Method and system for manufacturing a blank to form a carrier for a container

Abstract

A method for processing at least one blank to form a carrier for a container comprises the step of obtaining at least one blank comprising 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 comprises the steps of inserting at least one blank into a blank infeed assembly; moving at least one blank from the infeed assembly to a blank processing assembly having a forming belt and 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 joining portion of the blank processing assembly so that at least one blank is positioned to be joined with a group of containers.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims priority to U.S. provisional patent application No. 63 / 261,582 filed on September 24, 2021.

[0003] Inclusion by reference

[0004] The disclosure of U.S. provisional patent application No. 63 / 261,582 filed on September 24, 2021 is incorporated herein by reference for all purposes as the whole is presented herein. Background Technology

[0005] The present disclosure generally relates to a system and method for processing a blank to form a carrier, a package, and / or other suitable configuration. More specifically, the present disclosure relates to a method and system for processing a blank and a carrier formed therefrom. means of solving the problem

[0006] According to one embodiment, the present disclosure relates to a method for processing at least one blank to form a carrier for a container, comprising the step of obtaining at least one blank comprising 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 comprises the steps of inserting at least one blank into a blank infeed assembly; moving at least one blank from the infeed assembly to a blank processing assembly—the blank processing assembly comprises a forming belt and the blank processing assembly further comprises 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 so that at least one blank is positioned to engage with a group of containers.

[0007] According to another aspect, the present disclosure generally relates to a system for processing a blank to form a carrier for a container, the system comprising an upstream end, a downstream end defining a machine direction from the upstream end of the system to a downstream end, a blank infeed assembly adjacent to the upstream end of the system, and a blank processing assembly located downstream from the blank infeed assembly, the blank processing assembly comprising a forming belt driven in a closed path for a plurality of rollers and a forming wheel rotatably mounted on a support, the forming belt and the forming wheel are arranged so that at least one blank is processed before being at least partially received between the forming belt and the forming wheel and moved to a product engagement portion of the blank processing assembly.

[0008] Those skilled in the art will understand the aforementioned advantages and other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the drawings listed below. It is within the scope of this disclosure that the embodiments discussed above are provided individually and in various combinations. Brief explanation of the drawing

[0009] In accordance with common practice, the various features of the drawings discussed below are not necessarily drawn to scale. The dimensions of various features and elements within the drawings may be enlarged or reduced to more clearly illustrate embodiments of the present disclosure. FIG. 1 is a plan view of the outer surface of a blank for use with a system according to the present disclosure. FIG. 2 is a perspective view of a container suitable for use in a blank, carrier, and package formed by the system and method of the present disclosure. FIG. 3 is a perspective view of a system for processing a blank according to an exemplary embodiment of the present disclosure. Figure 4 is another perspective view of the system of Figure 3. Figure 5 is an enlarged perspective view of the blank infeed assembly of the system of Figure 3. Figure 6 is an enlarged perspective view of the blank processing assembly of the system of Figure 3. Figure 7 is another enlarged perspective view of the blank machining assembly of the system of Figure 3. FIG. 7a is an enlarged perspective view of a part of the blank machining assembly of the system of FIG. 3. Figure 8 is a perspective view of the forming wheel of the system of Figure 3. Fig. 9 is an enlarged perspective view of a part of the molding wheel of the system of Fig. 3. FIG. 10 is a perspective view of a part of an alternative configuration of a forming wheel. FIG. 11 is a perspective view of the blank of FIG. 1 processed by a part of the system of FIG. 3. FIG. 12 is a perspective view of a system for processing a blank according to a second exemplary embodiment of the present disclosure. Fig. 13 is another perspective view of the system of Fig. 12. FIG. 13a is an enlarged perspective view of the forming wheel of the system of FIG. 12. Corresponding parts are designated by corresponding drawing symbols throughout the drawing. Specific details for implementing the invention

[0010] The present disclosure relates to a system and method for manufacturing or processing a blank or other composition to further process and / or form a carrier for holding products, such as containers, e.g., food and beverage containers. The container may be made of a material suitable for composition for packaging a specific food or beverage article, and the material comprises, but is not limited to, glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and nylon; and aluminum and / or other metals; or any combination thereof.

[0011] Referring briefly to FIG. 2, a container for use with the carrier of the present disclosure is illustrated as a beverage container having a lower base portion (B), an upper portion (T) generally comprising a neck (N) tapering inward from the lower base portion, a flange portion (F) above the neck portion extending radially outward from the neck portion, and an upper surface (TS) below the flange portion comprising a pull tab (P). In one embodiment, the upper and / or lower end 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 end of the container may have a diameter (D1) of about 58 mm, and the central portion of the container may have a diameter (D2) of about 200 mm. Containers of different sizes, shapes, and configurations may be held in the carrier without departing from the present disclosure. In an embodiment, the carrier according to the present disclosure may be provided with one or more containers to form a package.

