crown panels 135a, 135b. For example, the sloping end 273c of the lower plow 271c can press the top panel 177 against a portion of the crown panel 135b, and then the sloping surface 174 can press the top panel 159 downward onto the crown panels 135a, 135b. The compression belt 281 can further press the top panels 159, 177 downward to facilitate bonding the top panels 159, 177 to the crown panels 135a, 135b via the bead of adhesive G2. In one embodiment, with the top panels 159, 177 secured to the crown panels 135a, 135b, the folding station 215 can be thought of as forming a triangle on an outer portion of the carrier when viewed from the end of the carrier 105. For example, the triangle can include each outer peripheral portion 138a, 138b, each side panel 155a, 155b, and each top panel 159, 177. In an exemplary embodiment, the triangle can help support a clip engagement between the carrier 105 and the container C.

[0056] Thus, top panels 159, 177 are adhered to crown panels 135a, 135b to form carrier 105 which clips container C to mounting panels 131a, 131b, and adhered to keel 180 to form package 110 which is moved to downstream end 205 of system 200 for further processing, storage, shipping, etc. Package 110 may be formed in other manners in system 200 without departing from this disclosure.

[0057] Although the system 200 has been described with respect to forming the package 110 with the carrier 105 from the blank 103, other blanks can be fed into the system to form other carriers. For example, a carrier without the top panels 159, 177 and / or side panels 155a, 155b (such as those shown and described in U.S. patent application Ser. No. 16 / 426,066, which is incorporated by reference) can be formed with the system 200, and the crown panel bonding unit 267, the plows 253, 271a, 271b, 271c and / or the compression belt 281 can be removed or otherwise deactivated.

[0058] Generally, the blanks of the present disclosure can be constructed from paperboard having a caliper so that it is heavier and more rigid than regular paper. The blanks can also be constructed from other materials such as corrugated board, or any other material having suitable properties to enable the carton to function at least generally as described above. The blanks can be coated with, for example, a clay coating. The clay coating can then be printed on with product, advertising, and other information or images. The blanks can then be coated with a varnish to protect the information printed on the blanks. The blanks can be coated with, for example, a moisture barrier layer on one or both sides of the blank. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.

[0059] As an example, the tear line can include a slit that extends partially into the material along the desired line of weakness, and / or a series of spaced slits that extend partially into the material along the desired line of weakness or completely through the material, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced slits that extend completely through the material, with adjacent slits spaced slightly apart such that a nick (e.g., a small, somewhat bridge-like portion of material) is defined between adjacent slits to typically temporarily connect the material across the tear line. The nick breaks upon tearing along the tear line. The nick is typically a relatively small percentage of the tear line, and alternatively, the nick can be omitted from the tear line or torn at the tear line such that the tear line is a continuous line of cut. That is, it is within the scope of this disclosure to replace each of the tear lines with a continuous slit, etc. For example, the cut line may be a continuous slit or may be wider than the slit without departing from this disclosure.

[0060] According to an exemplary embodiment, the fold line is not necessarily linear, but may be any substantially linear form of weakening that facilitates folding therealong. More specifically, but without the intent of narrowing the scope of the present disclosure, fold lines include score lines, such as lines formed with a blunt scoring knife or the like, that create a collapsed or recessed portion in the material along the desired line of weakness, cuts that extend partially into the material along the desired line of weakness, and / or a series of cuts that extend partially and / or completely through the material along the desired line of weakness, and various combinations of these features. In situations where cuts are used to create the fold lines, the cuts typically are not overly extensive in a manner that would cause a reasonable user to erroneously consider the fold line to be a tear line.

[0061] The above embodiments can be described as having one or more panels that are adhesively bonded together during assembly of the carton embodiment. The term "adhesive" is intended to encompass any type of adhesive commonly used to secure carton panels in place.

[0062] The foregoing description of the present disclosure illustrates and describes various embodiments. Since various changes can be made to the above configurations without departing from the scope of the present disclosure, all matters contained in the above description or shown in the accompanying drawings are intended to be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc. of the above-described embodiments. Furthermore, the present disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure presented herein, commensurate with the teachings above, and / or within the skill or knowledge of the relevant art. Furthermore, specific features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure.

