Method and system for preparing blanks for forming container carriers

Abstract

A method of processing at least one blank to form a container carrier includes obtaining at least one blank including a central panel having a plurality of container openings and at least one container retaining tab extending into each of the plurality of container openings. The method further includes inserting the at least one blank into a blank infeed assembly, moving the at least one blank from the infeed assembly to a blank processing assembly having a forming belt and a forming wheel, and moving the at least one blank between the forming belt and the forming wheel. Moving the at least one blank to a product engaging portion of the blank processing assembly such that the at least one blank is positioned to engage a group of containers.

Description

Technical Field

[0001] Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application 63 / 261,582, filed September 24, 2021.

[0002] Incorporation by Reference The disclosure of U.S. Provisional Patent Application 63 / 261,582, filed September 24, 2021, is hereby incorporated by reference herein in its entirety for all purposes as if fully set forth herein.

[0003] Background of the Disclosure The present disclosure generally relates to systems and methods for processing blanks for forming carriers, packages, and / or other suitable structures. More specifically, the present disclosure is directed to methods and systems for processing blanks and carriers formed therefrom.

Summary of the Invention

[0004] According to one aspect, the present disclosure generally relates to a method for processing at least one blank for forming a carrier for a container, the method including obtaining at least one blank comprising a central panel having a plurality of container openings and at least one container holding tab extending to each of the plurality of container openings. The method includes inserting at least one blank into a blank feed assembly and moving at least one blank from the feed assembly to a blank processing assembly, the blank processing assembly comprising a forming belt and the blank processing assembly further comprising a forming wheel, moving at least one blank between the forming belt and the forming wheel, and moving at least one blank to a product engagement portion of the blank processing assembly such that at least one blank is positioned to engage a group of containers.

[0005] In another aspect, the disclosure generally relates to a system for processing blanks for forming container carriers, comprising an upstream end, a downstream end defining a machine direction from the upstream end to the downstream end of the system, a blank feeding assembly adjacent to the upstream end of the system, and a blanking assembly located downstream of the blank feeding assembly. The blanking assembly comprises a forming belt for driving in a closed path around a plurality of rollers and a forming wheel rotatably mounted on a support, wherein the forming belt and forming wheel are configured such that at least one blank is at least partially received between the forming belt and the forming wheel and processed before moving to the product engagement portion of the blanking assembly.

[0006] Those skilled in the art will understand the above-mentioned advantages and other advantages and benefits of various additional embodiments by referring to the drawings listed below and reading the following detailed description of the embodiments. It is within the scope of this disclosure that the embodiments discussed above are provided both individually and in various combinations.

[0007] By convention, the various features of the drawings discussed below are not necessarily drawn to scale. The dimensions of various features and elements in the drawings may be enlarged or reduced to more clearly illustrate embodiments of this disclosure. [Brief explanation of the drawing]

[0008] [Figure 1] This is a plan view of the outer surface of the blank used in the system described herein. [Figure 2] This is a perspective view of a container suitable for use with blanks, carriers, and packages formed by the system and methods of this disclosure. [Figure 3] This is a perspective view of a system for processing blanks according to an exemplary embodiment of the present disclosure. [Figure 4] Figure 3 shows another perspective of the system. [Figure 5]Figure 3 is an enlarged perspective view of the blank feeding assembly of the system. [Figure 6] Figure 3 is an enlarged perspective view of the blanking assembly of the system. [Figure 7] Figure 3 shows another enlarged perspective view of the blanking assembly of the system. [Figure 7A] Figure 3 is an enlarged perspective view of a portion of the blanking assembly of the system. [Figure 8] Figure 3 is a perspective view of the formation wheel of the system. [Figure 9] Figure 3 is an enlarged perspective view of a portion of the forming wheel of the system. [Figure 10] This is a perspective view of some alternative configurations for forming wheels. [Figure 11] This is a perspective view of the blank in Figure 1, processed by a part of the system in Figure 3. [Figure 12] This is a perspective view of a system for processing blanks according to a second exemplary embodiment of the present disclosure. [Figure 13] Figure 12 shows another perspective view of the system. [Figure 13A] Figure 12 is an enlarged perspective view of the formation wheel of the system. [Modes for carrying out the invention]

[0009] Corresponding parts are designated by corresponding reference numbers throughout the drawing.

[0010] This disclosure relates, in general, to systems and methods for preparing and processing blanks or other structures for forming carriers for holding products such as containers, food and beverage containers. The containers may be made from materials suitable for compositions for packaging specific food or beverage products, and the materials include, but are not limited to, glass, plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, nylon, aluminum and / or other metals, or any combination thereof.