[0012] Referring to FIG. 1, an outer surface (21) of a blank (23) for forming a carrier for holding / supporting / distributing one or more containers is shown. As shown, the blank (23) may have a longitudinal axis (L1) and a transverse axis (L2) and may include a central panel or upper panel (25) having a container holding feature that includes a plurality of container holding openings or container openings (27).

[0013] As illustrated, the container openings (27) may be provided in a number of rows and columns corresponding to the desired number of containers to be held by the carrier formed from the blank (23). Although the upper panel (25) is illustrated as having container openings (27) provided in two rows / columns of three openings (27) each, it will be understood that different numbers and / or arrangements of container openings (27) may be provided without departing from the present disclosure.

[0014] The container opening (27) may generally have a circular configuration, and the container retaining tab (29) is foldably connected to the upper panel (25) at each portion of the curved fold line (31) / curved fold line (31) and is positioned to extend toward the center of each container opening (27). The container retaining tab (29) may be separated at each inclined weakening line (33) and may generally be provided in a circumferential arrangement that abuts, but it will be understood that a gap may be provided between adjacent container retaining tabs (29) without departing from the present disclosure.

[0015] Although the container holding tabs (29) are generally depicted as trapezoidal or rectangular elements having a free edge facing the center of each container opening (27), it will be understood that one or more of the container holding tabs (29) may have different configurations or arrangements without departing from the present disclosure.

[0016] As described in the specification, the container opening (27) is configured to receive at least partially each container, for example, the upper portion (T) of each container, and the container retaining tab (29) can be pressed upward from each fold line(s) (31) to extend into a portion of each container, for example, the flange portion (F), to provide a tight engagement between the carrier / upper panel (25) and each container.

[0017] In this regard, the manufacturing / processing of the blank (23) to form a carrier may include, for example, one or more steps of separating adjacent container retaining tabs (29) at a weakening line (33) and / or at least partially folding the container retaining tabs (29) upward at each folding line (31) in preparation for at least partially receiving each container (schematally, “pre-breaking”).

[0018] It will be understood that the blank (23) may have different configurations without departing from the present disclosure.

[0019] FIG. 3 generally illustrates a first exemplary embodiment of a system (100) for manufacturing / processing a blank (23) according to the present disclosure. As described herein, the system (100) may be configured to pre-break, for example, to separate adjacent container retaining tabs (29) at a weakening line (33) and / or to at least partially fold the container retaining tabs (29) upward at each folding line(s) (31) in preparation for at least partially receiving each container. The system (100) may also be configured to separate the blanks (23) from each other when supplied into the system (100) as a set of at least partially attached blanks (23), and / or pre-break the blanks (23) may also include such separation of the blanks (23).

[0020] The method and system (100) may include a machine frame that supports the various assemblies and components described herein. The machine frame may include one or more of bases, legs, struts, tie bars, platforms, etc., in various arrangements to provide a support structure for the assemblies and components described herein. For example, the machine frame may support these components on a base surface such as the ground or floor and may provide access routes at one or more locations for a human operator to inspect, maintain, and / or otherwise operate the system (100), for example. In one embodiment, the system (100) may be provided without an external frame.

[0021] With further reference to FIGS. 4 through 7a, the blank (23) can be moved through the system (100) from its upstream end (103) to its downstream end (105), generally in a downstream direction or machine direction (M)—which defines the downstream direction for the system (100) or is parallel to the downstream direction—and accordingly, the blank (23) is engaged with various parts and components of the system (100). In this regard, the upstream direction for the system (100) is opposite to the machine direction (M) / downstream direction.

[0022] The system (100) may include a blank infeed assembly (107) located near its upstream end (103) to receive and sequentially distribute a blank (23) in the machine direction (M) of the system (100). Accordingly, the system (100) may include a feeder mechanism such as a hopper, a chute, or other in-line or right-angle distribution mechanism.

