SYSTEMS AND METHODS FOR PACKAGING ARTICLES WITHIN A CARTON

FIELD

The present disclosure relates to article packaging and, more particularly, to systems and methods for packaging articles within a carton formed from a blank folded about the articles.

BACKGROUND

In the field of packaging, cartons are often used for carrying multiple articles. Cartons are useful for enabling consumers to transport, store, and access a group of articles for consumption. For cost and environmental considerations, such cartons or carriers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Further considerations include the strength of the carton and its suitability for holding and transporting articles. For example, it is desirable that the articles remain secure within the carton. Additional considerations include the level of automation available to form the carton around the articles. For example, it is desirable for a blank of sheet material to be fed into a packaging machine and automatically applied to (e.g., formed and/or wrapped about) the articles being packaged to form the carton. However, due to the design of the blank and/or the configuration of the carton that addresses the above-mentioned considerations, it can be challenging to automate formation of the carton from the blank using a machine. Accordingly, those skilled in the art continue with research and development efforts in the field of article packaging.

SUMMARY

Disclosed are a packaging system for forming a carton about a group of articles, a flap folding mechanism for folding a flap of a blank and a method for forming a carton about a group of articles, in particular, a method for folding a flap of a blank. The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure.

In an example, the disclosed system includes a conveyor configured to convey a group of articles and a blank, applied to the group of articles, along a packaging path. The system also includes a side panel folding mechanism, configured to fold a first side panel and a second side panel of the blank relative to a main panel of the blank and the group of articles and the blank travel along the packaging path. The system further includes an end panel folding mechanism, configured to fold an end panel of the blank relative to the main panel of the blank, after the first side panel and the second side panel of the blank are folded, as the group of articles and the blank travel along the packaging path. The system additionally includes a corner panel folding mechanism, configured to fold a first corner panel and a second corner panel of the blank relative to the first side panel and the second side panel of the blank, after the end panel is folded, as the group of articles and the blank travel along the packaging path. The system also includes a flap folding mechanism, configured to fold a flap of the blank relative to the end panel of the blank, after the first corner panel and the second corner panel of the blank are folded, as the group of articles and the blank travel along the packaging path. The flap is held between the end panel and the group of articles after the flap is folded.

In an example, the disclosed flap folding mechanism includes a base. The flap folding mechanism also includes a backing plate, coupled to the base. The flap folding mechanism further includes a pair of flap folding fingers, coupled to the base. The flap folding mechanism additionally include a first actuator, configured to rotate the pair of flap folding fingers relative to the backing plate between a first rotational position and a second rotational position. The flap folding mechanism also includes a second actuator, configured to move the pair of flap folding fingers relative to each other between a closed position and an open position.

In an example, the disclosed packaging method includes steps of: (1) folding a flap of a blank relative to an end panel of the blank such that the flap is positioned between the end panel and the group of articles; (2) folding a pair of wing portions of the flap into an approximately coplanar relationship with a central portion of the flap; and (3) holding the flap in position by the group of articles.

Other examples of the disclosed system, flap folding mechanism and method will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, plan view of an example of a blank for forming a carton;

FIG. 2 is a schematic, perspective view of an example of the carton formed from the blank shown in FIG. 1;

FIG. 3 is a schematic, perspective view of an example of the carton formed from the blank shown in FIG. 1, depicted in a stage of construction;

FIG. 4 is a schematic, perspective view of an example of the carton formed from the blank shown in FIG. 1, depicted in a stage of construction that is subsequent to the stage shown in FIG. 3;

FIG. 5 is a schematic, perspective view of an example of a portion of an interior of the carton formed from the blank shown in FIG. 1, depicted in a stage of construction that is subsequent to the stage shown in FIG. 4;

FIG. 6 is a schematic, plan view of another example of the blank for forming the carton;

FIG. 7 is a schematic, plan view of another example of the blank for forming the carton;

FIG. 8 is a schematic, plan view of an example of a second blank for forming the carton;

FIG. 9 is a schematic, plan view of an example of the carton formed from the blank shown in FIG. 7 and the second blank shown in FIG. 8, depicted in a stage of construction;

FIG. 10 is a schematic, plan view of an example of the carton formed from the blank shown in FIG. 7 and the second blank shown in FIG. 8, depicted in a stage of construction that is subsequent to the stage shown in FIG. 9;

FIG. 11 is a schematic, plan view of an example of the carton formed from the blank shown in FIG. 7 and the second blank shown in FIG. 8;

FIG. 12 is a schematic, enlarged view of an example of a portion of the carton shown in FIG. 11;

FIG. 13 is a schematic illustration of an example of a packaging system;

FIGS. 14-24 schematically illustrate examples of stages of a folding operation of the blank to form the carton;

FIG. 25 is a schematic illustration of an example of a portion of the packaging system shown in FIG. 13;

FIG. 26 is a schematic, perspective view of an example of a portion of the packaging system shown in FIG. 25;

FIG. 27 is a schematic, perspective view of an example of a portion of the packaging system;

FIG. 28 is a schematic, perspective view of an example of a portion of the packaging system;

FIG. 29 is a schematic, perspective view of an example of a flap folding mechanism, depicted in a first rotational position and in a closed position;

FIG. 30 is a schematic, perspective view of an example of the flap folding mechanism, depicted in a second rotational position and in an open position;

FIG. 31 is a schematic, elevational view of an example of the flap folding mechanism, depicted in the first rotational position and in the closed position;

FIG. 32 is a schematic, elevational view of an example of the flap folding mechanism, depicted in the closed position and moving between the first rotational position and the first rotational position;

FIG. 33 is a schematic, elevational view of an example of the flap folding mechanism, depicted in the second rotational position and in the closed position;

FIG. 34 is a schematic, elevational view of an example of the flap folding mechanism, depicted in the second rotational position and in the open position; and

FIGS. 35-48 schematically illustrate examples of stages of the folding operation of the blank to form the carton using the flap folding mechanism.

DETAILED DESCRIPTION

Referring to FIGS. 1-12, which schematically illustrate examples of a blank 400 (e.g., as shown in FIGS. 1 and 6-8) that is configured and used to form a carton 402 (e.g., as shown in FIGS. 2-5 and 9-12). The blank 400 is configured to be folded or otherwise formed about a plurality (e.g., a group) of articles B (e.g., as shown in FIGS. 2 and 9-11) such that at least a portion of each one of the articles B is packaged in the carton 402. As such, the carton 402 is configured to contain and carry the articles B. The examples of the carton 402 described herein and illustrated in the figures may also be referred to as an article carrier or a carrier.

Generally, each article B refers to a primary package for product. The carton 402 forms a secondary package for packaging the articles B (e.g., at least one primary product container or package). In the examples described herein, the terms “carton,” “carrier,” and like terms refer to a container for engaging and carrying articles, such as primary product containers. It is contemplated that the examples described herein can be applied to various product containers (e.g., different styles, types or configurations of articles B), which may be, but are not necessarily, tapered and/or cylindrical in shape. Exemplary articles B (e.g., product containers) include, but are not limited to, bottles (e.g., metallic, glass, or plastics bottles), cans (e.g., aluminum cans), tins, pouches, packets, other similar product containers, and the like.

In one or more examples, the blank 400 is configured to form the carton 402 for packaging an arrangement of articles B. The articles B may be arranged and packaged in the carton 402 in any suitable package configuration, such as in the form of a two pack, a four pack, a six pack, an eight pack (e.g., as shown in FIGS. 2 and 9-11), a twelve pack, etc. In the examples illustrated in FIGS. 1, 2 and 6-11, the arrangement is a 2×4 matrix or array. In the examples illustrated in FIGS. 2 and 9-11, two rows of four articles B are provided, and the articles B are beverage cans, such as 355 ml (12 oz) beverage cans. However, other types of articles B and/or other package configurations are also contemplated. As such, the blank 400 can be configured to form the carton 402 for packaging other types, numbers, and/or sizes or articles B and/or for packaging articles B in different arrangements or configurations. The articles B have been omitted from FIGS. 3-5 for illustrative purposes.

Referring generally to FIGS. 1, 6 and 7, in one or more examples, the blank 400 includes a plurality of panels connected to one another by a plurality of fold lines. Any one of the fold lines and/or hinge lines described herein, may include any suitable predefined or preformed line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided, such as a crease, a score, a perforation, relief cut, or the like. Generally, the fold lines transform the blank 400 into a plurality of separate but integral panels, flaps, tabs, etc. that form the carton 402. The preformed lines of weakening enable case in folding during assembly, construction and/or application of the carton 402.

Generally, the blank 400 is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, where suitable, for example, to provide the structure for the carton 402, as described in more detail below.

Accordingly, the packaging structure of the carton 402 may be formed from a sheet material such as paperboard, which may be made of or coated with materials to increase its strength. An example of such a sheet material is tear resistant NATRALOCK® paperboard made by WestRock Company. It should be noted that the tear resistant materials may be provided by more than one layer, to help improve the tear-resistance of the package. Typically, one surface of the sheet material may have different characteristics to the other surface. For example, the surface of the sheet material that faces outwardly from a finished package may be particularly smooth and may have a coating such as a clay coating or other surface treatment to provide good printability. The surface of the sheet material that faces inwardly may, on the other hand, be provided with a coating, a layer, a treatment or be otherwise prepared to provide properties such as one or more of tear-resistance, good glue-ability, heat sealability, or other desired functional properties.

Referring now to FIG. 1, which schematically illustrates a first example of the blank 400, which is capable of forming a first example of the carton 402 (e.g., as shown in FIG. 2) for containing and carrying a group of primary products, herein after referred to as the articles B (e.g., as shown in FIG. 2). Herein after, the first example of the blank 400 may also be referred to as blank 110 (e.g., as shown in FIG. 1) and the first example of the carton 402 may also be referred to as carton 190 (e.g., as shown in FIGS. 3-6).

In one or more examples, the blank 110 includes a plurality of panels (e.g., panels 112, 114A, 114B, 116A, 116B, 118, 120). In one or more examples, a main panel 112 forms a top wall or engaging panel of the carton 190 (e.g., as shown in FIG. 2).

In one or more examples, a first side panel 118 is hingedly connected to a first side of the main panel 112 by a hinged connection in the form of a fold line 117. A second side panel 120 is hingedly connected to a second side of the main panel 112 by a hinged connection in the form of a fold line 119.

In one or more examples, the blank 110 includes a first end structure. The first end structure includes a first upper end panel 114A that is hingedly connected to a first end of the main panel 112 by a hinged connection in the form of a fold line 113A. A first lower end panel 114B is hingedly connected to the first upper end panel 114A by a hinged connection in the form of a fold line 113B.

In one or more examples, the first end structure includes a first corner panel 160A that is hingedly connected to a first end of the first side panel 118 by a hinged connection in the form of a fold line 161A. A second corner panel 160B is hingedly connected to a first end of the second side panel 120 by a hinged connection in the form of a fold line 161B.

In one or more examples, the first end structure includes a first securing panel 164A that is hingedly connected to the first corner panel 160A by a hinged connection in the form of a fold line 163A. A second securing panel 164B is hingedly connected to the second corner panel 160B by a hinged connection in the form of a fold line 163B.

In one or more examples, a first web panel 168A is hingedly connected at one end to the first securing panel 164A by a hinged connection in the form of a fold line 169A and is hingedly connected at a second end to the first upper end panel 114A by a hinged connection in the form of a fold line 171A.

In one or more examples, a second web panel 168B is hingedly connected at one end to the second securing panel 164B by a hinged connection in the form of a fold line 169B and is hingedly connected at a second end to the first upper end panel 114A by a hinged connection in the form of a fold line 171B.

In one or more examples, the blank 110 includes a second end structure. The second end structure includes a second upper end panel 116A hingedly connected to a second end of the main panel 112 by a hinged connection in the form of a fold line 115A. A second lower end panel 116B is hingedly connected to the second upper end panel 116A by a hinged connection in the form of a fold line 115B.

In one or more examples, the second end structure includes a third corner panel 162A that is hingedly connected to a second end of the first side panel 118 by a hinged connection in the form of a fold line 165A. A fourth corner panel 162B is hingedly connected to a second end of the second side panel 120 by a hinged connection in the form of a fold line 165B.

In one or more examples, the first end structure includes a third securing panel 166A that is hingedly connected to the third corner panel 162A by a hinged connection in the form of a fold line 167A. A fourth securing panel 166B is hingedly connected to the fourth corner panel 162B by a hinged connection in the form of a fold line 167B.

In one or more examples, a third web panel 170A is hingedly connected at one end to the third securing panel 166A by a hinged connection in the form of a fold line 173A and is hingedly connected at a second end to the second upper end panel 116A by a hinged connection in the form of a fold line 175A.

In one or more examples, a fourth web panel 170B is hingedly connected at one end to the fourth securing panel 166B by a hinged connection in the form of a fold line 173B and is hingedly connected at a second end to the second upper end panel 116A by a hinged connection in the form of a fold line 175B.

It will be appreciated that the first side panel 118, the first corner panel 160A, the first securing panel 164A, the third corner panel 162A, and the third securing panel 166A form a first strap 164/160/118/162/166A along a first side of the main panel 112. Similarly, the second side panel 120, the second corner panel 160B, the second securing panel 164B, the fourth corner panel 162B, and the fourth securing panel 166B form a second strap 164B/160B/120/162B/166B along a second side of the main panel 112.

In one or more examples, the blank 110 includes first flap 172 that is hingedly connected to the first lower end panel 114B by a hinged connection. The hinged connection is defined, at least in part, by a cut line V1. The cut line V1 defines a tab P1 extending from an outer or lower edge of the first lower end panel 114B. The cut line V1 forms a receiver, in the form of an opening, slot or slit, for receiving a locking tab or detent C1. Each of the first and second securing panels 164A, 164B includes a locking tab or detent C1 extending from a lower edge thereof.

In one or more examples, the first flap 172 includes a pair of wing portions 174A, 174B that is hingedly connected by a respective fold line 177A, 177B to a central portion of the first flap 172. The fold lines 177A, 177B may be divergently arranged with respect to each other, for example, the fold lines 177A, 177B diverge towards the first lower end panel 114B.

In one or more examples, each of the first and second securing panels 164A, 164B includes a cutaway in the form of an aperture A5. Each aperture A5 forms a second receiver for receiving a respective second locking tab or detent C2. The first upper end panel 114A includes a pair of cut lines 101, each of which is substantially “U” shaped. Each cut line 101 defines a respective detent C2.