[0011] Referring here to Figure 2, a container for use with the carrier of the present disclosure is shown as a beverage container having a lower base portion B, a top portion T with a neck N tapered inward from the lower base portion, a flange portion F at the top of the neck portion extending radially outward from the neck portion, and a top surface TS below the flange portion including a pull tab P. In one embodiment, the upper and / or lower ends of the container may have a diameter D1 of about 66 mm, and the central portion of the container may have a diameter D2 of about 202 mm. In another embodiment, the upper and / or lower ends of the container may have a diameter DI of about 58 mm, and the central portion of the container may have a diameter D2 of about 200 mm. Containers of other sizes, shapes, and configurations may be held in the carrier without departing from the present disclosure. In embodiments, the carrier according to the present disclosure may comprise one or more containers to form a package.

[0012] Referring to Figure 1, the outer surface 21 of a blank 23 for forming a carrier for holding, supporting, and distributing one or more containers is shown. The blank 23 may have a longitudinal axis L1 and a transverse axis L2, as shown, and may include a central panel or top panel 25 having a container holding function section with a plurality of container holding openings or container openings 27.

[0013] As shown, the container openings 27 can be provided in a number corresponding to a desired number of containers to be held by the carrier formed from the blank 23, in a row-and-row arrangement. Although the top panel 25 is shown to have container openings 27 provided in two rows / columns of three openings 27 each, it should be understood that different numbers and / or arrangements of container openings 27 can be provided without departing from the present disclosure.

[0014] The container opening 27 can generally have a circular configuration, and the container retaining tabs 29 are each connected to the top panel 25 so as to be foldable at each of the respective curved fold lines 31 and portions of the curved fold lines 31, and are positioned to extend toward the center of each container opening 27. The container retaining tabs 29 can be provided in a generally circumferentially disposed arrangement that abuts, separated by respective diagonal weakened lines 33, although it will be understood that a spacing can be provided between adjacent container retaining tabs 29 without departing from the present disclosure.

[0015] The container retaining tabs 29 are shown as generally trapezoidal or rectangular elements having a free edge facing the center of each container opening 27, although it should be understood that one or more of the container retaining tabs 29 can have a different configuration or arrangement without departing from the present disclosure.

[0016] As described herein, the container opening 27 is configured to at least partially receive each container, for example, at least a top portion T of each container, such that the container retaining tabs 29 are biased upwardly at respective fold lines 31 to extend to a portion of each container, for example, to a flange portion F, to provide a secure engagement between the carrier / top panel 25 and each container.

[0017] In this regard, the preparation / processing of the blank 23 for forming the carrier can include one or more of separating adjacent container retaining tabs 29, for example, at the weakened lines 33, and / or at least partially folding the container retaining tabs 29 upwardly at respective fold lines 31 (broadly, “pre-breaking”) as preparation for at least partially receiving each container.

[0018] It will be understood that the blank 23 can have a different configuration without departing from the present disclosure.

[0019] Figure 3 generally shows a first exemplary embodiment of the system 100 for preparing / processing blanks 23 according to the present disclosure. As described herein, the system 100 can be configured to separate adjacent container-holding tabs 29, for example, to pre-break adjacent container-holding tabs 29 at a weakening line 33, and / or to fold the container-holding tabs 29 upward at each fold line 31, in preparation for at least partially receiving each container. The system 100 can also be configured to separate the blanks 23 from each other when supplied to the system 100 as a set of at least partially attached blanks 23, and / or pre-breaking the blanks 23 also includes such separation of the blanks 23.

[0020] The method and system 100 may include a mechanical frame for supporting various assemblies and their components as described herein. The mechanical frame may include, in various configurations, one or more bases, legs, columns, tie bars, platforms, etc., to provide a support structure for the assemblies and components described herein. For example, the mechanical frame may support such components above a base surface such as the ground or floor, and may provide access in one or more locations for a human operator to inspect, maintain, and / or otherwise operate the system 100. In one embodiment, the system 100 may be provided without an external frame.

[0021] Referring further to Figures 4 to 7A, the blank 23 can move through the system 100 from the upstream end 103 to the downstream end 105, generally in a downstream direction parallel to the downstream direction or in the machine direction M, defining the downstream direction with respect to the system 100, so that the blank 23 is engaged by various parts and components of the system 100. In this regard, the upstream direction with respect to the system 100 is the direction opposite to the machine direction M / downstream direction.

[0022] System 100 may include a blank feeding assembly 107 adjacent to its upstream end 103 for receiving the blanks 23 and sequentially distributing them in the machine direction M of System 100. Thus, System 100 may include feeder mechanisms such as hoppers, chutes, or other inline or right-angle distribution mechanisms.

[0023] As additionally shown, the blank feeding assembly 107 may include a substantially vertical base or support 109 (broadly speaking, the “first support”) on which a bed plate 111 is mounted for supporting one or more blanks 23 from the feeding mechanism. The bed plate 111 may be a substantially flat, elongated member defining a pair of substantially parallel slots 113 through which the bed plate 111 extends at least partially, as shown. The slots 113 are positioned to at least partially receive substantially upright blank engagement lugs 115, which are attached to and coupled to a drive belt 117 that is wound in a loop around a first roller 119 and a second roller 121.