[0023] As additionally illustrated, the blank infeed assembly (107) may include a generally vertical base or support (109) (schematically, "first support") on which a bed plate (111) is mounted to support one or more of the blanks (23) from the feeder mechanism. As illustrated, the bed plate (111) may be a generally flat and elongated member forming a pair of generally parallel slots (113) that extend at least a portion along the bed plate (111). The slots (113) are positioned to receive at least a portion of a generally upright / erect blank engaging lug (115) attached / coupled to a drive belt (117) looped around the first roller (119) and the 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 spur, gear, spoke, tread, knurl, etc., to facilitate engagement with the drive belt (117). Each of the first roller (119) and the second roller (121) may be rotatably mounted on a support (109) to rotate when driven by a rotating 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 a gear wheel.

[0025] In the illustrated embodiment, the system (100) may be provided with a motor (123) coupled to the second roller (121), such as a suitable transmission mechanism, such as a transmission shaft, a set of one or more gear units, to apply rotational force to the roller (121) when activated, for example, by an electrical signal. Although the motor (123) is illustrated as being coupled to the roller (121) to cause its rotation and the roller (119) is illustrated without an accompanying motor, it will be understood that an additional motor may be provided and coupled to the roller (119) to cause its rotation upon activation. In one embodiment, a single motor may apply rotation to each of the rollers (119, 121).

[0026] A motor as described in this specification may be any type of motor, engine, actuator, or other driving device that operates by converting energy, e.g., electrical energy and / or chemical fuel, into mechanical energy output.

[0027] Referring further to FIGS. 3 through 7a, the blank processing assembly (125) may be located downstream from the blank infeed assembly (107) in the machine direction (M). The blank processing assembly (125) may include a ramp (126) located adjacent to / abutting the downstream end of the bed plate (111). As illustrated, the ramp (126) may be inclined / slanted or otherwise shaped / oriented so as to extend further downstream along the blank processing assembly (125). In the illustrated embodiment, the ramp (126) is inclined upward from the blank infeed assembly (107) toward the forming wheel (131) as further described herein.

[0028] The ramp (126) may be configured to support one or more of the blanks (23) and may include a long slot or track (128) that accommodates a portion of the blank processing assembly (125) to facilitate the movement of the blank(s) (23) downstream of the blank processing assembly (125). Although the ramp (126) is illustrated and described as being located downstream of the blank infeed assembly (107) / bedplate (111), it will be understood that the ramp (126) may be considered as a downstream portion of the blank infeed assembly (107) / bedplate (111) without departing from the present disclosure.

[0029] As illustrated, the blank processing assembly (125) may include a forming belt (127) that extends around a series of rollers (129) so that the forming belt (127) is arranged in a closed path, for example, forming an outer circumference.

[0030] The roller (129) may have one or more features for engaging with the forming belt (127), such as spur, gear, spoke, tread, knurl, etc. The roller may be configured to rotate in a common direction, for example, counterclockwise, so that the forming belt (127) may be positioned around it in a desired direction. Also, as illustrated, one or more of the rollers (129) may be provided with a motor (123) to apply rotational force thereto, for example, when activated. As further described herein, the roller (129) may be driven and the forming belt (127) may be moved so that the portion of the forming belt (127) adjacent to the forming wheel (131) can generally move in the machine direction (M).

[0031] The forming belt (127) may be a generally flat member having a plurality of openings (133) formed therethrough as illustrated. The forming belt (127) may be formed of a material suitable for withstanding applied tension and / or engagement with each roller (129). In one embodiment, the forming belt (127) may comprise one or more of a polymer material, a composite material, and a metal material. In one embodiment, the forming belt (127) may comprise one or more reinforcing members, such as an embedded structure, a binder, a braid, etc.

[0032] As further described in this specification, the opening (133) of the forming belt (127) may 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) may extend at least partially through the thickness of the forming belt (127) so as to form, for example, each recess. In the illustrated embodiment, the opening (133) of the forming belt (127) may have a diameter (D2) corresponding to the distance from a portion of the curved fold line / curved fold line (31) to a portion of the blank (23) opposite to the curved fold line / curved fold line (31).

[0033] The aforementioned arrangement of the forming belt (127) is such that when the forming belt (127) is arranged in a generally flat arrangement over each blank (23), each opening (133) within the forming belt (127) can be aligned with the container opening (27) within the blank (23). Although the opening (133) is illustrated as being formed along a portion of the belt (127) in the illustrated embodiment, it will be understood that the opening (133) may be provided along a longer length of the forming belt (127) without departing from the present disclosure.

[0034] The transport band (135) may be wound around the outward surface of the forming belt (127) and, as illustrated, may be positioned between the rows of openings (133) of the forming belt. One or more blank engaging members, such as lugs (137), may be attached to the transport band (135) to follow the path of the forming belt (127) when the motor (123) is activated. In this regard, the lugs (137) are supported at least partially on the belt (127) through the transport band (135). It will be understood that the transport band (135) may have other configurations, such as cables, belts, plates, rods, etc. In one embodiment, the transport band (135) may be formed of a stretchable material, such as an elastomer material or otherwise an elastically deformable and / or elastic material.