Claims

1. 1. A method of at least partially forming a package, the method comprising: The method includes moving a blank and a plurality of articles in a downstream direction through a clip station, the blank including at least a first attachment panel, a second attachment panel, and a keel portion extending from the first attachment panel to the second attachment panel, the method including: forming a clipped assembly by clipping the first attachment panel and the second attachment panel of the blank to respective articles of the plurality of articles while moving the blank and the plurality of articles in the downstream direction through the clip station; moving the articles toward one another while moving the clipped assembly in the downstream direction to form a keel by folding the keel portion of the blank between the articles; and attaching said each article of said plurality of articles to said keel by adhering said keel to said each article.

2. 2. The method of claim 1, wherein the blank includes a plurality of openings extending through a keel portion, and attaching the respective articles to the keel includes applying a bead of adhesive to an area of ​​the keel portion such that at least a portion of each bead of adhesive adheres the respective article to the keel through a respective opening of the plurality of openings.

3. 2. The method of claim 1, wherein attaching each article of the plurality of articles to the keel comprises applying a bead of adhesive to a portion of the keel such that the bead of adhesive adheres at least a portion of the keel to the respective article as the keel is being formed.

4. 4. The method of claim 3, wherein forming the keel further comprises compressing the clipped assembly in a direction transverse to the downstream direction after folding the keel portion between the articles to press the keel between the articles and promote adhesion of the article to the keel with the bead of adhesive.

5. 2. The method of claim 1, wherein the clip station comprises two outer clip guides and two inner clip guides, each having an inclined surface, and clipping the first and second mounting panels to the respective articles comprises moving an outer portion of each of the blanks downwardly down the inclined surfaces of the two outer clip guides and moving an inner portion of each of the blanks downwardly down the inclined surfaces of the two inner clip guides while moving the blanks and the plurality of articles in a downstream direction through the clip station.

6. 6. The method of claim 5, wherein each of the first and second mounting panels has a respective inner peripheral portion and a respective outer peripheral portion, and wherein the outer portion of the blank is moved downwardly to fold the outer peripheral portion downwardly and engage under the respective chimes of the respective items, and the inner portion of the blank is moved downwardly to engage the inner peripheral portion under the respective chimes of the respective items.

7. The method of claim 5 , wherein the two inner clip guides are positioned at least partially downstream from the two outer clip guides.

8. 6. The method of claim 5, wherein the clip station further comprises two tension guides positioned at least partially downstream from the two outer clip guides, the two tension guides contacting the outer portion of the blank during at least a portion of moving the inner portion of the blank downwardly.

9. 2. The method of claim 1, wherein moving the blank and the plurality of articles downstream through the clip station includes moving the plurality of articles in a first article stream and a second article stream of at least one upstream conveyor and moving the blank on a lug belt.

10. The method of claim 9 , wherein the lug belt comprises lugs disposed at least partially above the blank and urging the blank in the downstream direction.

11. 2. The method of claim 1, wherein the clip station comprises a plurality of guide belts disposed above the blank, each of the plurality of guide belts pressing downwardly onto the respective first and second attachment panels while moving the blank and the plurality of articles downstream through the clip station.

12. 2. The method of claim 1, wherein moving the blank and the plurality of articles in a downstream direction through the clip station includes moving the plurality of articles in a first article stream and a second article stream, and forming the keel includes urging the articles in the first article stream and the second article stream toward each other at respective converging guides while allowing the keel portion of the blank to fold downwardly between the articles in the first article stream and the second article stream while moving the clipped assembly in the downstream direction.

13. 13. The method of claim 12, wherein moving the articles in the first article stream and the second article stream comprises moving the articles in the first article stream and the second article stream on respective first and second upstream conveyors, and urging the articles in the first article stream and the second article stream towards each other comprises moving the articles from the first and second upstream conveyors to a downstream conveyor.