[0024] One or both of the first roller 119 and the second roller 121 may have an overall configuration and / or one or more surface elements, such as a spool, gear, spoke, tread, knurling, etc., to facilitate engagement with the drive belt 117. The first roller 119 and the second roller 121 may each be rotatably mounted on the support 109 so as to rotate when driven by a rotation source, as described herein. In one embodiment, one or both of the first roller 119 and the second roller 121 may have the form of a gear or gear wheel.

[0025] In the illustrated embodiment, the system 100 may include a motor 123 coupled to a second roller 121 by a suitable transmission mechanism, such as a transmission shaft or one or more gear sets, to apply rotational force to the roller 121 when actuated, for example, by an electrical signal. The motor 123 is shown coupled to the roller 121 to cause its rotation, and the roller 119 is shown without an accompanying motor, but it will be understood that an additional motor may be provided and coupled to the roller 119 to cause its rotation when started. In one embodiment, a single motor may apply rotation to each of the rollers 119 and 121.

[0026] A motor as described herein may be any type of motor, engine, actuator, or other drive device that operates by converting energy, such as electrical energy and / or chemical fuel, into a mechanical energy output.

[0027] Continuing to refer to Figures 3-7A, the blanking assembly 125 can be positioned downstream of the blanking feed assembly 107 in the machine direction M. The blanking assembly 125 may include a ramp 126 positioned adjacent to and abutting the downstream end of the bed plate 111. The ramp 126 may be angled, inclined, otherwise formed, or oriented to extend further downstream along the blanking assembly 125, as shown. In the illustrated embodiment, the ramp 126 is inclined upward toward the forming wheel 131 from the blanking feed assembly 107, as will be further described herein.

[0028] The ramp 126 may be configured to support one or more blanks 23 and may include elongated slots or tracks 128 that receive a portion of the blanking assembly 125 and facilitate the downstream movement of the blanks 23 in the blanking assembly 125. Although the ramp 126 is shown and described as being located downstream of the blanking feed assembly 107 / bed plate 111, it will be understood that the ramp 126 may be considered a downstream portion of the blanking feed assembly 107 / bed plate 111 without departing from the present disclosure.

[0029] The blanking assembly 125 may include a forming belt 127 that extends around a series of rollers 129, for example, forming an outer circumference, so that the forming belt 127 is positioned in a closed path, as shown in the figure.

[0030] The rollers 129 may have one or more mechanisms for engaging with the forming belt 127, such as spurs, gears, spokes, treads, knurling, etc. The rollers may be configured to rotate in a common direction, for example counterclockwise, to position the forming belt 127 around them in a desired direction. As also shown, one or more of the rollers 129 may be equipped with a motor 123, for example, to apply a rotational force to it when activated. As further described herein, the rollers 129 may be driven to move the forming belt 127 so that the portion of the forming belt 127 that is close to the forming wheel 131 moves generally in the machine direction M.

[0031] The forming belt 127 can be a substantially flat member having a plurality of openings 133 formed through it, as shown. The forming belt 127 can be formed of a material suitable for withstanding the applied tension and / or engagement with each roller 129. In one embodiment, the forming belt 127 may include one or more polymer materials, composite materials, and metallic materials. In one embodiment, the forming belt 127 may include one or more reinforcing members, such as embedded structures, binders, braids, etc.

[0032] As further described herein, the opening 133 of the forming belt 127 can be formed with a diameter / arrangement corresponding to the diameter / arrangement of the container opening 27 and container retaining tab 29 of the blank 23. The opening 133 can extend, for example, through at least partially the thickness of the forming belt 127 so that the respective recesses are formed. In the illustrated embodiment, the opening 133 of the forming belt 127 may have a diameter D2 corresponding to the distance from a curved fold line / part of a curved fold line 31 of the blank 23 to a diametrically opposed curved fold line / part of a curved fold line 31.

[0033] When the forming belt 127 is positioned substantially planarly above each blank 23, the forming belt 127 is positioned as described above so that each opening 133 of the forming belt 127 can be aligned with the container opening 27 of the blank 23. In the illustrated embodiment, the openings 133 are shown to be formed along a portion of the belt 127, but it will be understood that the openings 133 can be provided along a longer length of the forming belt 127 without departing from the present disclosure.

[0034] A conveyor band 135 can be wrapped around the outer-facing surface of the forming belt 127 and positioned between rows of openings 133 in the forming belt, as shown in the figure. One or more blank engaging members, for example, lugs 137, can be coupled to the conveyor band 135 so as to follow the path of the forming belt 127 when the motor 123 is started. In this regard, the lugs 137 are at least partially supported on the belt 127 via the conveyor band 135. It will be understood that the conveyor band 135 can have different configurations, e.g., cables, belts, plates, rods, etc. In one embodiment, the conveyor band 135 can be formed from an elastic material, e.g., an elastomer material, or otherwise an elastically deformable and / or elastic material.