[0035] Referring further to FIGS. 3 through 7a, and to FIGS. 8 and 9, a forming wheel (131) may be rotatably mounted on a vertical support (109), and a motor (123) and an accompanying mechanical transmission / gear device may be provided to apply rotational force thereto upon activation. As illustrated, the forming wheel (131) may have an outer blank engagement surface (139) along the circumference of the forming wheel (131) for forming a plurality of forming members (141). As illustrated, one or more slots (151) may be formed along the forming wheel (131) to cut off 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 illustrated forming member (141) may be a generally cylindrical projection having a body portion (143) that is formed along the blank engagement surface (139) and defines a diameter (D2) that generally corresponds to the diameter (D2) of the container opening (27) / container retaining tab (29) of the blank (23) and the diameter of the opening (133) of the forming belt (127). Also, as illustrated, the forming member (141) may have a distal / free end portion (145) that tapers to a diameter smaller than the diameter of D2. In the illustrated embodiment, the distal end portion (145) of the forming member (141) may have an inclined surface (147) extending from the end of the body portion (143) to the distal end surface (149) of each forming member (141), for example, an inclined or sloped surface having an overall profile of a conical section.

[0037] The distal end surface (149) of each forming member (141) may define a diameter (D1) that generally corresponds to the diameter between the free edges of oppositely facing tabs (29) across the container opening (27) of the blank (23). In this regard, the diameter of the forming member (141) transitions from the diameter (D1) at the distal end surface (149) to the diameter (D2) at the main body portion (143) across the inclined surface (147). As further described herein, the distal end surface (149), the inclined surface (147), and / or the outer surface of the main body portion (143) may be positioned and configured to contact each portion of the blank (23). One or more forming members (141) may have other configurations without departing from the present disclosure. For example, one or both of the outer surfaces of the inclined surface (147) and / or the body part (143) may have one or more intersecting planar surfaces / slanted surfaces / segment surfaces / additional inclined surfaces along it.

[0038] Returning to FIG. 9, an alternative configuration of the forming wheel (131) is generally designated as 131A. The forming wheel (131A) may include a slot (151) having a radial depth sufficient to receive at least partially each cutting member (153) to position a cutting member (153) that cuts the blank engagement surface (139) and protrudes at least partially from the blank engagement surface (139). The cutting member (153) may include one or more nick-breaking edges (155) for separating the joined blank (23), as illustrated and further described below. In one embodiment, the slot (151) may be formed along one or more generally continuous portions of the blank engagement surface (139). In another embodiment, the forming wheel (131) may comprise a plurality of circumferential sections assembled to provide a blank engagement surface (139), and a slot (151) is formed between adjacent sections of the forming wheel (131) / blank engagement surface (139). It will be understood that a cutting member (153) may be provided within one or more of the respective slots (151) of the forming wheel (131) to provide the configuration described above.

[0039] As described in this specification, the manufacturing / processing of a blank (23) for forming into a carrier by the system (100) may include, for example, separating adjacent container retaining tabs (29) at a weakening line (33) and / or at least partially folding the container retaining tabs (29) upward at each folding line(s) (31) in preparation for at least partially receiving each container. It will be understood that in order to achieve the disclosed manufacturing / processing of the blank (23), the system (100) may have a configuration different from that described above.

[0040] Additionally, it will be understood that the system (100) described above may be adjusted to accommodate different types / arrangements / dimensions of blanks (23), for example, to simplify operations and minimize downtime, for example, to minimize the number of replacement / change parts associated with the use of the system (100) for different blanks. For example, one or more adjustment controls, for example, levers, knobs, toggles, buttons, tools (such as wrenches), may be coupled to one or more tolerance adjustment features of the system (100) (for example, nuts, bolts, screws, clamps, vises, jacks, lifts, cranks, wheels, etc.).

[0041] As another example, one or more of the parts of the blank processing assembly (125), such as the roller (129) and the forming wheel (131) as illustrated, may be mounted on a vertical support / base (110) (broadly, "second support") that is adjustable to the vertical support / base (109) supporting the rest of the blank processing assembly (125) to change the distance between the forming belt (127) and the forming wheel (131). As illustrated, a lifting mechanism (112), for example, a lift or jack (e.g., a hydraulic or pneumatic lift or jack, or other types of lift or jack), may be operably engaged with a vertical support / base (109) to lift or raise the vertical support / base (110) relative to the vertical support / base (109) in the vertical direction (V), and may, for example, make the forming belt (127) closer or more engaged with the blank engagement surface (139) of the forming wheel (131) and / or other parts of the blank processing assembly (125), such as the ramp (126). In one embodiment, such a lifting mechanism (112) may be driven by a motor (123).