In one or more examples, the blank 110 includes second flap 176 that is hingedly connected to the second lower end panel 116B by a hinged connection. The hinged connection is defined, at least in part, by a cut line V2. The cut line V2 defines a second tab P2 extending from an outer or lower edge of the second lower end panel 116B. The cut line V2 forms a receiver, in the form of an opening, slot or slit, for receiving a locking tab or detent C2. Each of the third and fourth securing panels 166A, 166B includes a locking tab or detent C2 extending from a lower edge thereof.

In one or more examples, the second flap 176 includes a pair of wing portions 178A, 178B that is hingedly connected by a respective fold line 179A, 179B to a central portion of the second flap 176. The fold lines 179A, 179B may be divergently arranged with respect to each other, for example, the fold lines 179A, 179B diverge towards the second lower end panel 116B.

In one or more examples, each of the third and fourth securing panels 166A, 166B includes a cutaway in the form of an aperture A5. Each aperture A5 forms a second receiver for receiving a respective second locking tab or detent C2. The second upper end panel 116A includes a pair of cut lines 101, each of which is substantially “U” shaped. Each cut line 101 defines a respective detent C2.

In one or more examples, the main panel 112 includes a plurality of article retention structures RT. For example, the main panel 112 includes eight article retention structures RT arranged in 2×4 matrix or array. Each of the article retention structures RT includes an opening or aperture A4.

In one or more examples, each of the article retention structures RT includes a plurality of teeth 140 or tabs disposed about the aperture A4.

In one or more examples, the plurality of teeth 140 is provided by the main panel 112. Each of the teeth 140 is hingedly connected to the main panel 112, by a hinged connection. The hinged connection may be defined by a plurality of cut lines 141. The plurality of cut lines 141 may be arranged as an annular series of cuts about the apertures A4.

In one or more examples, the plurality of cut lines 141 defines or approximates a portion of circle.

In one or more examples, each of the plurality of teeth 140 includes an engaging edge opposing a hinged edge. The engaging edges are defined by a linear portion of a cut line defining the aperture A4. Each engaging edge may define a part of a polygon. The illustrated example includes sixteen teeth 140 together defining a hexadecagon. Each tooth 140 includes a pair of side edges, the side edges are defined by cut lines 143, 145 extending radially outward from respective vertices of the hexadecagon, that is to say, from a respective vertex between a pair of adjacent linear portions of the cut line defining the portion of a hexadecagon. The cut lines 143, 145 are divergently arranged with respect to each other and define an angle therebetween. The angle may be about 22.5 degrees. Each of the plurality of cut lines 141 may be linear in shape.

Turning now to the construction of the carton 190 from the blank 110 and referring to FIGS. 2-5, the blank 110 may be formed into an assembled carton 190, as shown in FIG. 2, after the blank 110 is applied to a group of the articles B.

In one or more examples, the end structures are folded to secure the first and second side panels 118, 120 about sides of a group of articles B. In one or more examples, the blank 110 is applied to the group of articles B in a flat form and folded thereabout.

The blank 10 is applied to a group of articles B. The blank 10 is lowered with respect to a group of articles B. Each of the article retention structures RT of the blank 10 is aligned with a respective article B in the group. Portions of the articles B pass through the main panel 12. The toothed regions of the main panel 12 about each of the article retention structures RT may be folded out of the plane of the main panel 12.

In one or more examples, the main panel 112 is lowered with respect to a group of articles B. The first and second side panels 118, 120 are folded about the opposing side of the group of articles B. The corner panels 160A, 160B, 162A, 162B are folded about the corners of the group of articles B and the securing panels 164A, 164B, 166A, 166B are folded about ends of the group of articles B.

Each toothed region of the main panel 12 may be folded about one of the articles B received in the respective one of the article-retention structures RT. The main panel 12 may deform about the article B for example but not limited to a shoulder portion of the article B, where the article B is a can the shoulder portion may be provide by the neck-in, as shown in FIG. 2. The engaging edges of the teeth 140 engage beneath a projection. The projection may be located about the neck or chime of the article B (which may provide a flange) of an article B. When the article B is a can, the projection may be provided by a canner's end seam. In other embodiments it may be provided by a ridge or undercut shaping of the article B or by an end closure of the article B for example but not limited to a crown cork or closure. In this way, the engaging edges grip or hold the article B and prevent or inhibit the article B from unintentionally separating from the main panel 12.

In one or more examples, the first and second upper end panels 114A, 116A are folded downwards about a respective end of the group of articles B. The first and second lower end panels 114B, 116B are folded upwardly with respect to the first and second upper end panels 114A, 116A such that the detents C2 can be inserted into the apertures A5. The first and second lower end panels 114B, 116B are folded downwardly to return to a substantially coplanar relationship with the respective one of the first and second upper end panels 114A, 116A to which they are hinged (e.g., as shown in FIG. 3). The articles B have been omitted from FIG. 4 for illustrative purposes.

In one or more examples, the first and second flaps 172, 176 are folded internally, the wing portion 174A, 174B, 178A, 178B are folded with respect to the central portion so as to pass the side walls of adjacently disposed articles B (e.g., as shown in FIG. 4). The articles B have been omitted from FIG. 4 for illustrative purposes.

Referring to FIG. 5, which illustrates an interior view of an end portion of the carton 190, for example, formed by the second end structure of the blank 110. The articles B have been omitted from FIG. 5 for illustrative purposes. While not explicitly illustrated, the opposing end portion of the carton 190, for example, formed by the first end structure of the blank 110 may be substantially the same as illustrated in FIG. 5 and described herein below.

In one or more examples, the cut line V2 has formed an opening in which the locking tab C1 of each securing panel 166A, 166B is received. Similarly, in one or more examples, the cut line V1 has formed an opening in which the locking tab C1 of each securing panel 164A, 164B is received.

In one or more examples, the wing portions 178A, 178B are folded into coplanar relationship with the central portion of the flap 176. In this way, the flap 176 is held in position by the adjacently disposed articles B (not shown in FIG. 5). Similarly, in one or more examples, the wing portions 174A, 174B are folded into coplanar relationship with the central portion of the flap 172. In this way, the flap 172 is held in position by the adjacently disposed articles B.

In one or more examples, the flap 176 is held in the folded condition by the articles B (not shown in FIG. 5) and inhibits disengagement of the locking tabs C1 from the receiver. Similarly, in one or more examples, the flap 172 is held in the folded condition by the articles B and inhibits disengagement of the locking tabs C1 from the receiver.

In one or more examples, the flap 176 in the folded condition is in face-to-face relationship with the portions of the detents C2 received in the apertures A5 of the securing panels 166A, 166B. In one or more examples, the flap 176 inhibits disengagement of detents C2 from the apertures A5. Similarly, in one or more examples, the flap 172 in the folded condition is in face-to-face relationship with the portions of the detents C2 received in the apertures A5 of the securing panels 164A, 164B. In one or more examples, the flap 172 inhibits disengagement of detents C2 from the apertures A5.

In one or more examples, with the flap 176 in the folded condition, the locking tabs C1 of the securing panels 166A, 166B are received (e.g., at least a portion of the locking tabs C1 extend through) the cut line V2. Similarly, with the flap 172 in the folded condition, the locking tabs C1 of the securing panels 164A, 164B are received (e.g., at least a portion of the locking tabs C1 extend through) the cut line V1.

In one or more examples, the tabs P1, P2 may conceal or protect the locking tabs C1 so as to improve security of the locking tabs C1 in the receiver.

Referring now to FIG. 6, which schematically illustrates a second example of the blank 400, which is capable of forming a second example of the carton 402 (not shown) for containing and carrying a group of articles B. Herein after, the second example of the blank 400 may also be referred to as blank 210 (e.g., as shown in FIG. 6).

The second example of the blank 400 (e.g., blank 210) shares many common features with the first example of the blank 400 (e.g., blank 110 shown in FIG. 1). Similarly, the second example of the carton 402 (not shown), formed from the second example of the blank 400 (e.g., blank 210), shares many common features with the first example of the carton 402 (e.g., carton 190 as shown in FIGS. 2-5), formed from the first example of the blank 400 (e.g., blank 110). Therefore, only the differences from the examples illustrated in FIGS. 1-5 will be described in any greater detail. In the second example of the blank 400 (e.g., blank 210 shown in FIG. 6), like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “200” to indicate that these features belong to the second example of the blank 400.

In one or more examples, the blank 210 includes a plurality of panels (e.g., panels 212, 214A, 214B, 216A, 216B, 218, 220. In one or more examples, a main panel 212 forms a top wall or engaging panel of the second example of the carton 402 (not shown).

In one or more examples, the main panel 212 includes at least one article retention structure RT1, RT2. The main panel 212 includes a plurality of article retention structures RT1, RT2. For example, the main panel 212 includes eight article retention structures RT1, RT2 arranged in 2×4 matrix or array. Each of the article retention structures RT1, RT2 includes an opening or aperture A7, A8.

In one or more examples, the article retention structures RT1, RT2 of the illustrated example include or take the form of a plurality of teeth 246, 244 or tabs arranged in an annular series about a respective aperture A7, A8 to form part of an article receiving opening.

In one or more examples, the blank 210 includes four first or endmost article retention structures RT1, each including a first opening or aperture A7. In one or more examples, the blank 210 includes four second, medial or intermediate article retention structures RT2, each including a second opening or aperture A8.

In one or more examples, the endmost article retention structures RT1 include an article receiving opening defined in part by the first aperture A7, which is defined in, or struck from, the main panel 212.

In one or more examples, the intermediate article retention structures RT2 include an article receiving opening defined in part by the second aperture A8, which is defined in, or struck from, the main panel 212.

In one or more examples, the endmost article retention structures RT1 and the intermediate article retention structures RT2 each includes a plurality of teeth 246, 244 or tabs disposed about the first or second aperture A7, A8 respectively.

In one or more examples, the plurality of teeth 246, 244 are provided by the main panel 212. Each of the teeth 246, 244 is hingedly connected to the main panel 212, by a hinged connection. The hinged connection may be defined by a plurality of cut lines 242, 243. The plurality of cut lines 242, 243 may be arranged as an annular series of cuts about the first or second apertures A1, A2. The plurality of cut lines 242, 243 may define or approximate a portion of circle.

In one or more examples, each of the first article retention structures RT1 is substantially similar in construction and will therefore be described in detail with reference to a first one of the first article retention structures RT1 located adjacent to a first end of the blank 210 (e.g., as shown in FIG. 6).

In one or more examples, the first article retention structure RT1 includes a plurality of first or full teeth 246 disposed about the aperture A1. Each of the plurality of first teeth 246 includes an engaging edge E1 opposing a hinged edge. The engaging edges E1 are defined by a linear portion of a cut line defining the aperture A7. Each engaging edge E1 defines a part of a hexadecagon. The illustrated example includes eight first teeth 246 together defining a portion of a hexadecagon. Each tooth 246 includes a pair of side edges, the side edges are defined by cut lines 247, 248 extending radially outward from respective vertices of the hexadecagon, that is to say, from a respective vertex between a pair of adjacent linear portions of the cut line defining the aperture A7. The cut lines 247, 248 are divergently arranged with respect to each other and define an angle therebetween. The angle may be about 22.5 degrees.

In one or more examples, the first article retention structure RT1 includes a plurality of first circumferential cut lines 243. Each of the plurality of first circumferential cut lines 243 is aligned with one of the radial cut lines 247, 248 such that the one of the radial cut lines 247, 248, or a notional extension thereof, bisects a respective one of the plurality of first circumferential cut lines 243.

In one or more examples, each of the plurality of first circumferential cut lines 243 is spaced apart from the one of the radial cut lines 247, 248 bisecting it so as to define a connecting nick, or bridge portion, between a pair of adjacently disposed teeth 246, 244.

In one or more examples, each of the plurality of first circumferential cut lines 243 may be linear in shape.

In one or more examples, the first article retention structure RT1 includes a plurality of second circumferential cut lines 242. Each of the plurality of second circumferential cut lines 242 is disposed between a pair of the plurality of first circumferential cut lines 243 and is spaced apart therefrom so as to define a pair of connecting nick, or bridge portions, between each tooth 246, 244 and the main panel 212. The pair of connecting nick or bridge portions provide a hinged or foldable connection between each tooth 246, 244 and the main panel 212.

In one or more examples, each of the plurality of second circumferential cut lines 242 may be linear in shape.

Alternatively, in one or more examples, each of the plurality of first circumferential cut lines 243 may be arcuate or curved. The first circumferential cut lines 243 may include a radius of curvature that is equal to half the diameter of the article receiving openings. The first circumferential cut lines 243 may include a radius of curvature that is greater than half the diameter of the apertures A7.

Alternatively, in one or more examples, each of the plurality of second circumferential cut lines 242 may be arcuate or curved. The second circumferential cut lines 242 may include a radius of curvature that is equal to half the diameter of the article receiving openings. The second circumferential cut lines 242 may include a radius of curvature that is greater than half the diameter of the aperture A7.

In one or more examples, the first and second circumferential cut lines 242, 243 (e.g., when linear) may be considered to define portions of a circle of infinite radius.

In one or more examples, the radius of curvature of each of the plurality of second circumferential cut lines 242 is equal to the radius of curvature of each of the plurality of first circumferential cut lines 243. However, in other embodiments it may be different.

Optionally, in one or more examples, the plurality of teeth 246, 244 is interrupted by a first recess or cutaway 256B. The first recess 256B lies upon a first notional line y-y. First notional line y-y extends radially from the center C of the apertures A7, AB and passes through the center of the first recess 256B. The first notional line y-y may extend across the grain of the blank 210. The first notional line y-y may be oriented perpendicularly with respect to the grain direction. The first notional line y-y may extend longitudinally of the blank 210.

Optionally, in one or more examples, the plurality of teeth 246, 244 is interrupted by a second recess or cutaway 256C. The second recess 256C lies upon a second notional line x-x. Second notional line x-x extends radially from the center C of the apertures A7, AB and passes through the center of the second recess 256C. The second notional line x-x may extend along the grain of the blank 210. The notional line x-x may be oriented parallel with respect to the grain direction. The notional line x-x may extend transversely, or laterally, of the blank 210.