[0035] Continuing to refer to Figures 3 to 7A, and further to Figures 8 and 9, the forming wheel 131 can be rotatably mounted on a vertical support 109 and may be equipped with a motor 123 and associated mechanical transmission / gears for applying rotational force thereto in operation. As shown, the forming wheel 131 may have an outer blank engagement surface 139 along the outer circumference of the forming wheel 131 defining a plurality of forming members 141. As shown, one or more slots 151 may be defined along the forming wheel 131 and interrupt the blank engagement surface 139. In some embodiments, the slots 151 may be for at least partially receiving a cutting member, as further described herein.

[0036] The forming member 141 can be a generally cylindrical projection having a body portion 143 defined along the blank engagement surface 139 and a diameter D2 that roughly corresponds to the diameter D2 of the container opening 27 / container holding tab 29 in the blank 23 and the diameter of the opening 133 of the forming belt 127, as shown in the figure. As also shown, the forming member 141 can have a distal / free end portion 145 that tapers to a diameter smaller than the diameter D2. In the illustrated embodiment, the distal end portion 145 of the forming member 141 can have a bevel 147, for example, an angled or inclined surface having the overall shape of a conical cross-section, extending from the end of the body portion 143 to the distal end surface 149 of each forming member 141.

[0037] The distal end face 149 of each forming member 141 can define a diameter that approximately corresponds to the diameter D1 between the free edges of the diametrically opposed tabs 29 across the container opening 27 of the blank 23. In this regard, the diameter of the forming member 141 transitions across the bevel 147 from the diameter D1 at the distal end face 149 to the diameter D2 at the body portion 143. As further described herein, the outer surfaces of the distal end face 149, the bevel 147, and / or the body portion 143 may be positioned and configured to contact the respective portions of the blank 23. One or more of the forming members 141 may have different configurations without departing from the present disclosure. For example, one or both of the outer surfaces of the bevel 147 and / or the body portion 143 may have one or more intersecting planar surfaces, angled surfaces, segmented surfaces, or further inclined surfaces along them.

[0038] Referring to Figure 10, an alternative configuration of the forming wheel 131 is generally shown as 131A. The forming wheel 131 may include slots 151 that interrupt the blank engagement surface 139 to position cutting members 153 that at least partially protrude from the blank engagement surface 139 and have sufficient radial depth to at least partially receive each cutting member 153. As shown, the cutting members 153 may include one or more nick-breaking edges 155 for separating the joined blank 23, as will be further described below. In one embodiment, the slots 151 may be formed along one or more generally continuous portions of the blank engagement surface 139. In other embodiments, the forming wheel 131 may include a plurality of circumferential sections assembled to provide the blank engagement surface 139, and the slots 151 are defined between adjacent sections of the forming wheel 131 / blank engagement surface 139. It will be understood that the cutting members 153 may be provided in one or more of the respective slots 151 of the forming wheel 131 to provide the configurations described above.

[0039] As described herein, the preparation / processing of the blank 23 for formation into a carrier by system 100 may include, for example, separating adjacent container-holding tabs 29 at weakening lines 33 and / or folding the container-holding tabs 29 upward at each fold line 31 in preparation for at least partially accepting each container. It will be understood that system 100 may have configurations different from those described above to achieve the disclosed preparation / processing of the blank 23.

[0040] It will also be understood that the system 100 described above can be adapted to different types, configurations, and dimensions of blanks 23, for example, to streamline operation and minimize downtime, and to minimize the number of replacements and replacement parts involved in using the system 100 for different blanks. For example, one or more adjustment control units, such as levers, knobs, toggles, buttons, or tools (wrenches, etc.), can be connected to one or more tolerance adjustment components of the system 100 (e.g., nuts, bolts, screws, clamps, vises, jacks, lifts, cranks, wheels, etc.).

[0041] As another example, a portion of the blanking assembly 125, for example, one or more rollers 129 and forming wheel 131, as shown, can be mounted on a vertical support / base 110 (broadly speaking, a “second support”) that is adjustable relative to the vertical support / base 109 supporting the rest of the blanking assembly 125, thereby changing the distance between the forming belt 127 and the forming wheel 131. As shown, a lift mechanism 112, for example, a lift or jack (e.g., a hydraulic or pneumatic lift or jack, or other types of lift or jack), can be operably engaged with the vertical support / base 109 to raise the vertical support / base 110 vertically V relative to the vertical support / base 109, thereby bringing the forming belt 127 closer to or further engaging with the blanking engagement surface 139 of the forming wheel 131 and / or other parts of the blanking assembly 125, for example, the ramp 126. In one embodiment, such a lift mechanism 112 can be driven by a motor 123.

[0042] Referring again to Figures 1 to 7A, a method for preparing and processing a blank 23 using the system 100 according to an exemplary embodiment of the present disclosure will be described in general terms.

[0043] One or more blanks 23 can be inserted into the feed mechanism described above by placing them in the blank feeding assembly 107, for example, on a bed plate. It will be understood that the system 100 may be configured to handle a series of blanks 23 joined to each other by their respective lateral weakening lines. Such input of multiple consecutive blanks 23 into the system 100 can streamline the loading operation and reduce alignment errors, etc.