[0042] Referring again to FIGS. 1 to 7a, a method for manufacturing a blank (23) using a system (100) according to an exemplary embodiment of the present disclosure will be generally described.

[0043] One or more blanks (23) may be inserted into a blank in-feed assembly (107), for example, by placing the feeder mechanism described above on a bedplate. It will be understood that the system (100) may be configured to process a series of blanks (23) joined together at each transverse weakening line. Such input of multiple consecutive blanks (23) into the system (100) can simplify loading operations and enable the reduction of alignment errors, etc.

[0044] As illustrated in FIG. 1, each container opening (27) may be spaced apart by a longitudinal distance (D3) corresponding, for example, to a distance in the machine direction (M). In one embodiment, the distance between the container holding opening (27) adjacent to the transverse edge of the blank (27) and the transverse edge, for example, at the weakening line (37), may be D3 / 2. In this regard, the distance between the general center of the container holding opening (27) adjacent to the rear end edge of the blank (23) and the general center of the leading container holding opening (27) adjacent to the leading end edge of the next continuous blank (23) may be D3, so that the longitudinal distance between all adjacent combined blanks (23) and the continuous container holding openings (23) across them may be D3. This arrangement of the blank (23) / container opening (27) formed therein can also facilitate subsequent engagement of the blank (23) / carrier formed therefrom and the product, as further described in this specification.

[0045] For example, as each blank (23) reaches a generally flat engagement with the bedplate (111) so that the inner or downward facing surface of the blank (23) makes at least partial face-to-face contact with the bedplate (111), the blank engagement lug (115) can move along a curved path around the roller (119) and can be 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 lug (115) through each slot (113) along the bedplate (111) in the machine direction (M) can cause the blank (23) to move, for example, through a sliding engagement with the bedplate (111) in the machine direction (M).

[0046] It will be understood that multiple pairs of blank engagement lugs (115) may be attached to a drive belt (117) in a spaced-apart relationship along the machine direction (M). In one embodiment, the pairs of blank engagement lugs (115) may be spaced apart along the drive belt (117) by a distance sufficient for a pair of blank engagement lugs (115) to extend upward through a pair of container openings (27) at the leading edge of each successive blank (23) of the plurality of attached blanks (23). In another embodiment, the pairs of blank engagement lugs (115) may be spaced apart by different distances along the drive belt (117), for example, so that a pair of blank engagement lugs (115) are positioned upward through a pair of container openings (27) at a leading edge smaller than that of each successive blank (23) of the plurality of attached blanks (23). In some embodiments, the blank interlocking lugs (115) may be positioned to extend upward through each container opening (27) other than the leading edge of each blank (23).

[0047] Additional driving of the drive belt (117) by the rollers (119, 121) causes the blank(s) (23) to move in the machine direction (M) and approach the ramp (126) and the blank processing assembly (125). When entering the ramp (126) (and, when the motor (123) associated with the blank processing assembly (125) is activated), the forming belt (127) and the transport band (135) held thereon move to align with each blank (23) moving along the ramp (126), so that the blank (23) can be positioned between the forming belt (127) and the ramp (126). In this alignment, for example, the opening (133) in the forming belt (127) may be positioned overlapping / aligned with each container opening (27) in the blank (23) so as to provide a passage from / through the container opening (27) in the blank (23) to / through the opening (133) in the forming belt (127).

[0048] This alignment of the aforementioned portion of the forming belt (127) with the blank (23) can also position a lug (137) held on the transport band (135) to extend through the track (28) within the ramp (26) for at least partial insertion through / into at least each recess (35) of each blank (23) to further move the blank(s) (23) along the ramp (126).

[0049] This action of the transport band (135) / lug (137) can move the blank (23) to engage with the forming wheel (131). As the forming wheel (131) rotates clockwise, the blank (23) and the forming belt (127) / transport band (135) positioned thereon can at least partially wrap around or contour 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).