In one or more examples, the first recess 256B is dimensioned so as to occupy a first arc defined by a first minor sector. The first minor sector is defined in part by a first sector notional line extending radially from the center C of the notional circle and passing through a side edge of a first partial tooth 244 disposed adjacent a first side of the first recess 256B and in part by a second sector notional line extending radially from the center C of the notional circle and passing through a side edge of a second partial tooth 244 disposed adjacent a second, opposing, side of the first recess 256B. The first and second sector notional lines define a second angle therebetween. The second angle may be in the range of 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the second recess 256C is dimensioned so as to occupy a second arc defined by a second minor sector. The second minor sector is defined in part by a third sector notional line extending radially from the center C of the notional circle and passing through a side edge of a third partial tooth 244 disposed adjacent a first side of the second recess 256C and in part by a fourth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a fourth partial tooth 244 disposed adjacent a second, opposing, side of the second recess 256C. The third and fourth sector notional lines define a third angle therebetween. The third angle may be in the range of 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the first and third sector notional lines define a major or first toothed sector, the first toothed sector defines a third arc; the third arc is occupied by teeth 246, 244, that is to say, teeth 246, 244 are disposed about the third arc, in a perimeter region of the first aperture A7.

In one or more examples, the second and fourth sector notional lines define a third minor sector or second toothed sector, the second toothed sector defines a fourth arc; the fourth arc is occupied by teeth 246, 244, that is to say, teeth 246, 244 are disposed about the fourth arc, in a perimeter region of the first aperture A7.

In one or more examples, the first article retention structure RT1 includes a first engaging tab T1 opposing the second recess 256C and a second engaging tab T2 opposing the first recess 256B.

In one or more examples, the first engaging tab T1 is disposed proximate the first or second side panel 218, 220. The second engaging tab T2 is disposed proximate the first or second upper end panel 214A, 216A. The first engaging tab T1 is integral with the main panel 212, that is to say, the first and second circumferential cut lines 242, 243 have been omitted. The first engaging tab T1 is proximate to the fold line 217, 219 hinging the main panel 212 to the respective side panel 218, 220.

In one or more examples, the second engaging tab T2 is integral with the main panel 212, that is to say, the first and second circumferential cut lines 242, 243 have been omitted. The second engaging tab T2 is proximate to the fold line 213A, 215A hinging the main panel 212 to the respective upper end panel 214A, 216A.

In one or more examples, each of the second article retention structures RT2 is substantially similar in construction and will therefore be described in detail with reference to a first one of the second article retention structures RT2 located adjacent to the first one of the first article retention structures RT1 (e.g., as shown in FIG. 6).

In one or more examples, the second article retention structure RT2 includes an article receiving opening defined in part by a second aperture A8.

In one or more examples, the second article retention structure RT2 includes a plurality of teeth 246, 244 disposed about the second aperture A8. The plurality of teeth 246, 244, or at least free edges thereof, may define or approximate a second notional circle.

In one or more examples, the plurality of teeth 246, 244 are hinged to the main panel 212 by a fold line. The fold line may be defined by a plurality of cut lines 242, 243. The plurality of cut lines 242, 243 may define or approximate a circle.

In one or more examples, the second aperture A8 includes a plurality of first or full teeth 246 disposed about the second aperture A8. Each of the plurality of first teeth 246 includes an engaging edge E1 opposing a hinged edge. The engaging edges E1 are defined by a linear portion of a cut line defining the second aperture A8. Each engaging edge E1 defines a part or side of a hexadecagon. The illustrated example includes seven first teeth 246 together defining a portion of a hexadecagon. Each tooth 246 includes a pair of side edges, the side edges are defined by cut lines 247, 248 extending radially outward from respective vertices of the hexadecagon, that is to say, from a respective vertex between a pair of adjacent linear portions of the cut line defining the second aperture A8. The cut lines 247, 248 are divergently arranged with respect to each other and define an angle therebetween. The angle may be about 22.5 degrees.

In one or more examples, the second article retention structure RT2 includes a plurality of first circumferential cut lines 243. Each of the plurality of first circumferential cut lines 243 is aligned with one of the radial cut lines 247, 248 such that the one of the radial cut lines 247, 248, or a notional extension thereof, bisects a respective one of the plurality of first circumferential cut lines 243.

In one or more examples, each of the plurality of first circumferential cut lines 243 is spaced apart from said one of the radial cut lines 247, 248 bisecting it so as to define a connecting nick, or bridge portion, between a pair of adjacently disposed teeth 246, 244. The connecting nick or bridge portion is disposed proximate a base of the teeth 246.

In one or more examples, each of the plurality of first circumferential cut lines 243 may be linear in shape.

In one or more examples, the second article retention structure RT2 includes a plurality of second circumferential cut lines 242. Each of the plurality of second circumferential cut lines 242 is disposed between a pair of the plurality of first circumferential cut lines 243 and is spaced apart therefrom so as to define a pair of connecting nick, or bridge portions, between each tooth 246, 244 and the main panel 212. The pair of connecting nick or bridge portions provide a hinged or foldable connection between each tooth 246, 244 and the main panel 212.

In one or more examples, each of the plurality of second circumferential cut lines 242 may be linear in shape.

In one or more examples, the plurality of teeth 246, 244 is interrupted by a first recess or cutaway 256B, by a second recess or cutaway 256C and by a third recess or cutaway 256A. The first and third recesses 256B, 256A each lie upon the first notional line y-y. The first notional line y-y may extend radially from the center C of the second aperture A8 and passes through the center of each of the first and third recesses 256B, 256A.

In one or more examples, the first recess 256B is dimensioned so as to occupy a first arc defined by a first minor sector. The first minor sector is defined in part by a first sector notional line extending radially from the center C of the notional circle and passing through a side edge of a first partial tooth 244, disposed adjacent to a first side of the first recess 256B, and in part by a second sector notional line extending radially from the center of the notional circle and passing through a side edge of a second partial tooth 244, disposed adjacent to a second, opposing, side of the first recess 256B. The first and second sector notional lines define an angle therebetween. The angle may be in the range of 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the second recess 256C is dimensioned so as to occupy a second arc defined by a second minor sector. The second minor sector is defined in part by a third sector notional line extending radially from the center C of the notional circle and passing through a side edge of a third partial tooth 244, disposed adjacent to a first side of the second recess 256C, and in part by a fourth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a fourth partial tooth 244, disposed adjacent to a second, opposing, side of the second recess 256C. The third and fourth sector notional lines define an angle therebetween. The third angle may be in the range of 35 degrees to 5 degrees and may be approximately 45 degrees.

In one or more examples, the third recess 256A is dimensioned so as to occupy a third arc defined by a third minor sector. The third minor sector is defined in part by a fifth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a fifth partial tooth 244, disposed adjacent to a first side of the third recess 256A, and in part by a sixth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a sixth partial tooth 244, disposed adjacent to a second, opposing, side of the third recess 256A. The fifth and sixth sector notional lines define an angle therebetween. The third angle may be in the range of 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the first and fifth sector notional lines define a major or first toothed sector, the first toothed sector defines a fourth arc; the fourth arc is occupied by teeth 246, 244, that is to say, teeth 246, 244 are disposed about the fourth arc, in a perimeter region of the second aperture A8.

In one or more examples, the second and fourth sector notional lines define a third minor sector or second toothed sector, the second toothed sector defines a fifth arc; the fifth arc is occupied by teeth 246, 244, that is to say teeth 246, 244 are disposed about the fifth arc, in a perimeter region of the second aperture A8.

In one or more examples, the third and sixth sector notional lines define a fourth minor sector or third toothed sector, the third toothed sector defines a sixth arc; the sixth arc is occupied by teeth 246, 244, that is to say, teeth 246, 244 are disposed about the sixth arc, in a perimeter region of the second aperture A8.

In one or more examples, the first and third recesses 256B, 256A are diametrically opposed to each other.

In one or more examples, the second recess 256C is oriented or disposed substantially orthogonally to the first and third recesses 256B, 256A.

In one or more examples, the center of the first and third recesses 256B, 256A of the second article retention structure RT2 are collinear with the center of the first recess 256B of the first article retention structure RT1.

In one or more examples, the first recess 256B of the second article retention structure RT2 is disposed proximate to the first recess 256B of the first article retention structure RT1 and is oriented in opposition thereto.

In one or more examples, each of the second recesses 256C of the second article retention structures RT2 is disposed proximate to a second recess of an adjacently disposed second article retention structures RT2 and is oriented in opposition thereto.

In one or more examples, each of the second recesses 256C of the first article retention structures RT1 is disposed proximate to a second recess 256C of an adjacently disposed first article retention structures RT1 and is oriented in opposition thereto.

In one or more examples, the second article retention structure RT2 includes a first engaging tab T1 opposing the second recess 256C.

In one or more examples, the first engaging tab T1 is disposed proximate the first or second side panel 218, 220. The first engaging tab T1 is integral with the main panel 212, that is to say, the first and second circumferential cut lines 242, 243 have been omitted. The first engaging tab T1 is proximate to the fold line 217, 219 hinging the main panel 212 to the respective side panel 218, 220.

In one or more examples, the grain of the material forming the blank 210 may be arranged to be tangential to the center of the first and third recesses 256B, 256A of the second article retention structure RT2. The grain of the material forming the blank 210 may be arranged to be tangential to the center of the first recess 256B of the first article retention structure RT1. In this way, in order for a tear to propagate between the first aperture A7 and the second aperture A8, the tear must propagate across the grain of the blank 210. In this way, the blank 210 is arranged to provide maximum resistance to tear propagation between the first and second apertures A7, A8.

In one or more examples, removal of the teeth 246, by providing recesses 256B, 256C, 256A at locations where two adjacent apertures A7, A8 are disposed in close proximity, for example, when packaging articles B of the sleek or slim design (e.g., articles B that are substantially of the same diameter over their entire height). In some examples, the variation in diameter between a top closure of the article B and the main body of the article B may be less than 7 millimeters, may be less than 5 millimeters, and optionally may be less than 4 millimeters, has been found to reduce the likelihood of tear propagation. This beneficial advantage may be a result of removal of the radial cut lines 247, 248 in regions of the blank 210 where the apertures A7, AB are in close proximity.

Referring now to FIG. 7, which schematically illustrates a third example of the blank 400, which is capable of forming a third example of the carton 402 (e.g., as shown in FIG. 9) for containing and carrying a group of articles B. Herein after, the third example of the blank 400 may also be referred to as blank 210A (e.g., as shown in FIG. 7) and the third example of the carton 402 may also be referred to as carton 292 (e.g., as shown in FIG. 9).

The third example of the blank 400 (e.g., blank 210A shown in FIG. 7) shares many common features with the first example of the blank 400 (e.g., blank 110 shown in FIG. 1) and with second example of the blank 400 (e.g., blank 210 shown in FIG. 6). Similarly, the third example of the carton 402 (e.g., carton 292 shown in FIG. 9), formed from the third example of the blank 400 (e.g., blank 210A shown in FIG. 7), shares many common features with the first example of the carton 402 (e.g., carton 190 as shown in FIGS. 2-5), formed from the first example of the blank 400 (e.g., blank 110 shown in FIG. 1) and with the second example of the carton 402 (not shown), formed from the second example of the blank 400 (e.g., blank 210 shown in FIG. 6). Therefore, only the differences from the examples illustrated in FIGS. 1-6 will be described in any greater detail. In the third example of the blank 400 (e.g., blank 210A shown in FIG. 7) and the third example of the carton 402 (e.g., carton 292 shown in FIG. 9), like numerals have, where possible, been used to denote like parts.

In one or more examples, the blank 210A includes a plurality of panels (e.g., panels 212, 214A, 214B, 216A, 216B, 218, 220). In one or more examples, a main panel 212 forms a top wall or engaging panel of the carton 292 (e.g., as shown in FIG. 9).

In one or more examples, a first side panel 218 is hingedly connected to a first side of the main panel 212 by a hinged connection in the form of a fold line 217.

In one or more examples, a second side panel 220 is hingedly connected to a second side of the main panel 212 by a hinged connection in the form of a fold line 219.

In one or more examples, the blank 210A includes a first end structure. The first end structure includes a first upper end panel 214A that is hingedly connected to a first end of the main panel 212 by a hinged connection in the form of a fold line 213A. A first lower end panel 214B is hingedly connected to the first upper end panel 214A by a hinged connection in the form of a fold line 213B.

In one or more examples, the first end structure includes a first corner panel 260A that is hingedly connected to a first end of the first side panel 218 by a hinged connection in the form of a fold line 261A. A second corner panel 260B is hingedly connected to a first end of the second side panel 220 by a hinged connection in the form of a fold line 261B.

In one or more examples, the first end structure includes a first securing panel 264A that is hingedly connected to the first corner panel 260A by a hinged connection in the form of a fold line 263A. A second securing panel 264B is hingedly connected to the second corner panel 260B by a hinged connection in the form of a fold line 263B.

In one or more examples, a first web panel 268A is hingedly connected at one end to the first securing panel 264A by a hinged connection in the form of a fold line 269A and is hingedly connected at a second end to the first upper end panel 214A by a hinged connection in the form of a fold line 271A.

In one or more examples, a second web panel 268B is hingedly connected at one end to the second securing panel 264B by a hinged connection in the form of a fold line 269B and is hingedly connected at a second end to the first upper end panel 214A by a hinged connection in the form of a fold line 271B.

In one or more examples, the blank 210A includes a second end structure. The second end structure includes a second upper end panel 216A that is hingedly connected to a second end of the main panel 212 by a hinged connection in the form of a fold line 215A. A second lower end panel 216B is hingedly connected to the second upper end panel 216A by a hinged connection in the form of a fold line 215B.

In one or more examples, the second end structure includes a third corner panel 262A that is hingedly connected to a second end of the first side panel 218 by a hinged connection in the form of a fold line 265A. A fourth corner panel 262B is hingedly connected to a second end of the second side panel 220 by a hinged connection in the form of a fold line 265B.

In one or more examples, the first end structure includes a third securing panel 266A that is hingedly connected to the third corner panel 262A by a hinged connection in the form of a fold line 267A. A fourth securing panel 266B is hingedly connected to the fourth corner panel 262B by a hinged connection in the form of a fold line 267B.