[0044] As shown in Figure 1, each container opening 27 can be spaced apart by a longitudinal distance D3, for example, corresponding to a distance M in the machine direction. In one embodiment, the distance between a container holding opening 27 adjacent to the side edge of the blank and the side edge, for example, at a weakening line 37, can be D3 / 2. In this regard, the distance between the approximate center of a container holding opening 27 adjacent to the rear edge of a blank 23 and the approximate center of a preceding container holding opening 27 adjacent to the front edge of the next consecutive blank 23 can be D3, and therefore the longitudinal distance between all adjacent joined blanks 23 and consecutive container holding openings traversing them can be D3. Such arrangement of blanks 23 and container openings 27 formed therein can also facilitate the subsequent engagement of the blanks 23, the carrier formed therefrom, and the product, as will be further described herein.

[0045] Each blank 23 engages substantially planar with the bed plate 111 such that, for example, the inner or downward surface of the blank 23 is in at least partially face-to-face contact with the bed plate 111. The blank engagement lugs 115 can move along a curved path around the roller 119 and are positioned to extend upward through a pair of container openings 27 at the leading edge of each blank 23. Further movement of the blank engagement lugs 115 through each slot 113 along the bed plate 111 in the machine direction M can move the blanks 23 in the machine direction M, for example, through sliding engagement with the bed plate 111.

[0046] It will be understood that multiple pairs of blank engagement lugs 115 can be attached to the drive belt 117 in a spaced-out relationship along the machine direction M. In one embodiment, pairs of blank engagement lugs 115 can be spaced along the drive belt 117 by a distance sufficient to allow each pair of blank engagement lugs 115 to extend upward through each pair of container openings 27 at the leading edge of each consecutive blank 23 of the multiple mounted blanks 23. In other embodiments, pairs of blank engagement lugs 115 can be spaced along the drive belt 117 by different distances, for example, so that each pair of blank engagement lugs 115 is positioned upward through each pair of container openings 27 at the leading edge of each consecutive blank 23 of the multiple mounted blanks 23. In some embodiments, blank engagement lugs 115 can be positioned to extend upward through each container opening 27 other than those at the leading edge of each blank 23.

[0047] Further driving of the drive belt 117 by rollers 119 and 121 moves the blank 23 in the machine direction M, bringing it closer to the ramp 126 and the blanking assembly 125. Upon entering the ramp 126 (when the motor 123 associated with the blanking assembly 125 is started), the forming belt 127 and the conveyor band 135 supported on it can be moved to align with each blank 23 as it moves slidably along the ramp 126, so that the blank 23 is positioned between the forming belt 127 and the ramp 126. In such alignment, the opening 133 of the forming belt 127 can be positioned to overlap and align with each of the container openings 27 of the blank 23, for example, so that a passage is provided from the container opening 27 of the blank 23 to the opening 133 of the forming belt 127 and through the opening 133.

[0048] Such alignment of the aforementioned portion of the forming belt 127 with the blank 23 also allows the blank 23 to move further along the ramp 126 by positioning the lugs 137 carried on the conveyor band 135 to extend through at least each recess 35 of each blank 23 and through the track 28 in the ramp 26 for at least partial insertion into the recess 35.

[0049] Such movement of the conveyor band 135 / lug 137 allows the blank 23 to move and engage with the forming wheel 131. As the forming wheel 131 rotates clockwise, the blank 23 and the forming belt 127 / conveyor band 135 positioned on it are at least partially wrapped around the outer blank engagement surface 139 of the forming wheel 131, so that the blank 23 is positioned between the forming belt 127 and the forming wheel 131, thereby forming the contour of the outer blank engagement surface.

[0050] In this configuration, the forming member 141 extending outward from the forming wheel 131 can be positioned to extend at least partially through each container opening 27 of the blank 23 into the opening 133 of the forming belt 127 above it. As the forming member 141 enters or extends through each container opening 27, the container retaining tabs 29 are contacted by the bevel 147 of the forming member 141 and can be biased to fold at least partially upward along their respective curved fold lines 31 or portions thereof. Such movement of the container retaining tabs 29 can also separate each adjacent container retaining tab 29 at their respective oblique weakening lines 33, at least partially. The thickness of the forming belt 127, its opening 133, can provide clearance for the container retaining tabs 29 of the blank 23 to separate and extend upward as described above. An example of a blank 23 pre-broken in this manner is shown in Figure 11.

[0051] In some embodiments, the pre-broken blank 23 can be maintained in a state of at least partial engagement with the forming belt 127 via frictional engagement between the container holding tab 29 and the portion of the forming belt 127 defining each container opening 27.