[0050] In this arrangement, a forming member (141) extending outward from the forming wheel (131) may be positioned to extend through each container opening (27) of the blank (23) and at least partially into the opening (133) of the forming belt (127) above it. When the forming member (141) enters / extends through each container opening (27), the container holding tab (29) may be pressed by contact with the inclined surface (147) of the forming member (141) so as to be folded at least partially upward along each curved fold line (31) / part thereof. This movement of the container holding tab (29) may also cause each adjacent container holding tab (29) to be separated from each other at least partially along each inclined weakening line (33). The thickness of the internal forming belt (127) / opening (133) may provide a gap so that the container retaining tab (29) of the blank (23) separates / extends upward as described above. An example of a pre-broken blank (23) in such a way is shown in FIG. 11.

[0051] In some embodiments, the pre-fractured blank (23) may be maintained in at least partial engagement with the forming belt (127) through frictional engagement of the portion of the forming belt (127) that forms the container holding tab (29) and the respective container opening (27).

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

[0053] Accordingly, each blank (23) can be processed / pre-fractured and separated from adjacent blanks (23) as it moves across the forming wheel (131). This processing of the blank (23) can facilitate subsequent attachment to each container of the blank (23) / carrier formed therefrom. In this regard, the blank (23) may pass over the forming wheel (131) to be applied directly to the product container or further moved downstream for this purpose, for example, to a product engagement station. In one embodiment, the blank (23) processed by the system (100) may be wrapped, laminated, packaged, and otherwise prepared for transport / shipping.

[0054] In this regard, a downstream portion of the blank processing assembly (125) may form a product engagement portion (157) of the blank processing assembly (125) / system (100), wherein one or more blanks (23) processed by the blank processing assembly (125) may be positioned / prepared to be placed on a series of products, such as containers (C). Accordingly, the product engagement portion (157) of the blank processing assembly (125) / system (100) may be positioned over a product conveyor or a product group area so that the blanks (23) can be lowered onto each group of containers (C). The pre-broken blanks (23) are shown in FIG. 11 as being positioned on a group of containers (C) and prepared to be engaged with the group of containers (C). In some embodiments, the pre-broken blanks (23) may have a carrier configuration and may have one or more containers (C) as a package.

[0055] In addition to the number of simplified operations performed by the system (100) to manufacture the blank (23) as described above, in an embodiment where a number of combined 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 within all adjacent blanks (23) and between continuous container holding openings (27) across the blanks (23), so that a product, e.g., a beverage container (C), can be transported / transported toward the processed blanks (23) in a generally uniform arrangement without the need for product grouping or spacing to form a number of special groups corresponding to, e.g., the container openings (27) of each blank (23).

[0056] Referring to FIGS. 12, 13 and 13a, a system for manufacturing / processing a blank (23) according to a second exemplary embodiment of the present disclosure is generally designated as 200. The system (200) may have one or more features identical or similar to those described above in relation to the system (100), and the similar or similar features are designated by similar or similar reference numerals.

[0057] As illustrated, the system (100) may have an upstream end (203) and a downstream end (205), a blank infeed assembly (107) adjacent to the upstream end (203), and a blank processing assembly (225) downstream from the blank infeed assembly (107). One or more motors (123) may be provided to rotate one or more rollers of each blank infeed assembly (107) and / or blank processing assembly (225) as described above in relation to the system (100).

[0058] The blank processing assembly (225) may include a generally flat looped member having an opening (133) that extends at least partially to a predetermined depth through the forming belt (227), which is generally similar to the forming belt (227) described above. However, in the illustrated embodiment, the forming belt (227) may be provided without a transport band and instead may be configured to receive at least partially or otherwise support one or more blank engaging members, such as lugs (137).

[0059] In some embodiments, the forming belt (227) may be configured to receive / support the lugs (137) at selected locations along the belt (227) so that the 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 blank processing assembly (225) may further include a ramp (226) that slopes generally downward from a downstream end portion of the blank infeed assembly (107) to receive and move the blank (23) along the blank processing assembly (225). In some embodiments, the ramp (226) may form one or more tracks to receive a portion of the blank processing assembly (225), e.g., a lug.

[0061] As illustrated, the ramp (226) extends downward, generally at an angle, from the blank infeed assembly (107) toward the forming wheel (231) and / or product engagement portion (257) of the blank processing assembly (225). The ramp (226) may be positioned in an arrangement generally parallel to a portion of the forming belt (227) and may have a discontinuity where the forming wheel (231) may at least partially intersect or come into contact with the travel path of the blank (23).

[0062] The forming wheel (231) may be rotatably mounted on a vertical support (109) and may be equipped with a motor such as a motor (123) and an accompanying mechanical transmission / gear device for applying rotational force thereto when activated. The forming wheel (231) has an outer blank engagement surface (239) along the circumference of the forming wheel (231). One or more slots (251) may be positioned to have a radial depth sufficient to at least partially accommodate each cutting member (253) to cut the blank engagement surface (239) and position a cutting member (253) protruding at least partially from the blank engagement surface (239).