In one or more examples, a third web panel 270A is hingedly connected at one end to the third securing panel 266A by a hinged connection in the form of a fold line 273A and is hingedly connected at a second end to the second upper end panel 216A by a hinged connection in the form of a fold line 275A.

In one or more examples, a fourth web panel 270B is hingedly connected at one end to the fourth securing panel 266B by a hinged connection in the form of a fold line 273B and is hingedly connected at a second end to the second upper end panel 216A by a hinged connection in the form of a fold line 275B.

It will be appreciated that the first side panel 218, the first corner panel 260A, the first securing panel 264A, the third corner panel 262A, and the third securing panel 266A form a first strap 264A/260A/218/262A/266A along a first side of the main panel 212. The second side panel 220, the second corner panel 260B, the second securing panel 264B, the fourth corner panel 262B, and the fourth securing panel 266B form a second strap 264B/260B/220/262B/266B along a second side of the main panel 212.

In one or more examples, the blank 210A includes a first flap 272 that is hingedly connected to the first lower end panel 214B by a hinged connection. The hinged connection is defined, at least in part, by a cut line V1. The cut line V1 defines a tab P1 extending from an outer or lower edge of the first lower end panel 214B. The cut line V1 forms a receiver, in the form of an opening, slot or slit, for receiving a locking tab or detent D1. Each of the first and second securing panels 264A, 264B includes a locking tab or detent D1 extending from a lower edge thereof.

In one or more examples, the first flap 272 includes a pair of wing portions 274A, 274B that is hingedly connected by a respective fold line 277A, 277B to a central portion of the first flap 272. The fold lines 277A, 277B may be divergently arranged with respect to each other, for example, the fold lines 277A, 277B diverge towards the first lower end panel 214B.

In one or more examples, each of the first and second securing panels 264A, 264B includes a cutaway in the form of an aperture A9. Each aperture A9 forms a second receiver for receiving a respective second locking tab or detent D2. The first upper end panel 214A includes a pair of cut lines 201, each of which is substantially “U” shaped. Each cut line 201 defines a respective detent D2.

In one or more examples, the blank 210A includes second flap 276 that is hingedly connected to the second lower end panel 216B by a hinged connection. The hinged connection is defined, at least in part, by a cut line V2. The cut line V2 defines a second tab P2 extending from an outer or lower edge of the second lower end panel 216B. The cut line V2 forms a receiver, in the form of an opening, slot or slit, for receiving a locking tab or detent D1. Each of the third and fourth securing panels 266A, 266B includes a locking tab or detent D1 extending from a lower edge thereof.

In one or more examples, the second flap 276 includes a pair of wing portions 278A, 278B hingedly connected by a respective fold line 279A, 279B to a central portion of the second flap 276. The fold lines 279A, 279B may be divergently arranged with respect to each other, for example, the fold lines 279A, 279B diverge towards the second lower end panel 216B.

In one or more examples, each of the third and fourth securing panels 266A, 266B includes a cutaway in the form of an aperture A9. Each aperture A9 forms a second receiver for receiving a respective second locking tab or detent D2. The second upper end panel 216A includes a pair of cut lines 201, each of which is substantially “U” shaped. Each cut line 201 defines a respective detent D2.

In one or more examples, the main panel 212 includes at least one article retention structure RT1, RT2. The main panel 212 includes a plurality of article retention structures RT1, RT2. For example, the main panel 212 includes eight article retention structures RT1, RT2 arranged in 2×4 matrix or array. In one or more examples, each of the article retention structures RT1, RT2 includes an opening or aperture A7, A8.

In one or more examples, the article retention structures RT1, RT2 of the illustrated example include or take the form of a plurality of teeth 244, 246 or tabs arranged in an annular series about an aperture A7, A8 to form part of an article receiving opening.

In one or more examples, the blank 210A includes four first or endmost article retention structures RT1, each including a first opening or aperture A7. The blank 210A includes four second, medial or intermediate article retention structures RT2, each including a second opening or aperture A8.

In one or more examples, the endmost article retention structures RT1 and the intermediate article retention structures RT2 each include a plurality of teeth 244, 246 or tabs disposed about the first or second aperture A7, A8 respectively.

In one or more examples, the plurality of teeth 244, 246 are provided by the main panel 212. Each of the teeth 244, 246 is hingedly connected to the main panel 212, by a hinged connection. The hinged connection may be defined by a plurality of cut lines 251, 253. The plurality of cut lines 251, 253 may be arranged as an annular series of cuts about the first or second apertures A7, A8. The plurality of cut lines 251, 253 may define or approximate a portion of circle.

In one or more examples, each of the first article retention structures RT1 is substantially similar in construction and will therefore be described in detail with reference to a first one of the first article retention structures RT1, located adjacent to a first end of the blank 210A (e.g., as shown in FIG. 7).

In one or more examples, the first article retention structure RT1 includes an article receiving opening defined in part by the first aperture A7. In one or more examples, the first article retention structure RT1 includes a plurality of first or full teeth 244 disposed about the first aperture A7. Each of the plurality of first teeth 244 includes an engaging edge E1 opposing a hinged edge. The engaging edges E1 are defined by a linear portion of a cut line defining the aperture A7.

In one or more examples, each engaging edge E1 defines a part of a hexadecagon. The illustrated example includes six first teeth 244 together defining a portion of a hexadecagon. Each tooth 244 includes a pair of side edges, the side edges are defined by cut lines 241, 243 extending radially outward from respective vertices of the hexadecagon, that is to say, from a respective vertex between a pair of adjacent linear portions of the cut line defining the aperture A7. The cut lines 241, 243 are divergently arranged with respect to each other and define an angle therebetween. The angle may be approximately 22.5 degrees.

In one or more examples, the first article retention structure RT1 includes a plurality of first circumferential cut lines 251. Each of the plurality of first circumferential cut lines 251 is aligned with one of the radial cut lines 241, 243 such that the one of the radial cut lines 241, 243, or a notional extension thereof, bisects a respective one of the plurality of first circumferential cut lines 251.

In one or more examples, each of the plurality of first circumferential cut lines 251 is spaced apart from said one of the radial cut lines 241, 243 bisecting it so as to define a connecting nick, or bridge portion, between a pair of adjacently disposed teeth 244, 246.

In one or more examples, each of the plurality of first circumferential cut lines 251 may be linear in shape.

In one or more examples, the first article retention structure RT1 includes a plurality of second circumferential cut lines 253. Each of the plurality of second circumferential cut lines 253 is disposed between a pair of the plurality of first circumferential cut lines 251 and is spaced apart therefrom so as to define a pair of connecting nick, or bridge portions, between each tooth 244, 246 and the main panel 212. The pair of connecting nick or bridge portions provide a hinged or foldable connection between each tooth 244, 246 and the main panel 212.

In one or more examples, each of the plurality of second circumferential cut lines 253 may be linear in shape.

Alternatively, in one or more examples, each of the plurality of first circumferential cut lines 251 may be arcuate or curved. The first circumferential cut lines 251 may include a radius of curvature that is equal to half the diameter of the article receiving openings. The first circumferential cut lines 251 may include a radius of curvature that is greater than half the diameter of the apertures A7.

Alternatively, in one or more examples, each of the plurality of second circumferential cut lines 253 may be arcuate or curved. The second circumferential cut lines 253 may include a radius of curvature that is equal to half the diameter of the article receiving openings. The second circumferential cut lines 253 may include a radius of curvature that is greater than half the diameter of the aperture A7.

In one or more examples, the first and second circumferential cut lines 251, 253 (e.g., when linear) may be considered to define portions of a circle of infinite radius.

In one or more examples, the radius of curvature of each of the plurality of second circumferential cut lines 253 is equal to the radius of curvature of each of the plurality of first circumferential cut lines 251. However, in other examples it may be different.

Optionally, in one or more examples, the plurality of teeth 244, 246 is interrupted by a first recess or cutaway C2. The first recess C2 lies upon a first notional line y-y. First notional line y-y may extend radially from the center C of the apertures A7, A8 and passes through the center of the first recess C2. The first notional line y-y may extend across the grain of the blank 210A The first notional line y-y may be oriented perpendicularly with respect to the grain direction. The first notional line y-y may extend longitudinally of the blank 210A.

Optionally, in one or more examples, the plurality of teeth 244, 246 is interrupted by a second recess or cutaway C3. The second recess C3 lies upon a second notional line x-x. Second notional line x-x may extend radially from the center C of the apertures A7, A8 and passes through the center of the second recess C3. The second notional line x-x may extend along the grain of the blank 210A. The notional line x-x may be oriented parallel with respect to the grain direction. The notional line x-x may extend transversely, or laterally, of the blank 210A.

Optionally, in one or more examples, the plurality of teeth 244, 246 is interrupted by a third recess or cutaway C4. The third recess C4 lies upon the second notional line x-x. The first recess C2 is dimensioned so as to occupy a first arc defined by a first minor sector. The first minor sector is defined in part by a first sector notional line extending radially from the center C of the notional circle and passing through a side edge of a first partial tooth 246 disposed adjacent a first side of the first recess C2 and in part by a second sector notional line extending radially from the center C of the notional circle and passing through a side edge of a second partial tooth 246 disposed adjacent a second, opposing, side of the first recess C2. The first and second sector notional lines define a second angle therebetween. The second angle may be in the range of 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the second recess C3 is dimensioned so as to occupy a second arc defined by a second minor sector. The second minor sector is defined in part by a third sector notional line extending radially from the center C of the notional circle and passing through a side edge of a third partial tooth 246 disposed adjacent a first side of the second recess C3 and in part by a fourth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a fourth partial tooth 246 disposed adjacent a second, opposing, side of the second recess C3. The third and fourth sector notional lines define a third angle therebetween. The third angle may be in the range from 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the third recess C4 is dimensioned so as to occupy a third arc defined by a third minor sector. The third minor sector is defined in part by a fifth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a fifth partial tooth 246 disposed adjacent a first side of the third recess C4 and in part by a sixth sector notional line extending radially from the center C of the notional circle and passing through a side edge of a sixth partial tooth 246 disposed adjacent a second, opposing, side of the third recess C4. The third and fourth sector notional lines define a third angle therebetween. The third angle may be in the range from 35 degrees to 50 degrees and may be approximately 45 degrees.

In one or more examples, the second and third recesses C3, C4 are diametrically opposed to each other.

In one or more examples, the third and fifth sector notional lines define a major or first toothed sector, the first toothed sector defines a fourth arc; the fourth arc is occupied by teeth 244, 246, that is to say, teeth 244, 246 are disposed about the third arc, in a perimeter region of the first aperture A7.

In one or more examples, the first and fourth sector notional lines define a fourth minor sector or second toothed sector, the second toothed sector defines a fifth arc; the fifth arc is occupied by teeth 244, 246, that is to say, teeth 244, 246 are disposed about the fifth arc, in a perimeter region of the first aperture A7.

In one or more examples, the second and sixth sector notional lines define a fifth minor sector or third toothed sector, the third toothed sector defines a sixth arc; the sixth arc is occupied by teeth 244, 246, that is to say, teeth 244, 246 are disposed about the sixth arc, in a perimeter region of the first aperture A7.

In one or more examples, the first article retention structure RT1 includes a first engaging tab 249 opposing the first recess C2. The engaging tab 249 is disposed proximate the first or second upper end panel 214A, 216A. The engaging tab 249 is integral with the main panel 212, that is to say, the first and second circumferential cut lines 251, 253 have been omitted. The engaging tab 249 is proximate to the fold line 213A, 215A hinging the main panel 212 to the respective upper end panel 214A, 216A.

In one or more examples, each of the second article retention structures RT2 is substantially similar in construction and will therefore be described in detail with reference to a first one of the second article retention structures RT2, located adjacent to the first one of the first article retention structures RT1 (e.g., as shown in FIG. 7).

In one or more examples, the second article retention structure RT2 includes an article receiving opening defined in part by the second aperture A8. In one or more examples, the second article retention structure RT2 includes a plurality of teeth 244, 246 disposed about the second aperture A8. The plurality of teeth 244, 246, or at least free edges thereof, may define, or approximate, a second notional circle.

In one or more examples, the plurality of teeth 244, 246 is hinged to the main panel 212 by a fold line. The fold line may be defined by a plurality of cut lines 251, 253. The plurality of cut lines 251, 253 may define or approximate a circle.

In one or more examples, the second article retention structure RT2 is substantially similar in construction to the first article retention structure RT1, albeit the engaging tab 249 has been replaced with a fourth recess C1.

In one or more examples, the first and fourth recesses C2, C1 are diametrically opposed to each other.

In one or more examples, the second and third recesses C3, C4 are diametrically opposed to each other.

In one or more examples, the second and third recesses C3, C4 are oriented or disposed substantially orthogonally to the first and fourth recesses C2, C1.

In one or more examples, the center of the first and fourth recesses C2, C1 of the second article retention structure RT2 are collinear with the center of the first recess C2 of the first article retention structure RT1.

In one or more examples, the fourth recess C1 of the second article retention structure RT2 is disposed proximate to the first recess C1 of the first article retention structure RT1 and is oriented in opposition thereto.

In one or more examples, each of the second recesses C3 of the second article retention structures RT2 is disposed proximate to a second recess C3 of an adjacently disposed second article retention structures RT2 and is oriented in opposition thereto.

In one or more examples, each of the second recesses C3 of the first article retention structures RT1 is disposed proximate to a second recess C3 of an adjacently disposed first article retention structures RT1 and is oriented in opposition thereto.

In one or more examples, the grain of the material forming the blank 210A may be arranged to be tangential to the center of the first and fourth recesses C2, C1 of the second article retention structure RT2. The grain of the material forming the blank 210A may be arranged to be tangential to the center of the first recess C2 of the first article retention structure RT1. In this way, in order for a tear to propagate between the first aperture A7 and the second aperture A8, the tear must propagate across the grain of the blank 210A. In this way, the blank 210A is arranged to provide maximum resistance to tear propagation between the first and second apertures A7, A8.

In one or more examples, removal of the teeth 244, by providing recesses C1, C2, C3 at locations where two adjacent apertures A7, A8 are disposed in close proximity, may be advantageous, for example, when packaging articles B of the sleek or slim design, and has been found to reduce the likelihood of tear propagation. Slim design articles B are those that are substantially of the same diameter over their entire height. In some examples, the variation in diameter between a top closure of the article B and the main body of the article B may be less than 7 millimeters, may be less than 5 millimeters, and, optionally, may be less than 4 millimeters. This beneficial advantage may be a result of removal of the radial cut lines 241, 243 in regions of the blank 210A where the apertures A7, A8 are in close proximity.