[0052] In one embodiment, the cutting member 153 can be positioned to protrude from the outer blank engagement surface 139 of the forming wheel 131 or 131A so as the blank 23 moves / passes over the forming wheel 131 or 131A, it can be positioned to cut / break the weakening line between the leading blank 23 (broadly defined as the "first blank") and the next consecutive / successor blank 23 (broadly defined as the "second blank"). In this regard, the blank 23 can be aligned with movement in the system 100 so that the weakening line between consecutive blanks 23 is substantially aligned with the cutting member 153 / slot 151 associated with the forming wheel 131, 131A. In other embodiments, for example, in a configuration of the system 100 where the forming wheel is provided without a cutting member, the consecutive blanks 23 can be separated by tension along each series of blanks 23 when engaged with the forming wheel 131, 131A as described above.

[0053] Therefore, each blank 23 can be processed, pre-broken, and separated from adjacent blanks 23 as it moves across the forming wheel 131. Such processing of the blanks 23 can facilitate the subsequent attachment of the blanks 23 and the carriers formed therefrom to their respective containers. In this regard, the blanks 23 can pass over the forming wheel 131 and be applied directly to product containers, or move further downstream for such purposes, for example, to a product engagement station. In one embodiment, the blanks 23 processed by the system 100 can be packaged, stacked, packed, or otherwise prepared for transport / shipment.

[0054] In this regard, the downstream portion of the blanking assembly 125 can form a product engagement portion 157 of the blanking assembly 125 / system 100, and one or more blanks 23 processed by the blanking assembly 125 can be positioned / prepared to be positioned on a series of products, such as containers C. Thus, the product engagement portion 157 of the blanking assembly 125 / system 100 can be positioned on a product conveyor or product group area so that the blanks 23 can be lowered into each group of containers C. The pre-broken blanks 23 are shown in Figure 11 as being positioned on a group of containers C and ready to engage with them. In some embodiments, the pre-broken blanks 23 can have a carrier configuration and may comprise one or more containers C as a package.

[0055] In addition to the several streamlined operations performed by the system 100 to process the blanks 23 as described above, in embodiments in which multiple joined blanks 23 are processed by the system 100, such separated blanks 23 can exit the system 100 / forming wheel 131 at intervals such that a generally uniform longitudinal distance D2 can be provided between the continuous container-holding openings 27 in all adjacent blanks 23, so that a product can be manufactured. For example, beverage containers C can be transported and carried toward the blanks 23 processed in a generally uniform arrangement without requiring product grouping or spacing to form specific groups corresponding to, for example, the number of container openings 27 in each blank 23.

[0056] Referring to Figures 12, 13, and 13A, a system for processing / machining a blank 23 according to a second exemplary embodiment of the present disclosure is shown as 200. System 200 may have one or more features that are the same or similar as those described above with respect to System 100, and similar or similar features are designated by similar or similar reference numbers.

[0057] As shown, the system 100 may have an upstream end 203 and a downstream end 205, a blank feeding assembly 107 adjacent to the upstream end 203, and a blanking assembly 225 downstream of the blank feeding assembly 107. One or more motors 123 may be provided to rotationally drive one or more respective rollers of each blank feeding assembly 107 and / or blanking assembly 225, as described above with respect to the system 100.

[0058] The blanking assembly 225 may include a generally flat and loop-shaped member having an opening 133 that extends to a depth that at least partially penetrates the forming belt 227, for example, a forming belt 227 generally similar to the forming belt 227 described above. However, in the illustrated embodiment, the forming belt 227 may be provided without a conveying band and instead be configured to at least partially receive or otherwise support one or more blanking engagement members, for example, lugs 137.

[0059] In some embodiments, the forming belt 227 may be configured to receive and support the lugs 137 at selected positions along the belt 227, so that a desired arrangement / spacing of the lugs 137 can be positioned along the belt 227 to engage with blanks 23 of different sizes and configurations.

[0060] The blanking assembly 225 may further include a ramp 226 that slopes generally downward from the downstream end of the blanking feed assembly 107 to receive the blank 23 and move the blank 23 along the blanking assembly 225. In some embodiments, the ramp 226 may define one or more tracks for receiving portions of the blanking assembly 225, such as lugs.

[0061] The ramp 226 extends generally diagonally downward from the blank feeding assembly 107 toward the forming wheel 231 and / or product engagement portion 257 of the blanking assembly 225, as shown in the figure. The ramp 226 can be positioned substantially parallel to a portion of the forming belt 227 and may have discontinuities where the forming wheel 231 intersects or abuts with the movement path of the blank 23 at least partially.

[0062] The forming wheel 231 can be rotatably mounted on a vertical support 109 and may be equipped with a motor such as a motor 123 and accompanying mechanical transmission members, gears, etc., for applying rotational force to it during operation. The forming wheel 231 has an outer blank engagement surface 239 along its circumference. One or more slots 251 may be configured to interrupt the blank engagement surface 239 and have a radial depth sufficient to at least partially receive each cutting member 253 so as to position the cutting members 253 that at least partially protrude from the blank engagement surface 239.

[0063] The cutting member 253 may include one or more nick-breaking edges for separating the joined blanks 23, as will be further described below. In some embodiments, the cutting member or nick-breaking edge may be formed as a projection from the blank engagement surface 239 of the forming wheel 231.