[0063] The cutting member (253) may include one or more nick-break edges that separate the joined blanks (23) as further described below. In some embodiments, the cutting member or nick-break edge may be formed as a protrusion from the blank engagement surface (239) of the forming wheel (231).

[0064] In some embodiments, the molding wheel (231) may have one of the configurations of the molding wheel (131, 131A) without departing from the present disclosure.

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

[0066] When entering the ramp (226), the forming belt (227) can be moved to align with each blank (23). In this aligned state, the opening (133) in the forming belt (127) can be positioned to overlap / align with each container opening (27) in the blank (23), for example, so as to provide a passage from the container opening (27) in the blank (23) to / through the opening (133) in the forming belt (227).

[0067] This alignment of the aforementioned portions of the blank (23) and the forming belt (227) may also position the lugs (137) held on the forming belt (227) to extend into and / or through the track within the ramp (226) for at least partial insertion through / into each of the respective recesses (35) of each blank (23), thereby allowing the blank(s) (23) to be moved further along the ramp (226).

[0068] This movement of the blank(s) (23) along the ramp (226) can move the blank(s) (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) may be positioned to protrude from the outer blank engagement surface (239) of the forming wheel (231) so as to cut / break the weakening line between the leading blank (23) and the next continuous / rear blank (23) as the blank (23) moves / passes over the forming wheel (231). In this regard, the blank (23) may be aligned with the movement of the system (200) so that the weakening line between the continuous blanks (23) is generally aligned with the cutting member (253) / slot (251) associated with the forming wheel (231).

[0069] Accordingly, each blank (23) can be separated from adjacent blanks (23) as it moves across the forming wheel (231). This processing of the blank (23) can facilitate subsequent attachment to each container of the blank (23) / carrier formed therefrom. In this regard, the blank (23) may pass over the forming wheel (231) and be applied directly to the product container or further moved downstream for this purpose, for example, to a product engagement station. In one embodiment, the blank (23) processed by the system (200) may be wrapped, laminated, packaged, and otherwise prepared for transport / shipping.

[0070] In this regard, the downstream portion of the blank processing assembly (225) may form a product engagement portion (257) of the blank processing assembly (225) / system (200), wherein one or more blanks (23) processed by the blank processing assembly (225) may be positioned / prepared to be placed on a series of products, e.g., containers (C). When engaged with a group of containers (C), the container holding tabs (29) of each blank (23) may be separated from each other at least partially at each inclined weakening line (33) and may be folded at least partially upward at each folding line (31) in the configuration shown in FIG. 11.

[0071] In the illustrated embodiments, one or more portions of the blank processing assembly (225) may have an increased length in the machine direction (M). For example, in some embodiments, the ramp (226) may have a generally increased length in the machine direction (M) and a shallow angle of inclination so as to allow processing of the blank (23) or a series of blanks (23) for a generally longer length, with its rear end not entangled around the portion of the forming belt (227) in a curved engagement with the roller (129). In some embodiments, the product engagement portion (257) may have a generally increased length in the machine direction (M) to facilitate the disengagement of the lug (137) from each blank (23), for example, at the downstream end (203) of the system (200). In some embodiments, the portion of the forming belt (227) that curves around the roller (129) at the downstream end (203) of the system (100) may extend upward and rearward from it to facilitate this disengagement of the lug (137) from each blank (23).

[0072] In this regard, the system (200) may be configured to manufacture / process a blank (23) having advantages similar to those described above in relation to the system (100).

[0073] It will be understood that one or more components of the system described herein may have different configurations without departing from the present disclosure. It will be further understood that suitable support structures (e.g., bases, legs, platforms, supports, pedestals, etc.) may be provided to support the various components described herein and to facilitate their operation.

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

[0075] The foregoing description of the present disclosure illustrates and describes various embodiments. Since various variations may be made from the above configurations without departing from the scope of the present disclosure, all matters included in the foregoing description or depicted in the accompanying drawings are intended to be interpreted as examples rather than as limitations. Furthermore, the scope of the present disclosure includes various modifications, combinations, changes, etc., of the embodiments described above. Additionally, while the present disclosure illustrates and describes only selected embodiments, various other combinations, modifications, and settings are within the scope of the disclosure as expressed herein, correspond to the teachings above, and / or are within the art or knowledge of the relevant field. Furthermore, specific features and characteristics of each embodiment may be optionally interchangeable and applied to other illustrated and unillustrated embodiments of the present disclosure.