In one or more examples, the main panel 212 includes a handle structure. The handle structure may include at least one handle opening A2. In the illustrated example, the blank 210A includes two handle openings A2. Each handle opening A2 is defined in or struck from a region of the main panel 212 disposed centrally between four aperture A7, A8 arranged as two adjacent pairs of apertures A7, A8. A first one of the handle openings A2 is disposed between a first pair of endmost apertures A7 and an adjacent pair of intermediate apertures A8. A second one of the handle openings A2 is disposed between a second pair of endmost apertures A7 and an adjacent pair of intermediate apertures A8. The second pair of endmost apertures A7 being disposed at an opposing end of the main panel 212 to the first pair of endmost apertures A7.

Turning now to the construction of the carton 292 from the blank 210A. The carton 292 formed from the blank 210A is shown in FIG. 9. The blank 210A may be formed into an assembled carton 292 after the blank 210A is applied to a group of the articles B.

In one or more examples, the end structures are folded to secure the first and second side panels 218, 220 about sides of a group of articles B. The blank 210A can be applied to the group of articles B in a flat form and folded thereabout.

In one or more examples, the main panel 212 is lowered with respect to a group of articles B. The first and second side panels 218, 220 are folded about opposing sides of the group of articles B. The corner panels 260A, 260B, 262A, 262B are folded about the corners of the group of articles B and the securing panels 264A, 264B, 266A, 266B are folded about ends of the group of articles B.

In one or more examples, the first and second upper end panels 214A, 216A are folded downwards about a respective end of the group of articles B. The first and second lower end panels 214B, 216B are folded upwardly with respect to the first and second upper end panels 214A, 216A such that the detents D2 can be inserted into the apertures A9. The first and second lower end panels 214B, 216B are folded downwardly to return to a substantially coplanar relationship with the respective one of the first and second upper end panels 214A, 216A to which they are hinged.

In one or more examples, the first and second flaps 272, 276 are folded internally and the wing portions 274A, 274B, 278A, 278B are folded with respect to the central portion so as to pass the side walls of adjacently disposed articles B.

In one or more examples, the cut lines V1, V2 form an opening in which the locking tab D1 of each securing panel 264A, 264B, 266A, 266B is received.

In one or more examples, the wing portions 274A, 274B, 278A, 278B are folded into coplanar relationship with the central portion of the respective flaps 272, 276. In this way, the flaps 272, 276 are held in position by the adjacently disposed articles B.

In one or more examples, the flaps 272, 276 are held in the folded condition by the articles B and, thus, inhibit disengagement of the locking tabs D1 from the receiver.

In one or more examples, the flaps 272, 276 in the folded condition are in face-to-face relationship with the portions of the detents D2 received in the apertures A9 and may inhibit disengagement of detents D2 from the apertures A9.

In one or more examples, the tabs P1, P2 may conceal or protect the locking tabs D1 so as to improve security of the locking tabs D1 in the receiver.

Referring now to FIG. 8, which schematically illustrates an example of a second blank 210B, which is capable of forming a portion of a fourth example of the carton 402 (e.g., as shown in FIGS. 10-12) for containing and carrying a group of articles B. Herein after, the fourth example of the of the carton 402 may also be referred to as carton 290 (e.g., as shown in FIG. 10-12). Generally, the second blank 210B forms a top cover or cover panel for the carton 290.

In one or more examples, the blank 210A and the second blank 210B form the carton 290. In other words, the second blank 210B (e.g., shown in FIG. 8) forms the top cover for the carton 292 (e.g., shown in FIG. 9) formed from the blank 210A (e.g., as shown in FIG. 7). However, in other examples, the blank 110 and the second blank 210B may form the carton 290. In other words, the second blank 210B (e.g., shown in FIG. 8) forms the top cover for the carton 190 (e.g., as shown in FIGS. 2-5) formed from the blank 110 (e.g., as shown in FIG. 1). In yet other examples, the blank 210 and the second blank 210B may form the carton 290. In other words, the second blank 210B (e.g., shown in FIG. 8) forms the top cover for the carton (not shown) formed from the blank 210 (e.g., as shown in FIG. 6)

The fourth example of the carton 402 (e.g., carton 290 shown in FIGS. 10-12), formed from the third example of the blank 400 (e.g., blank 210A shown in FIG. 7) and the second blank 210B (e.g., as shown in FIG. 8), shares many common features with the first example of the carton 402 (e.g., carton 190 as shown in FIGS. 2-5), formed from the first example of the blank 400 (e.g., blank 110 shown in FIG. 1), with the second example of the carton 402 (not shown), formed from the second example of the blank 400 (e.g., blank 210 shown in FIG. 6), and with the third example of the carton 402 (e.g., shown in FIG. 9), formed from the third example of the blank 400 (e.g., blank 210A shown in FIG. 7). Therefore, only the differences from the examples illustrated in FIGS. 1-7 and 9 will be described in any greater detail. In the fourth example of the carton 402 (e.g., carton 290 shown in FIGS. 10-12), like numerals have, where possible, been used to denote like parts.

In one or more examples, the second blank 210B includes a cover panel 254 having opposed marginal regions 254A, 254B. A first marginal region 254A is defined at least in part by a first fold line 257A. A second marginal region 254B is defined by a second fold line 257B.

In one or more examples, the first fold line 257A is interrupted by a plurality of article receiving structures in the form of slits or cut lines 256A. The slits 256A may be curvilinear in shape and may be substantially ‘U’ shaped.

In one or more examples, the second fold line 257B is interrupted by a plurality of article receiving structures in the form of slits or cut lines 256B. The slits 256B may be curvilinear in shape and may be substantially ‘U’ shaped.

In one or more examples, then the first and second marginal regions 254A, 254B are folded about the first and second fold lines 257A, 257B, respectively, the slits 256A, 256B open to form an article receiving slot or aperture. An edge of the first and second marginal regions 254A, 254B defined by the slits 256A, 256B provides an engaging edge that engage below a flange, chime or other projection or undercut provided by an article B received in the article receiving slot or aperture formed when the marginal regions 254A, 254B are folded with respect to a medial portion of the cover panel 254.

In one or more examples, the cover panel 254 includes at least one locking structure for locking the cover panel 254 to the main panel 212. A locking element L cooperates with the handle openings A2 in the main panel 212 to secure the cover panel 254 thereto.

In one or more examples, the handle openings A2 in the main panel 212 form receivers. The illustrated example includes two receivers.

In one or more examples, the locking structure includes at least one locking element L for being received in the receiver. The locking element L includes a tab 280 struck from the cover panel 254. The illustrated example includes two tabs 280, each arranged to be engageable with one of the handle openings A2. Each tab 280 is hinged to the cover panel 254 by a hinged connection 281. Each tab 280 may include at least one fold line 283, 285. In the illustrated example, the tab 280 includes a pair of fold lines 283, 285. The pair of fold lines 283, 285 may be divergently arranged with respect to each other. Each of the pair of fold lines 283, 285 may be non-linear in shape, for example, but not limited, to arcuate or curvilinear in shape.

In one or more examples, the nonlinear fold lines 283, 285 may encourage the tab 280 to return to a planar arrangement to increase security of the tab 280 when folded to be received within the receiver.

In one or more examples, the tab 280 may be substantially ‘arrow head’ shaped so as to define a pair of opposing shoulders or detents S (e.g., as shown in FIG. 12) for securely engaging the handle opening A2.

Turning now to the construction of the carton 290 and referring to FIGS. 10-12. In order to form the carton 290 (e.g., as shown in FIG. 10), the second blank 210B (FIG. 8) is lowered over the carton 292 (e.g., as shown in FIG. 9). The marginal regions 254A, 254B are folded downwardly about shoulders or necks of the articles B. The slits 256A, 256B open and receive a flange or lip of a respective article B (e.g., as shown in FIG. 10).

In one or more examples, the cover panel 254 is secured to the carton 292 by engaging the locking elements L in the receiver provided by the handle opening A2 in the main panel 212 (e.g., as shown in FIGS. 11 and 12). FIG. 12 shows an enlarged view of the tab 280 engaging the main panel 212 disposed therebelow. The tab 280 extends across a gap or void between the cover panel 254 and the main panel 212. The articles B maintain the cover panel 254 in a spaced apart relationship from the main panel 212. The upper portions of the articles B that pass through the main panel 212 prevent, or at least inhibit, the cover panel 254 from adopting a face contacting relationship with the main panel 212.

The present disclosure is directed to examples of the carton 402, which is a carrier of the top engaging type having improved article retention structures or article top engaging devices.

The examples of the carton 402 (e.g., carton 190 shown in FIG. 1, carton 292 shown in FIG. 9, carton 390 shown in FIG. 24) provide an article carrier for clipping or engaging on at least one article B. The carton 402 includes an engaging panel (e.g., main panel 112, main panel 212, main panel 312) that has at least one article-engaging structure RT; RT1, RT2 for engaging a part of the at least one article B. In one or more examples, the carton 402 includes a bundling, grouping or support structure for encircling the at least one article B. The bundling structure includes a first segment and a second segment.

In one or more examples, the first segment includes a first panel (e.g., first side panel 118, second side panel 218) that is hingedly connected to the engaging panel and a bridging portion (e.g., bridging portion 160A/164A, bridging portion 260A/264A) that is hingedly connected to the first panel.

In one or more examples, the second segment includes a second panel (e.g., first upper end panel 114A/first lower end panel 114B, first upper end panel 214A/first lower end panel 214B) that is hingedly connected to the engaging panel, a third panel (e.g., first flap 172, first flap 272) that is hingedly connected to the second panel and that is disposed in an overlapping position with the second panel, and a bridge-engaging feature in engagement with the bridging portion of the first segment.

In one or more examples, the bridging portion (e.g., bridging portion 160A/164A, bridging portion 260A/264A) may include a catch or detent for arresting or inhibiting relative movement between the bridging portion and the second panel and the third panel.

In one or more examples, the bridge-engaging feature is provided at least by the second panel and third panel such that at least part of the bridging portion is disposed between the second and third panels in face-contacting arrangement with the second and third panels. The bridge-engaging feature may include a first cutaway defined in at least one of the second and third panels. The first cutaway provides a first receiver for a first portion of the bridging portion.

In one or more examples, the bridge-engaging feature may include a second cutaway in at least one of the engaging panel and the second panel. The second cutaway provides a second receiver for a second portion of the bridging portion. The second cutaway may extend from or interrupt at least one article-engaging structure RT1, RT2.

In one or more examples, the carton 402 may include a handle opening defined, at least in part, in one of the panels forming the first or second segment. The handle opening may be defined in part in the engaging panel.

In one or more examples, the carton 402 may include a handle opening defined, at least in part, in the engaging panel.

The examples of the blank 400 (e.g., blank 110, blank 210, blank 210A, blank 310) may include at least a paperboard substrate. The material of the paperboard substrate may be selected from any conventional paperboard, for example, ranging in weight upwardly from about 10 pt., preferably from about 16 pt. to about 28 pt. (0.028″/−0.7 mm). An example of such a substrate is a 27-point (pt.) SBS board (solid bleached sulfate paperboard coated on one side, trade name PrintKote®) or CNK® board (Coated Natural Kraft®—an unbleached kraft paperboard having a clay coating on one side, trade name CarrierKote™) manufactured by WestRock® Company. The paperboard substrate may be a bleached or unbleached board. The board may be coated on at least one side, optionally the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and board composition.

The examples of the blank 400 may include a tear resistant layer laminated to the paperboard layer. It optionally includes an adhesive layer between the paperboard substrate and the tear resistant layer. The tear resistant layer may be disposed over the uncoated side of the paperboard substrate and may be formed of polymeric material and secured to the substrate. The tear resistant layer imparts toughness to the laminate structure. Suitable tear resistant materials may include, but not be limited to, tear resistant laminated sheet material, e.g., NATRALOCK®, which may include a layer of an n-axially oriented film, e.g., MYLAR®, which is a bi-axially oriented polyester, oriented nylon, cross-laminated polyolefin or high-density polyolefin. The orientation and cross-laminated structure of these materials contribute to the tear resistant characteristic. Also, tear resistance may be attributed to the chemical nature of the tear resistant material such as extruded metallocene-catalyzed polyethylene (mPE).

Alternatively, the tear resistant layer may be a layer of linear low-density polyethylene (LLDPE). In embodiments where linear low-density polyethylene (LLDPE) or mPE is used, it is not necessary to incorporate an adhesive layer. Other suitable materials having a high level of tear resistance may also be used.

The adhesive layer may be formed of polyolefin material such as a low-density polyethylene (LDPE). The adhesive layer may be placed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

Referring now to FIGS. 13 and 25-28, by way of examples, the present disclosure is directed to a packaging system 404. The present disclosure is also directed to portions, sub-systems, or machines of the system 404.

The packaging system 404 is configured to package the articles B within the carton 402, for example, by applying the blank 400 to the articles B and forming the blank 400 about the articles B. The examples of the carton 402 (e.g., carton 190 shown in FIGS. 2-5; carton 292 shown in FIG. 9; carton 290 shown in FIGS. 10-12, carton 390 shown in FIG. 24) may be formed from the examples of the blank 400 (e.g., blank 110 shown in FIG. 1; blank 210 shown in FIG. 6, blank 210A shown in FIG. 7, second blank 210B shown in FIG. 8, blank 310 shown in FIG. 14). Generally, the blank 400 is folded or formed about the articles B as described herein above. The articles B are packaged within the carton 402. The carton 402 filled with the group of articles B is also referred to herein as a completed package 406 (e.g., as shown in FIGS. 2, 11 and 24).

Referring now to FIGS. 14-24, which schematically illustrate a fourth example of the blank 400 in various stages of construction to form a fifth example the carton 402 (e.g., as shown in FIG. 24) for containing and carrying a group of articles B. Herein after, the fourth example of the blank 400 may also be referred to as blank 310 (e.g., as shown in FIGS. 14-23) and the fifth example of the carton 402 may also be referred to as carton 390 (e.g., as shown in FIG. 24).