[0064] In some embodiments, the forming wheel 231 may have one of the forming wheels 131, 131A without departing from the present disclosure.

[0065] According to one exemplary embodiment, the system 200 can receive one or more blanks 23 at its upstream end 203, for example, in a blank feeding assembly 107, and proceed downstream through the blank feeding assembly 107 in the manner described above with respect to the system 100. Such starting and operation of the system 200 may include starting one or more of the motors 123.

[0066] Upon entering the ramp 226, the forming belt 227 can move to align with each blank 23. In such alignment, the openings 133 of the forming belt 127 can be positioned to overlap and align with each container opening 27 of the blank 23, for example, so that a passage through the opening 133 is provided from the container opening 27 of the blank 23 to the opening 133 of the forming belt 227.

[0067] Such alignment of the aforementioned portion of the forming belt 227 with the blank 23 can also be positioned to extend through the tracks in the ramp 226, in order to insert at least partially into the recesses 35 of each blank 23 and move the blank 23 further along the ramp 226.

[0068] Such movement of the blank 23 along the ramp 226 can move the blank 23 to engage with the forming wheel 231 so that the blank 23 is positioned between the forming belt 227 and the forming wheel 231. As the forming wheel 231 rotates clockwise, the cutting member 253 can be positioned to protrude from the outer blank engagement surface 239 of the forming wheel 231 so that it is positioned to cut and break the weakening line between the preceding blank 23 and the next consecutive subsequent blank 23 as the blank 23 moves and passes over the forming wheel 231. In this regard, the blank 23 can be aligned with respect to the movement of the system 200 so that the weakening line between consecutive blanks 23 is roughly aligned with the cutting member 253 / slot 251 associated with the forming wheel 231.

[0069] Therefore, each blank 23 can be separated from adjacent blanks 23 as it moves across the forming wheel 231. Such processing of the blanks 23 can facilitate the subsequent attachment of the blanks 23 and the carriers formed therefrom to each container. In this regard, the blanks 23 can pass over the forming wheel 231 and be applied directly to the product container, or they can be moved further downstream for such purposes, for example, to a product engagement station. In one embodiment, the blanks 23 processed by the system 200 can be packaged, stacked, packed, or otherwise prepared for transport / shipment.

[0070] In this regard, the downstream portion of the blanking assembly 225 can form a product engagement portion 257 of the blanking assembly 225 / system 200, where one or more blanks 23 processed by the blanking assembly 225 can be positioned and prepared on a series of products, such as containers C. For engagement with a group of containers, the container-holding tabs 29 of each blank 23 can be at least partially separated from each other by their respective diagonal weakening lines 33 and can be at least partially folded upward by their respective fold lines 31 in a configuration as shown in Figure 11.

[0071] In the illustrated embodiments, one or more portions of the blanking assembly 225 may have an increased length in the machine direction M. For example, in some embodiments, the ramp 226 may have an increased length generally in the machine direction M, and the ramp 226 may be positioned at a shallow bevel to allow for the machining of generally longer blanks 23 or a series of blanks 23 without the rear end of the blank curving into the portion of the forming belt 227 that curves into the roller 129. In some embodiments, the product engagement portion 257 may have an increased length generally in the machine direction M to facilitate the disengagement of the lugs 137 from each blank 23 at the downstream end 205 of the system 200, for example. In some embodiments, the portion of the forming belt 227 that curves around the roller 129 at the downstream end 205 of the system 100 may extend upward and backward from there to facilitate such disengagement of the lugs 137 from each blank 23.

[0072] In this regard, system 200 can be configured to provide and process blanks 23, which have the same advantages as those described above with respect to system 100.

[0073] It will be understood that one or more of the components of the systems described herein may have different configurations without departing from this disclosure. It will also be understood that appropriate support structures (e.g., bases, legs, platforms, supports, braces, etc.) may be provided to support and facilitate the operation of the various components described herein.

[0074] Generally, the blanks of this disclosure may be formed from cardboard having calipers to be heavier and more rigid than ordinary paper. The blanks may also be formed from other materials such as cardboard, or any other material having properties suitable for enabling the structure to function at least generally as described above. The blanks may be coated with, for example, a clay coating. The clay coating may then be printed with products, advertisements, and other information or images. The blanks may then be coated with varnish to protect the information printed on the blanks. The blanks may also be coated on one or both sides of the blank with, for example, a moisture barrier layer. The blanks may also be laminated with or coated with one or more sheet materials in a selected panel or panel section.

[0075] The foregoing description of this disclosure illustrates and describes various embodiments. Since various modifications can be made to the above configurations without departing from the scope of this disclosure, all matters included in the foregoing description or shown in the accompanying drawings are intended to be interpreted as illustrative rather than restrictive. Furthermore, the scope of this disclosure encompasses various modifications, combinations, changes, etc., to the embodiments described above. In addition, while this disclosure shows and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of this disclosure as expressed herein, corresponding to the foregoing teachings and / or within the scope of the skills or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchangeable and applied to other illustrated and unillustrated embodiments of this disclosure.