Claims

Claim 1 A method for processing at least one blank to form a carrier for a container, comprising the steps of: 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; inserting at least one blank into a blank infeed assembly; moving at least one blank from the infeed assembly to a blank processing assembly, wherein the blank processing assembly comprises a forming belt, and the blank processing assembly further comprises a forming wheel and at least one cutting member protruding from the forming wheel to engage with at least one blank; 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 so that the at least one blank is positioned for engagement with a group of containers. Claim 2 A method according to claim 1, wherein the forming belt comprises a plurality of openings, and the method further comprises the step of aligning each of the plurality of openings of a plurality of openings of at least one blank with each of the respective openings of the plurality of openings of the forming belt. Claim 3 A method according to paragraph 2, wherein at least one blank is a first blank and is detachably connected to a second blank, and the step of moving at least one blank between a forming belt and a forming wheel includes the step of separating the first blank from the second blank. Claim 4 A method according to paragraph 2, wherein the forming wheel comprises a plurality of forming members protruding from the forming wheel, and the step of moving at least one blank between the forming belt and the forming wheel further comprises the step of receiving each of the plurality of forming members at least partially in each of the openings of the plurality of openings of the forming belt. Claim 5 A method according to claim 4, wherein the step of moving at least one blank between a forming belt and a forming wheel further comprises the step of partially folding at least one container tab of at least one blank for each of the container openings of a plurality of container openings. Claim 6 In paragraph 2, the forming belt supports at least one lug protruding from the forming belt, and the method further comprises the step of moving at least one blank in at least a portion along a blank processing assembly by engaging at least one portion of the blank with at least one lug. Claim 7 A method according to claim 6, wherein the step of moving at least one blank from a blank infeed assembly to a blank processing assembly comprises the step of sliding at least one blank along a ramp extending upward from the blank infeed assembly toward a forming wheel. Claim 8 In claim 6, the step of moving at least one blank from a blank infeed assembly to a blank processing assembly comprises the step of sliding at least one blank along a ramp extending downward from the blank infeed assembly toward a forming wheel. Claim 9 In paragraph 2, the blank infeed assembly and the forming wheel are at least partially mounted on the first support, and at least a part of the blank processing assembly is mounted on the second support, and the method further comprises the step of moving the first support relative to the second support to change the distance between the forming belt and the forming wheel. Claim 10 A system for processing a blank to form a carrier for a container, comprising: an upstream end; a downstream end defining a machine direction from the upstream end of the system to the downstream end; a blank infeed assembly adjacent to the upstream end of the system; and a blank processing assembly located downstream from the blank infeed assembly, comprising a forming belt driven in a closed path for a plurality of rollers, a forming wheel rotatably mounted on a support, and at least one cutting member protruding from the forming wheel to separate adjacent blanks; wherein the forming belt and the forming wheel are arranged such that at least one blank is processed before being at least partially received between the forming belt and the forming wheel and moved to the product engagement portion of the blank processing assembly. Claim 11 In paragraph 10, the forming belt comprises a plurality of openings for aligning with each of the container openings of at least one blank. Claim 12 delete Claim 13 In claim 11, the forming wheel comprises a blank engagement surface separated by at least one slot, and at least one cutting member is at least partially received within at least one slot, a system. Claim 14 A system according to claim 11, wherein the forming wheel comprises a plurality of forming members positionable to protrude from the forming wheel and be inserted at least partially into each of the plurality of openings of the forming belt. Claim 15 A system according to claim 14, wherein at least one of the plurality of molding members comprises a main body portion and a tapered distal portion, and the main body portion has a diameter corresponding to the diameter of each opening of the plurality of openings of the molding belt. Claim 16 A system according to claim 11, wherein the forming belt supports at least one lug protruding from the forming belt, and the lug is configured to engage with at least one blank. Claim 17 In paragraph 16, a system in which a transport band is positioned at least partially around a forming belt, and at least one lug is supported on the transport band. Claim 18 In paragraph 11, the system comprises a blank processing assembly including a ramp extending upward from the blank infeed assembly toward the forming wheel. Claim 19 In paragraph 17, the system comprises a blank processing assembly including a ramp extending downward from the blank infeed assembly toward the forming wheel. Claim 20 In paragraph 11, the blank infeed assembly and forming wheel are at least partially mounted on a first support, at least a portion of the blank processing assembly is mounted on a second support, and the second support is movable relative to the first support, a system.

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