The fourth example of the blank 400 (e.g., blank 310 shown in FIGS. 14-23) shares many common features with the first example of the blank 400 (e.g., blank 110 shown in FIG. 1), with second example of the blank 400 (e.g., blank 210 shown in FIG. 6) and with the third example of the blank 400 (e.g., blank 210A shown in FIG. 7). Similarly, the fifth example of the carton 402 (e.g., carton 390 shown in FIG. 24), formed from the fourth example of the blank 400 (e.g., blank 310 shown in FIGS. 14-23), shares many common features with the first example of the carton 402 (e.g., carton 190 as shown in FIGS. 2-5), formed from the first example of the blank 400 (e.g., blank 110 shown in FIG. 1), with the second example of the carton 402 (not shown), formed from the second example of the blank 400 (e.g., blank 210 shown in FIG. 6), with the third example of the carton 402 (e.g., carton 292 shown in FIG. 9), formed from the third example of the blank 400 (e.g., blank 210A), and with the fourth example of the carton 402 (e.g., carton 402 (e.g., carton 290 shown in FIG. 11), formed from the third example of the blank 400 (e.g., blank 210A shown in FIG. 7) and the second blank 210B (e.g., shown in FIG. 8). Therefore, only the differences from the examples illustrated in FIGS. 1-12 will be described in any greater detail. In the fourth example of the blank 400 (e.g., blank 310 shown in FIGS. 14-23) and the fifth example of the carton 402 (e.g., carton 390 shown in FIG. 24), like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “300” to indicate that these features belong to the fourth example of the blank 400 and the fifth example of the carton 402.

Referring to FIG. 14, in one or more examples, the blank 310 includes a main panel 312, a first side panel 318 and a second side panel 320. The blank 310 includes a first end structure 322 and a second end structure 324.

In one or more examples, the main panel 312 also includes at least one article retention structure RT that is configured to retain (e.g., receive, contain, and hold) at least one article B. Each of the article retention structures RT includes an opening or aperture A4. In one or more examples, each of the article retention structures RT includes a plurality of teeth or tabs, referred to herein as retention tabs 344, (e.g., as shown in FIG. 15) disposed about the aperture A4.

In one or more examples, the first end structure 322 includes a first end panel 314. The first end panel 314 includes a first upper end panel 314A and a first lower end panel 314B. The first end structure 322 also includes a first corner panel 360A and a first securing panel 364A. The first end structure 322 further includes a second corner panel 360B and a second securing panel 364B. The first end structure 322 additionally includes a first web panel 368A and a second web panel 368B. The first end structure 322 also includes a first flap 372.

In one or more examples, the second end structure 324 includes a second end panel 316. The second end panel 316 includes a second upper end panel 316A and a second lower end panel 316B. The second end structure 324 also includes a third corner panel 362A and a third securing panel 366A. The second end structure 324 further includes a fourth corner panel 362B and a fourth securing panel 366B. The second end structure 324 additionally includes a third web panel 370A and a fourth web panel 370B. The second end structure 324 also includes a second flap 376.

In one or more examples, the blank 310 includes other features, components or elements, such as those described herein above with respect to the blank 110, the blank 210 and/or the blank 210A and illustrated in FIGS. 1, 6 and 7.

Referring now to FIG. 13, in one or more examples, the packaging system 404 is a continuous motion packaging system for continuously packaging the group of articles B within the carton 402. In one or more examples, the packaging system 404 is configured to continuously process multiple blanks 400 to form (e.g., construct or assemble) multiple completed cartons 402 filled with multiple groups of the articles B (e.g., multiple completed packages 406).

While the examples generally illustrated in FIGS. 2, 9-11, 14-28, 35, 37, 39, 41, 43, 45 and 47 show a group of cans being packaged within the carton 402, those skilled in the art will recognize that various other products or articles B, such as bottles or other similar products containers, can be wrapped or otherwise packaged in cartons 402 moving through the packaging system 404. In one or more examples, the carton 402 includes a flat, top-engaging, wrap-style blank 400 that is designed to fold or be otherwise wrapped about the group of articles B received through the main panel of the blank 400 (e.g., the bottom or base panel of the carton 402).

In one or more examples, the packaging system 404 includes a plurality of stations, stages, modules, sub-systems, and/or machines. Each one of the stations is configured to perform (e.g., automatically or semi-automatically perform) one or more packaging operation. In one or more examples, the packaging system 404 includes a first station 408, a second station 410, a third station 412, and a fourth station 414. However, in other examples, the packaging system 404 may include other numbers and/or types of station, such as less than four stations or more than four stations.

In one or more examples, the packaging operation, or operations, described in association with any one of the stations may be associated with a different one of the stations or may be associated with an additional station that is configured to perform that discrete operation. Further, not every operation associated with packaging the articles B and/or forming the carton 402 is necessarily described in detail herein or associated with a particular station of the packaging system 404. As such, certain packaging operations, components, and/or materials, such as those that are well known or common in the industry, are not necessarily described in detail. Accordingly, the illustrative examples of the packaging system 404 and/or any one of the stations is not meant to imply structural or operational limitations with respect to the illustrative example.

In one or more examples, the first station 408 is configured to transport (e.g., continuously transport) a plurality of the articles B for packaging. In one or more examples, the first station 408 receives the articles B, which are output in a non-uniform and rapid manner from a filling or bottling line (not shown) and which are delivered on a mass conveyor (not shown).

In one or more examples, the second station 410 is connected to, such as in series with, the first station 408. In one or more examples, the second station 410 is configured to receive the articles B from the first station 408. In one or more examples, the second station 410 is further configured to group the articles B (e.g., in a 2×4 array as shown in FIG. 14). In one or more examples, the second station 410 is also configured to initially apply the blank 400 to the group of articles B (e.g., as shown in FIG. 15).

In one or more examples, the third station 412 is connected to, such as in series with, the second station 410. In one or more examples, the third station 412 is configured to receive the group of articles B and the blank 400, applied to the articles B, from the second station 410. In one or more examples, the third station 412 is further configured to fold the blank 400 about the group of articles B (e.g., as shown in FIG. 16-23) to form the carton 402 (e.g., as shown in FIG. 24).

In one or more examples, the fourth station 414 is connected to, such as in series with, the third station 412. In one or more examples, the fourth station 414 is configured to receive the completed package 406 (e.g., the fully formed carton 402 and the group of articles B packaged in the carton 402 (e.g., as shown in FIG. 24) from the third station 412. In one or more examples, the fourth station 414 is further configured to transport and discharge the completed package 406.

In one or more examples, the packaging system 404 includes a conveyor 416. The conveyor 416 is configured to convey (e.g., continuously convey) the articles B and the blank 400 along a packaging path. The packaging path defines a direction of travel (e.g., as indicated by directional arrows 418 shown in FIG. 13) of the articles B and the blank 400 during formation of the carton 402.

In one or more examples, the conveyor 416 includes a plurality of portions associated with certain packaging operations performed by the system 404. In one or more examples, the conveyor 416 includes a feed conveyor 420, a grouping conveyor 422, an assembly conveyor 424, and a discharge conveyor 426, each of which forming portions of the conveyor 416 of the packaging system 404. The conveyor 416, such as one or more of the feed conveyor 420, the grouping conveyor 422, the assembly conveyor 424, and the discharge conveyor 426, include any suitable features and/or components common to automated conveyor lines and configured to convey articles along an upper surface thereof, such as rollers, belts, endless chains, side lugs, front lugs, rear lugs, drive mechanisms, and the like.

The examples of the system 404 and operations performed to construct the carton 402 from the blank 400, described herein below and illustrated in FIGS. 25-28 refer to and depict the fourth example of the blank 400 (e.g., blank 310 shown in FIGS. 14-23) that forms the fifth example of the carton 402 (e.g., carton 390 shown in FIG. 24). However, the examples of the packaging system 404 and the operations for construction of the carton 402 from the blank 400 may be applied to other examples of the blank 400 (e.g., blank 110, blank 210, blank 210A).

In one or more examples, the feed conveyor 420 forms a portion of the first station 408. The feed conveyor 420 may also be referred to as an article feed conveyor or first conveyor. The feed conveyor 420 is configured to transport a series of the articles B along an article infeed path (e.g., a portion of the packaging path), such as in discrete lines or lanes defined by lane guides, as the articles B enter the packaging system 404 at an upstream end thereof. The lane guides are configured to maintain the articles B in their respective lanes and redirect the line of articles B toward an arranging and loading position.

In one or more examples, the packaging system 404 includes a processing machine (not shown). In one or more examples, the processing machine forms a portion of the first station 408. The processing machine is configured to receive and funnel an incoming mass of articles B into one or more lanes to create an incoming stream of articles B, such as that is one or two articles wide. The incoming stream of articles B is conveyed on the feed conveyor 420.

In one or more examples, the grouping conveyor 422 forms a portion of the second station 410. The grouping conveyor 422 may also be referred to as an article grouping conveyor or second conveyor. In one or more examples, the grouping conveyor 422 is in communication with the feed conveyor 420. The stream of articles B is transferred from the feed conveyor 420 to the grouping conveyor 422.

In one or more examples, the grouping conveyor 422 is configured to arrange a series of articles B (e.g., from the stream of articles B) in a suitable package configuration, such as a group of articles B in a 2×4 matrix or array. For example, the grouping conveyor 422 is configured to separate the series of articles B into groups of the correct number of articles B per blank 310. In one or more examples, the grouping conveyor 422 is configured to transport the series of articles B along one or more article grouping paths, such as in discrete lines or lanes defined by lane guides, as the articles B enter the grouping conveyor 422 at an upstream end thereof (e.g., from the feed conveyor 420) and move along the grouping conveyor 422. The lane guides are configured to maintain the articles B in their respective lanes and redirect the lines of articles B for arrangement in the group and for application of the blank 310.

In one or more examples, the packaging system 404 includes a machine for applying the blank 310 to the articles B, referred to herein as applicator machine 428. The applicator machine 428 may also be referred to as a blank applicator machine. In one or more examples, the applicator machine 428 forms a portion of the second station 410.

In one or more examples, the applicator machine 428 is configured to retrieve (e.g., pick up) the blank 310. In one or more examples, the applicator machine 428 is configured to transfer the blank 310 to the grouping conveyor 422. In one or more examples, the applicator machine 428 is configured to apply the blank 310 to the arranged group of articles B (e.g., as shown in FIG. 15).

In one or more examples, the blank 310 is aligned with and is applied to a group of articles B. Each one of the article retention structures RT of the blank 310 is aligned with a respective one of the articles B in the group (e.g., as shown in FIG. 14). A portion (e.g., an upper portion) of each one of the articles B passes through a corresponding, or respective, article retention apertures A4 in the main panel 312. The retention tabs 344 (e.g., as shown in FIG. 15) of the article retention structure RT, about each one of the retention apertures A4, are folded out of the plane of the main panel 312.

In one or more examples, the applicator machine 428 applies the blank 310 to the group of articles B such that upper ends of the articles B extend through the main panel 312 of the blank 310 (e.g., pass through the retention aperture A4) and are retained by the retention tabs 344 (e.g., as shown in FIG. 15). In one or more examples, the applicator machine 428 positions the blank 310 over the group of articles B (e.g., as shown in FIG. 14) and presses the blank 310 downwardly onto the group of articles B to load the group of articles B into the main panel 312 of the blank 310 (e.g., as shown in FIG. 15).

In one or more examples, the system 404 includes a hopper (not shown) in which a plurality of blanks 310, in a flat condition, are held ready for processing. In one or more examples, the hopper forms a portion of the second station 410. The blanks 310 are retrieved (e.g., received or removed) from the hopper by an applicator machine 428.

In one or more examples, the applicator machine 428 includes, or takes the form of, a rotary vacuum feeder (not shown). In one or more examples, the rotary vacuum feeder includes a plurality of grippers (e.g., suction cups coupled to a vacuum system). The grippers are connected to a rotating wheel unit driven by a drive shaft. A drive mechanism, such as a servo motor, is used to rotate the drive shaft.

In other examples, the applicator machine 428 may include additional or alternative components and/or operate in different manners. In one or more examples, the applicator machine 428 may include, or take the form of, any one of various other machines or tool heads configured to retrieve the blank 310, position the blank 310 relative to the group of articles B, and apply the blank 31 to the group of articles B.

In one or more examples, the assembly conveyor 424 forms a portion of the third station 412. The assembly conveyor 424 may also be referred to as a carton assembly conveyor or third conveyor. In one or more examples, the assembly conveyor 424 is in communication with the grouping conveyor 422. The group of articles B, with the blank 310 applied thereto, is transferred from the grouping conveyor 422 to the assembly conveyor 424.

In one or more examples, the assembly conveyor 424 is configured to transport the group of articles B, with the blank 310 secured to the articles B, along a carton assembly path, such as in discrete lines or lanes defined by lane guides, as the group of articles B and the blank 310 enter the assembly conveyor 424 at an upstream end thereof (e.g., from the grouping conveyor 422) and move along the assembly conveyor 424. The lane guides are configured to maintain the group of articles B and the blank 310 in their respective lanes for folding the blank 310 about the group of articles B to assemble the carton 390.

In one or more examples, the system 404 includes a machine for folding the blank 310 about the articles B, referred to herein as a folding machine 430. The folding machine 430 may also be referred to as a blank folding machine. In one or more examples, the folding machine 430 forms a portion of the third station 412.

In one or more examples, the folding machine 430 is configured to fold portions of the blank 310, such as the first side panel 318, the second side panel 320, the end structure 322, and the second end structure 324 of the blank 310 (e.g., as shown in FIGS. 16-23), about the group of articles B, to at least partially form the carton 390 (e.g., as shown in FIG. 24).

In one or more examples, the system 404 includes a machine for aligning the blank 310, for example, at least during an initial formation operation of the carton 390, referred to herein as an alignment machine 432. The alignment machine 432 may also be referred to as a blank alignment machine. In one or more examples, the alignment machine 432 forms a portion of the third station 412.

In one or more examples, the alignment machine 432 is configured to suitably position the blank 310 while portions of the blank 310, such as the first side panel 318 and the second side panel 320, are folded relative to the main panel 312 (e.g., as shown in FIG. 16).

In one or more examples, the discharge conveyor 426 forms a portion of the fourth station 414. The discharge conveyor 426 may also be referred to as a package discharge conveyor or a fourth conveyor. In one or more examples, the discharge conveyor 426 is in communication with the assembly conveyor 424. The completed package 406 is transferred from the assembly conveyor 424 to the discharge conveyor 426.