Claims

1. A method for processing at least one blank for forming a container carrier, To prepare at least one blank comprising a central panel having multiple container openings, and at least one container holding tab extending to each of the multiple container openings and foldably connected to the central panel, Inserting the prepared at least one blank into the blank feeding assembly, Transferring at least one blank from the blank feeding assembly to a blanking assembly comprising a forming belt and a forming wheel, A method comprising moving the at least one blank between the forming belt and the forming wheel to at least partially bend the at least one container-holding tab of the at least one blank.

2. The method according to claim 1, wherein the forming belt includes a plurality of openings, and the method further comprises aligning each of the plurality of openings of the forming belt with each of the plurality of container openings of the at least one blank.

3. The method according to claim 1, wherein the at least one blank is a first blank and is detachably connected to a second blank, and moving the at least one blank between the forming belt and the forming wheel includes separating the first blank from the second blank using at least one cutting member configured to protrude from the forming wheel.

4. The method according to claim 2, wherein the forming wheel includes a plurality of forming members protruding therefrom, and moving the at least one blank between the forming belt and the forming wheel further includes receiving each of the plurality of forming members at least partially into each of the plurality of openings in the forming belt.

5. The method according to claim 1, wherein the at least one container retaining tab includes adjacent container retaining tabs that are detachably connected, and moving the at least one blank between the forming belt and the forming wheel includes separating the adjacent container retaining tabs.

6. The method according to claim 1, wherein the forming belt supports at least one lug protruding from the forming belt, and the method further comprises moving the at least one blank at least partially along the blanking assembly by engaging the at least one lug with a portion of the at least one blank.

7. The method according to claim 1, wherein moving the at least one blank from the blank feeding assembly to the blanking assembly includes moving the at least one blank slidably along a ramp extending upward toward the forming wheel from the blank feeding assembly.

8. The method according to claim 1, wherein moving the at least one blank from the blank feeding assembly to the blanking assembly includes moving the at least one blank slidably along a ramp extending downward toward the forming wheel from the blank feeding assembly.

9. The method according to claim 1, wherein the blank feeding assembly and the forming wheel are at least partially mounted on a first support, and at least a portion of the blanking assembly is mounted on a second support, the method further comprising moving the first support relative to the second support to change the distance between the forming belt and the forming wheel.

10. A system for processing blanks for forming container carriers, Upstream end and The downstream end defines the machine direction from the upstream end to the downstream end of the aforementioned system, A blank feeding assembly located near the upstream end of the system, A blanking assembly located downstream of the blank feeding assembly, comprising a forming belt driven in a closed path around a plurality of rollers, and a forming wheel rotatably mounted on a support, A system in which the forming belt and the forming wheel are configured to move at least one blank between the forming belt and the forming wheel, thereby at least partially bending the at least one container holding tab of the at least one blank, which comprises a central panel having a plurality of container openings and at least one container holding tab extending to each of the plurality of container openings and foldably connected to the central panel.

11. The system according to claim 10, wherein the forming belt has a plurality of openings that are aligned with each of the container openings of the plurality of container openings of the at least one blank.

12. The system according to claim 10, wherein the at least one blank is a first blank and the first blank is separated from the second blank by at least one cutting member configured to be detachably connected to the second blank and protruding from the forming wheel.

13. The system according to claim 10, wherein the at least one container-holding tab includes adjacent container-holding tabs that are detachably connected, and the forming belt and the forming wheel are configured to move the at least one blank between the forming belt and the forming wheel to separate the adjacent container-holding tabs.

14. The system according to claim 12, wherein the forming wheel comprises a blank engagement surface interrupted by at least one slot, and the at least one cutting member is at least partially received within the at least one slot.

15. The system according to claim 11, wherein the forming wheel comprises a plurality of forming members that protrude from the forming wheel and are positioned to be at least partially inserted into each of the plurality of openings of the forming belt.

16. The system according to claim 15, wherein at least one of the plurality of forming members includes a main body portion and a tapered distal portion, and the main body portion has a diameter corresponding to the diameter of each of the plurality of openings of the forming belt.

17. The system according to claim 10, wherein the forming belt supports at least one lug protruding from the forming belt, and the lug is configured to engage with the at least one blank.

18. The system according to claim 17, wherein a conveying band is positioned at least partially around the forming belt, and the at least one lug is supported on the conveying band.

19. The system according to claim 10, wherein the blanking assembly comprises a ramp extending upward from the blank feeding assembly toward the forming wheel.

20. The system according to claim 10, wherein the blanking assembly comprises a ramp extending downward from the blank feeding assembly toward the forming wheel.

21. The system according to claim 10, wherein the blank feeding assembly and the forming wheel are at least partially mounted on a first support, and at least a portion of the blanking assembly is mounted on a second support, the second support being movable relative to the first support.

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