14. 1. A system for at least partially forming a package, the system comprising: a clip station for receiving a blank including at least a first attachment panel, a second attachment panel, and a keel portion extending from the first attachment panel to the second attachment panel, and a plurality of articles, the clip station clipping the first attachment panel and the second attachment panel of the blank to respective articles of the plurality of articles to form a clipped assembly while moving the blank and the plurality of articles in a downstream direction; a merge station that receives the clipped assembly from the clip station, the merge station moving the plurality of articles toward one another while moving the clipped assembly in the downstream direction such that the keel portion of the blank is folded between the articles to form a keel between the articles, the merge station configured to at least partially attach each of the plurality of articles to the keel by adhering the keel to the respective article.

15. 15. The system of claim 14, wherein the blank includes a plurality of openings extending through the keel portion, the system further including an adhesive applicator that applies a bead of adhesive to an area of ​​the keel portion such that at least a portion of each bead of adhesive adheres each article to the keel through a respective opening of the plurality of openings when the meet station forms the keel between the articles.

16. 15. The system of claim 14, further comprising an adhesive applicator that applies a bead of adhesive to the keel portion such that at least a portion of each bead of adhesive adheres each article to the keel portion when the meet station forms the keel between the articles.

17. 17. The system of claim 16, further comprising a pair of belts that receive the clipped assembly from the junction station, the belts being disposed on opposite sides of the clipped assembly and configured to compress the articles in the clipped assembly together with the keel therebetween as the clipped assembly moves in the downstream direction to facilitate adhering the articles to the keel with the bead of adhesive.

18. 15. The system of claim 14, wherein the clip station comprises two outer clip guides and two inner clip guides, each having an inclined surface, and as the blank and the plurality of articles move in the downstream direction, the two outer clip guides are positioned to contact respective outer portions of the blanks and move the respective outer portions of the blanks downwardly down the inclined surfaces of the two outer clip guides, and as the blank and the plurality of articles move in the downstream direction, the two inner clip guides are positioned to contact respective inner portions of the blanks and move the respective inner portions of the blanks downwardly down the inclined surfaces of the inner clip guides.

19. 20. The system of claim 18, further comprising an overhead assembly mounted above the blank, the overhead assembly comprising the two outer clip guides, the two inner clip guides, and a lug belt, the lug belt moving the blank at least partially in the downstream direction.

20. The system of claim 18 , wherein the two inner clip guides are positioned at least partially downstream from the two outer clip guides.

21. 20. The system of claim 18, wherein the clip station further comprises two tension guides positioned at least partially downstream from the two outer clip guides, the two tension guides contacting the outer portions of the blank while at least a portion of the two inner clip guides contact the respective inner portions of the blank.

22. 15. The system of claim 14, further comprising at least one upstream conveyor and a lug belt, the plurality of articles being disposed in a first article stream and a second article stream of the at least one upstream conveyor, the lug belt comprising lugs positioned at least partially above the blank and pushing the blank in the downstream direction.

23. 15. The system of claim 14, wherein the clip station comprises a plurality of guide belts positioned above the blank, each guide belt of the plurality of guide belts configured to press downwardly on the first and second attachment panels of each of the blanks while the blank and the plurality of articles are moved in the downstream direction through the clip station.

24. 15. The system of claim 14, further comprising a first upstream conveyor, a second upstream conveyor, and a downstream conveyor, the first upstream conveyor and the second upstream conveyor extending along at least a portion of the clip station and the merging station, at least a portion of the downstream conveyor being positioned between the first upstream conveyor and the second upstream conveyor at the merging station, the plurality of articles being disposed in a first article stream on the first upstream conveyor and a second article stream on the second upstream conveyor, and the merging station comprising a merging guide configured to gradually urge the articles in the first article stream and the articles in the second article stream toward each other from the respective first upstream conveyor and second upstream conveyor onto the downstream conveyor as the articles are moved in the downstream direction by the first upstream conveyor, the second upstream conveyor, and the downstream conveyor.

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