In one or more examples, the discharge conveyor 426 is configured to transport the completed package 406 along a discharge path, such as in discrete lines or lanes defined by lane guides, as the completed package 406 enters the discharge conveyor 426 at an upstream end thereof (e.g., from the assembly conveyor 424) and moves along the discharge conveyor 426. In one or more examples, the discharge conveyor 426 is configured to transport the completed package 406 away from the packaging system 404, such as for further packaging and/or storage.

Referring now to FIGS. 25-28, which schematically illustrate a portion of the packaging system 404, such as the third station 412. In FIG. 26, certain portions of the packaging system 404 (e.g., as shown in FIG. 25) have been removed for the purpose of clarity of illustration.

In one or more examples, the blank 310 is in a substantially flat configuration and is applied to the upper ends of the articles B when the group of articles B and the blank 310 enter the assembly conveyor 424. In one or more examples, as the group of articles B and the blank 310 enter and move through the assembly conveyor 424, the blank 310 has a leading end and a trailing end in the direction of travel (e.g., as shown by directional arrow 418).

In one or more examples, the packaging system 404 includes a series (e.g., plurality) of side lugs 434 configured to engage each opposing side of the group of articles B. In one or more examples, the series of side lugs 434 form a portion of the alignment machine 432. In one or more examples, the side lugs 434 are configured to suitably position the group of articles B on the assembly conveyor 424. In one or more examples, the series of side lugs 434 are configured to move the group of articles B along the packaging path on the assembly conveyor 424. In one or more examples, the packaging system 404 includes a side lug drive 436, such as a continuous chain and drive mechanism, that is configured to move the series of side lugs 434 along a continuous path.

Referring briefly to FIG. 26, in one or more examples, the alignment machine 432 includes a pair of series of side lugs 434, each with an associated side lug drive 436. In one or more examples, the pair of series of side lugs 434 is opposite to each other along the assembly conveyor 424, such that the each of the pair of series of side lugs 434 contact opposite sides of the group of articles B as the group of articles B move along the travel path.

Referring again to FIGS. 25-28, in one or more examples, the folding machine 430 is configured to fold the first side panel 318 and the second side panel 320 of the blank 310 relative to the main panel 312 of the blank 310 (e.g., as shown in FIG. 16) as the group of articles B and the blank 310, applied to the upper ends of the articles B, travel along a portion of the packaging path. In one or more examples, the folding machine 430 concurrently folds the first side panel 318 and the second side panel 320. In one or more examples, the folding machine 430 sequentially folds the first side panel 318 and the second side panel 320.

In one or more examples, the folding machine 430 is configured to fold the first end structure 322 and the second end structure 324 of the blank 310 relative to the main panel 312 of the blank 310 (e.g., as shown in FIGS. 17-23) as the group of articles B and the blank 310, applied to the upper ends of the articles B, travel along a portion of the packaging path. The first end structure 322 and the second end structure 324 are folded after the first side panel 318 and the second side panel 320 are folded. In one or more examples, the folding machine 430 concurrently folds the first end structure 322 and the second end structure 324. In one or more examples, the folding machine 430 sequentially folds the first end structure 322 and the second end structure 324.

In one or more examples, the folding machine 430 includes a plurality of components, apparatuses, and/or mechanisms, each configured to perform at least a portion of the folding operation. In one or more examples, the folding machine 430 includes a side panel folding mechanism 470, an end panel folding mechanism 454, a corner panel folding mechanism 456, and a flap folding mechanism 472.

In one or more examples, the side panel folding mechanism 470 includes a series (e.g., a plurality) of dies 438. Each one of the dies 438 engages an associated group of articles B and the blank 310, applied to the upper ends of the articles B, traveling along a portion of the packaging path. The die 438 folds the first side panel 318 and the second side panel 320 of the blank 310 relative to the main panel 312 of the blank 310 (e.g., as shown in FIG. 16). In one or more examples, the die 438 engages the group of articles B and the blank 310 from above.

In one or more examples, each one of the dies 438 includes a main portion 446, a first side portion 448 that is connected to the main portion 446 and a second side portion 450 that is connected to the main portion 446, opposite the first side portion 448. As the die 438 approaches the group of articles B and contacts the blank 310, the main portion 446 of the die 438 aligns with the main panel 312 of the blank 310. The first side portion 448 of the die 438 contacts and folds (e.g., urges, pushes, or otherwise brings) the first side panel 318 of the blank 310 into a non-coplanar relationship with the main panel 312, such as approximately, or at least substantially, perpendicular to the main panel 312 (e.g., as shown in FIGS. 16 and 26). The second side portion 450 of the die 438 contact and folds the second side panel 320 of the blank 310 into a non-coplanar relationship with the main panel 312, such as approximately, or at least substantially, perpendicular to the main panel 312 (e.g., as shown in FIGS. 16 and 26).

In one or more examples, the side panel folding mechanism 470 includes a die drive 440, such as a continuous chain and drive mechanism, a carousel and the like. The series of dies 438 is coupled to the die drive 440. The die drive 440 is configured to move the series of dies 438 along a continuous path (e.g., as shown by directional arrow 442 in FIG. 25).

In one or more examples, the movement of the dies 438 is synchronized with the flow rate of the group of articles B and the blank 310 such that the die 438 suitably engage the blank 310 to fold the first side panel 318 and the second side panel 320 into the folded positions as the group of articles B and the blank 310 pass under the die 438.

In one or more examples, the folding machine 430 is configured to appropriately orient the group of articles B and the blank 310, applied to the articles B, traveling along a portion of the packaging path for a subsequent folding operation. In an example, the group of articles B and the blank 310 are in a first orientation as the group of articles B and the blank 310 enter the third station 412 (e.g., the assembly conveyor 424). In an example, with the blank 310 in the first orientation, the first end structure 322 forms the leading end of the blank 310 in the direction of travel (e.g., as shown by directional arrow 418) and the second end structure 324 forms the trailing end of the blank 310 in the direction or travel. In another example, with the blank 310 in the first orientation, the second end structure 324 forms the leading end of the blank 310 in the direction of travel and the first end structure 322 forms the trailing end of the blank 310 in the direction or travel.

After folding the first side panel 318 and the second side panel 320, the folding machine 430 rotates the group of articles B and the blank 310 from the first orientation to a second orientation. In an example, the with blank 310 in the second orientation, the second side panel 320 forms the leading end of the blank 310 in the direction of travel (e.g., as shown by directional arrow 418) and the first side panel 318 forms the trailing end of the blank 310 in the direction or travel, for example, depending on the direction of rotation. In another example, the with blank 310 in the second orientation, the first side panel 318 forms the leading end of the blank 310 in the direction of travel and the second side panel 320 forms the trailing end of the blank 310 in the direction or travel, for example, depending on the direction of rotation.

Rotation of the group of articles B and the blank 310 from the first orientation to the second orientation appropriately positions the first end structure 322 and the second end structure 324 for folding by the end panel folding mechanism 454, the corner panel folding mechanism 456, and the flap folding mechanism 472.

After folding the first end structure 322 and the second end structure 324, the folding machine 430 rotates the group of articles B and the blank 310 from the second orientation back to the first orientation (e.g., with the first end structure 322 forming the leading end of the blank 310 in the direction of travel and the second end structure 324 forming the trailing end of the blank 310 in the direction or travel, for example, for transfer of the completed package 406 from the assembly conveyor 424 to the discharge conveyor 426.

In one or more examples, the die 438 rotates the group of articles B and the blank 310 after folding the first side panel 318 and the second side panel 320. For example, with the die 438 engaged with the group of articles B and the blank 310, the die 438 rotates about a rotation axis 444 (e.g., as shown in FIGS. 25 and 26), thereby, rotating the group of articles B and the blank 310.

In one or more examples, the die 438 rotates the group of articles B and the blank 310 approximately 90 degrees, between the first orientation and the second orientation as the group of articles B and the blank 310 move along the travel path. For example, the die 438 rotates the group of articles B and the blank 310 from the first orientation to the second orientation for folding of the first end structure 322 and the second end structure 324. The die 438 maintains the group of articles B and the blank 310 in the second orientation during folding of the first end structure 322 and the second end structure 324. The die 438 then rotates the completed package 406 back to the first orientation for discharge.

In one or more examples, the folding machine 430 includes a die actuator 452. The die actuator 452 is coupled to the die 438 and is operable to rotate the die 438 about the rotation axis 444. In one or more examples, the die actuator 452 is any suitable type of rotary actuator that selectively controls the angular orientation of the die 438 about the rotation axis 444.

Referring briefly to FIG. 27, in one or more examples, the die 438 is configured to apply the second blank 210B to the group of articles B and the blank 310, for example, when forming the fourth example of the carton 402 (e.g., carton 290 as shown in FIG. 11). In an example, the second blank 210B is transferred to the die 438 (e.g., by a second applicator machine 458) such that the second blank 210B is positioned on the main portion 446 of the dic 438. When the die 438 engages the group of articles B and the blank 310, the die 438 applies a downward force on the second blank 210B and folds the marginal regions 254A, 254B downwardly about shoulders or necks of the articles B such that the slits 256A, 256B open and receive a flange or lip of a respective article B (e.g., as shown in FIG. 10).

In one or more examples, the second blank 210B is temporarily secured to the die 438, for example, to the main portion 446 before being applied to the group of articles B. In an example, vacuum is used to temporarily hold the second blank 210B to the die 438. For example, the main portion 446 may include at least one vacuum port that is coupled to and in fluid communication with a vacuum source. Vacuum is applied to a portion of the second blank 210B through the main portion 446, via the vacuum port, to temporarily hold the second blank 210B in place as the die 438 travels along its travel path (e.g., as shown by directional arrow 442).

Referring again to FIGS. 25-28, in one or more examples, the end panel folding mechanism 454 and the corner panel folding mechanism 456 work in combination to fold a portion of the one of the first end structure 322 or the second end structure 324, for example, depending on the rotated orientation of the blank 310. In one or more examples, the pair of end panel folding mechanisms 454 and the pair of corner panel folding mechanisms 456 (e.g., as shown in FIG. 26) work in combination to fold a portion of the first end structure 322 and the second end structure 324.

In one or more examples, the corner panel folding mechanism 456 is downstream of the end panel folding mechanism 454. In one or more examples, the corner panel folding mechanism 456 is proximate the end panel folding mechanism 454, such that the folding operation performed by the corner panel folding mechanism 456 immediately follows the folding operation performed by the end panel folding mechanism 454.

In one or more examples, the flap folding mechanism 472 is downstream of the corner panel folding mechanism 456. In one or more examples, the flap folding mechanism 472 is proximate to the corner panel folding mechanism 456, such that the folding operation performed by the flap folding mechanism 472 immediately follows the folding operation performed by the corner panel folding mechanism 456.

In one or more examples, the end panel folding mechanism 454 is located adjacent to the assembly conveyor 424, such that the end panel folding mechanism 454 is appropriately positioned to contact an associated portion of the blank 310 (e.g., the first end panel 314 or the second end panel 316) as the group of articles B and the blank 310 move along the travel path on the assembly conveyor 424.

In one or more examples, the corner panel folding mechanism 456 is located adjacent to the assembly conveyor 424, such that the corner panel folding mechanism 456 is appropriately positioned to contact an associated portion of the blank 310 (e.g., the first and second corner panels 360A, 360B or the third and fourth corner panels 362A, 362B) as the group of articles B and the blank 310 move along the travel path on the assembly conveyor 424.

In one or more examples, the flap folding mechanism 472 is located adjacent to the assembly conveyor 424, such that the flap folding mechanism 472 is appropriately positioned to contact an associated portion of the blank 310 (e.g., the first flap 372 or the second flap 376) as the group of articles B and the blank 310 move along the travel path on the assembly conveyor 424.

Referring briefly to FIG. 26, in one or more examples, the folding machine 430 includes a pair of end panel folding mechanisms 454 (e.g., identified individually as first end panel folding mechanism 454A and second end panel folding mechanism 454B). In one or more examples, the pair of end panel folding mechanisms 454 is opposite to each other along the assembly conveyor 424, such that the first end panel 314 and the second end panel 316 are folded concurrently by the pair of end panel folding mechanisms 454 as the group of articles B and the blank 310 move along the travel path.

In one or more examples, the folding machine 430 includes a pair of corner panel folding mechanisms 456 (e.g., identified individually as first corner panel folding mechanism 456A and second corner panel folding mechanism 456B). In one or more examples, the pair of corner panel folding mechanisms 456 is opposite to each other along the assembly conveyor 424, such that the first and second corner panels 360A, 360B and the third and fourth corner panels 362A, 362B are folded concurrently by the pair of corner panel folding mechanisms 456 as the group of articles B and the blank 310 move along the travel path.

In one or more examples, the folding machine 430 includes a pair of flap folding mechanisms 472 (e.g., identified individually as first flap folding mechanism 472A and second flap folding mechanism 472B). In one or more examples, the pair of flap folding mechanisms 472 is opposite to each other along the assembly conveyor 424, such that the first flap 372 and the second flap 376 are folded concurrently by the pair of flap folding mechanisms 472 as the group of articles B and the blank 310 move along the travel path.

Referring again to FIGS. 25-28, the following portion of the present disclosure describes an example of the folding operations for the first end structure 322 using the end panel folding mechanism 454, the corner panel folding mechanism 456 and the flap folding mechanism 472 (e.g., first end panel folding mechanism 454A, first corner panel folding mechanism 456A and first flap folding mechanism 472A as shown in FIG. 26). Accordingly, in the examples illustrated in FIGS. 25-28 depicting the blank 310 in the first orientation, that the second end structure 324 forms the leading end of the blank 310 and the first end structure 322 forms the trailing end of the blank 310 in the direction or travel. In the examples illustrated in FIGS. 25-27 depicting the blank 310 in the second orientation, the second side panel 320 forms the leading end of the blank 310 and the first side panel 318 forms the trailing end of the blank 310 in the direction or travel. However, the operations of the end panel folding mechanism 454, the corner panel folding mechanism 456 and the flap folding mechanism 472 are similarly applicable to folding the second end structure 324. For example, an example of the folding operations for the second end structure 324 using the end panel folding mechanism 454, the corner panel folding mechanism 456 and the flap folding mechanism 472 (e.g., second end panel folding mechanism 454B, second corner panel folding mechanism 456B and second flap folding mechanism 472B as shown in FIG. 26) is substantially the same of the example of the folding operations for the first end structure 322.

Referring to FIGS. 25 and 28, in one or more examples, the end panel folding mechanism 454 includes an end panel folding arm 460. the end panel folding arm 460 engages an interior or underside surface of a portion of the first end panel 314 of blank 310 as the group of articles B and the blank 310 move along the travel path.

In an example, the end panel folding arm 460 contacts at least one of the first end panel 314 (e.g., first upper end panel 314A and/or first lower end panel 314B) and/or the first flap 372 from below to bring the first end panel 314 into a non-coplanar relationship with the main panel 312, such as oblique to the main panel 312 (e.g., as shown in FIG. 17.) In other words, the end panel folding arm 460 folds the first upper end panel 314A, the first lower end panel 314B, and the first flap 372 upward relative to the main panel 312.

Referring briefly to FIG. 17, as the first upper end panel 314A is folded upwardly relative to the main panel 312 by the end panel folding arm 460 (e.g., as shown in FIGS. 25 and 28), the first web panel 368A brings the first corner panel 360A and the first securing panel 364A into a non-coplanar relationship with the first side panel 318, such as oblique to the first side panel 318, and the second web panel 368B brings the second corner panel 360B and the second securing panel 364B into a non-coplanar relationship with the second side panel 320, such as oblique to the second side panel 320. In other words, folding the first upper end panel 314A upwardly pulls the first corner panel 360A and the second corner panel 360B toward the main panel 312 such that the first securing panel 364A and the second securing panel 364B converge toward each other via the first web panel 368A and the second web panel 368B, respectively.

Referring to FIG. 25, in one or more examples, the end panel folding mechanism 454 includes an end panel folding wheel 474. The end panel folding wheel 474 is configured to rotate about a first rotation axis (e.g., an approximately horizontal axis). In one or more examples, the end panel folding arm 460 projects radially from the end panel folding wheel 474. In one or more examples, during rotation of the end panel folding wheel 474, the end panel folding arm 460 engages the interior or underside surface of a portion of the end panel 314 of blank 310 as the group of articles B and the blank 310 move along the travel path.

In one or more examples, the end panel folding mechanism 454 includes a first rotary drive (not shown). The first rotary drive is configured to rotate the end panel folding wheel 474 about the first rotation axis in a direction of rotation (e.g., as shown by directional arrow 462 in FIG. 25). In one or more examples, the first rotary drive is connected to the end panel folding mechanism 454 (e.g., folding wheel) by a drive shaft (not shown). The first rotary drive includes any suitable rotary drive mechanism, such as a servo motor.

Referring to FIG. 28, in one or more examples, the end panel folding mechanism 454 includes first arm drive 476, such as a continuous chain and drive mechanism, a carousel and the like. The end panel folding arm 460 is coupled to the first arm drive 476. The first arm drive 476 is configured to move the end panel folding arm 460 along a continuous path (e.g., as shown by directional arrow 478 in FIG. 28).

In one or more examples, the movement of the end panel folding arm 460 is synchronized with the flow rate of the group of articles B and the blank 310 such that the end panel folding arm 460 suitably engages the blank 310 to fold the first end panel 314 into the folded position as the group of articles B and the blank 310 pass along the end panel folding mechanism 454.

Referring again to FIG. 25, in one or more examples, the corner panel folding mechanism 456 includes a first corner panel folding arm 466. The first corner panel folding arm 466 engages an exterior surface of a portion of the first end structure 322 of blank 310 as the group of articles B and the blank 310 move along the travel path.

In an example, the first corner panel folding arm 466 contacts an exterior of the first corner panel 360A and/or the first securing panel 364A from the side to fold the first corner panel 360A inward toward the main panel 312 such that the first corner panel 360A and the first securing panel 364A wrap around a portion of an end one of the articles B of the group of articles B (e.g., as shown in FIG. 18.) In other words, the first corner panel folding arm 466 folds the first corner panel 360A and the first securing panel 364A inward relative to the first side panel 318.

In one or more examples, the corner panel folding mechanism 456 includes a second corner panel folding arm 468. The second corner panel folding arm 468 engages an exterior surface of another portion of the first end structure 322 of blank 310 as the group of articles B and the blank 310 move along the travel path.

In an example, the second corner panel folding arm 468 contacts an exterior of the second corner panel 360B and/or the second securing panel 364B from the side to fold the second corner panel 360B inward toward the main panel 312 such that the second corner panel 360B and the second securing panel 364B wrap around a portion of another end one of the articles B of the group of articles B (e.g., as shown in FIG. 18.) In other words, the second corner panel folding arm 468 folds the second corner panel 360B and the second securing panel 364B inward relative to the second side panel 320.

In one or more examples, the corner panel folding mechanism 456 initially folds a leading one of the corner panels (e.g., the second corner panel folding arm 468 folds the second corner panel 360B) as the group of articles B and the blank 310 move across the assembly conveyor 424 along the travel path. The corner panel folding mechanism 456 subsequently folds a trailing one of the corner panels (e.g., the first corner panel folding arm 466 folds the first corner panel 360A) as the group of articles B and the blank 310 move across the assembly conveyor 424 along the travel path. However, in other examples, the corner panel folding mechanism 456 initially folds a trailing one of the corner panels (e.g., the first corner panel folding arm 466 folds the first corner panel 360A) and subsequently folds the leading one of the corner panels (e.g., the second corner panel folding arm 468 folds the second corner panel 360B) as the group of articles B and the blank 310 move across the assembly conveyor 424 along the travel path.

In one or more examples, the corner panel folding mechanism 456 includes a corner panel folding wheel 480. The corner panel folding wheel 480 is configured to rotate about a second rotation axis (e.g., an approximately vertical axis). In one or more examples, the first corner panel folding arm 466 and the second corner panel folding arm 468 project from, or are coupled to, the corner panel folding wheel 480. In one or more examples, during rotation of the corner panel folding wheel 480, the second corner panel folding arm 468 engages the exterior surface of a portion of the second corner panel 360B of blank 310 as the group of articles B and the blank 310 move along the travel path. During further rotation of the corner panel folding wheel 480, the first corner panel folding arm 466 engages the exterior surface of a portion of the first corner panel 360A of blank 310 as the group of articles B and the blank 310 move further along the travel path.

In one or more examples, the corner panel folding mechanism 456 includes a second rotary drive (not shown). The second rotary drive is configured to rotate the corner panel folding wheel 480 about the second rotation axis in a direction of rotation (e.g., as shown by directional arrow 464 in FIG. 25). In one or more examples, the second rotary drive is connected to the corner panel folding wheel 480 by a drive shaft (not shown). The second rotary drive includes any suitable rotary drive mechanism, such as a servo motor.

In one or more examples, the corner panel folding mechanism 456 includes second arm drive (not shown), such as a continuous chain and drive mechanism, a carousel and the like. The first corner panel folding arm 466 and the second corner panel folding arm 468 are coupled to the second arm drive. The second arm drive is configured to move the first corner panel folding arm 466 and the second corner panel folding arm 468 along a continuous path.

In one or more examples, the corner panel folding mechanism 456 includes a plurality (e.g., a pair) of first corner panel folding arms 466 and a plurality (e.g., a pair) of second corner panel folding arms 468. In one or more examples, the pair of first corner panel folding arms 466 and the pair of second corner panel folding arms 468 are coupled to the corner panel folding wheel 480 (e.g., as shown in FIG. 25). In one or more examples, the pair of first corner panel folding arms 466 is approximately diametrically opposed to each other. In one or more examples, the pair of second corner panel folding arms 468 is approximately diametrically opposed to each other. In these examples, the corner panel folding mechanism 456 may fold the first and second corner panels 360A, 360B of two blanks 310 for every rotation of the corner panel folding wheel 480.

In one or more examples, the movement of the first corner panel folding arm 466 and/or the second corner panel folding arm 468 is synchronized with the flow rate of the group of articles B and the blank 310 such that the first corner panel folding arm 466 and/or the second corner panel folding arm 468 suitably engages the blank 310 to fold the first corner panel 360A and/or the second corner panel 360B into the folded position as the group of articles B and the blank 310 pass along the corner panel folding mechanism 456.

Referring again to FIGS. 25-28, in one or more examples, the folding machine 430 includes an end panel fold guide 482, such as an opposed pair of end panel fold guides 482 (e.g., as shown in FIG. 26). In one or more examples, the end panel fold guide 482 is located above and downstream of the end panel folding mechanism 454. In one or more examples, the end panel fold guide 482 extends along at least a portion of the packaging path, for example, along at least a portion of the corner panel folding mechanism 456. In one or more examples, the end panel fold guide 482 is configured to hold the first end panel 314 in the upwardly folded orientation as the group of articles B and the blank 310 travel along the corner panel folding mechanism 456 for folding of the first and second corner panels 360A, 360B.

In one or more examples, the end panel fold guide 482 passively assists the active folding operation performed by the end panel folding mechanism 454. In one or more examples, the end panel fold guide 482 is configured to passively fold the first end panel 314 upwardly as the group of articles B and the blank 310 travel along the end panel fold guide 482. For example, the end panel fold guide 482 may take the place of the end panel folding mechanism 454.

In one or more examples, the end panel fold guide 482 (e.g., each one of the pair of end panel fold guides 482) includes an engaging end extending in an upstream direction of the packaging path. In one or more examples, the end panel fold guide 482 includes a plow, a turning plate, a turning rod, or other mechanism configured to hold and/or passively urge the first end panel 314 in a folded position as the blank 310 travels along the packaging path. In one or more examples, the end panel fold guide 482 includes an engaging edge configured to contact the blank 310. In one or more examples, the engaging end of the end panel fold guide 482 is curved.

In one or more examples, the folding machine 430 includes a corner panel fold guide 484, such as an opposed pair of corner panel fold guides 484 (e.g., as shown in FIG. 26). In one or more examples, the corner panel fold guide 484 is located above the corner panel folding mechanism 456. In one or more examples, the corner panel fold guide 484 extends along at least a portion of the packaging path, for example, along at least a portion of the corner panel folding mechanism 456. In one or more examples, the corner panel fold guide 484 is configured to hold the first and second corner panels 360A, 360B in the inwardly folded orientation as the group of articles B and the blank 310 travel past the corner panel folding mechanism 456.

In one or more examples, the corner panel fold guide 484 passively assists the active folding operation performed by the corner panel folding mechanism 456, for example, for at least one of the first and second corner panels 360A, 360B. In one or more examples, the corner panel fold guide 484 is configured to passively fold at least one of the first and second corner panels 360A, 360B (e.g., a leading one of the corner panels) inwardly as the group of articles B and the blank 310 travel along the corner panel fold guide 484. For example, the corner panel fold guide 484 may take the place of at least one of the first and second corner panel folding arms 466, 468.

In one or more examples, the corner panel fold guide 484 (e.g., each one of the pair of corner panel fold guides 484) includes an engaging end extending in an upstream direction of the packaging path. In one or more examples, the corner panel fold guide 484 includes a plow, a turning plate, a turning rod, or other mechanism configured to hold and/or passively urge the first and/or second corner panels 360A, 360B in a folded position as the blank 310 travels along the packaging path. In one or more examples, the corner panel fold guide 484 includes an engaging edge configured to contact the blank 310. In one or more examples, the engaging end of the corner panel fold guide 484 is curved.

In one or more examples, the folding machine 430 includes a end panel fold guide 486, such as an opposed pair of end panel fold guides 486 (e.g., as shown in FIG. 26). In one or more examples, the end panel fold guide 486 extends along at least a portion of the packaging path, for example, downstream of the corner panel folding mechanism 456 and upstream of the flap folding mechanism 472. In one or more examples, the end panel fold guide 486 is configured to passively fold the end panel 314 downward, for example, approximately perpendicular to the main panel 312 (e.g., as shown in FIG. 19-21), as the group of articles B and the blank 310 travel along the packaging path from the corner panel folding mechanism 456 to the flap folding mechanism 472. In one or more examples, the end panel fold guide 486 is configured to hold the first end panel 314 in the downwardly folded position as the group of articles B and the blank 310 travel to the flap folding mechanism 472.

In other examples, a different mechanism may be used to downwardly fold the first end panel 314 into the folded position relative to the main panel 312 prior to the flap folding mechanism 472, such as another end panel folding mechanism.

In one or more examples, as the first end panel 314 is being downwardly folded relative to the main panel 312, the detents of the first end panel 314 are received in the corresponding apertures of the first and second securing panels 364A, 364B.

Referring now to FIGS. 29-34, which schematically illustrate examples of the flap folding mechanism 472. The flap folding mechanism 472 is configured or is operable to fold the first flap 372 relative to the first end panel 314, such as the first lower end panel 314B, (e.g., as shown in FIGS. 22 and 23) to bring the first flap 372 into a face-to-face relationship with the first and second securing panels 364A, 364B and aligned with (e.g., in an approximately parallel relationship with) the first end panel 314 such that the first and second securing panels 364A, 364B are positioned (e.g., sandwiched) between the first end panel 314 and the first flap 372 to complete construction of the carton 390 (e.g., as shown in FIG. 24).

In one or more examples, the flap folding mechanism 472 includes a base 502, a backing plate 504, a pair of flap folding fingers 506, a first actuator 508 and a second actuator 510. In one or more examples, the backing plate 504 is coupled to the base 502. In one or more examples, the pair of flap folding fingers 506 is coupled to the base. In one or more examples, the pair of flap folding fingers 506 is rotationally movable relative to the base 502 (e.g., in the directions of directional arrow 512 shown in FIGS. 29 and 30). In one or more examples, the pair of flap folding fingers 506 is rotationally movable relative to the backing plate 504 (e.g., in the directions of directional arrow 512 shown in FIGS. 29 and 30). In one or more examples, the first actuator 508 is configured to rotate the pair of flap folding fingers 506 relative to the backing plate 504 between a first rotational position (e.g., as shown in FIG. 29) and a second rotational position (e.g., as shown in FIG. 30). In one or more examples, the second actuator 510 is configured to move the pair of flap folding fingers 506 relative to each other between a closed position (e.g., as shown in FIG. 29) and an open position (e.g., as shown in FIG. 30).

In one or more examples, the backing plate 504 extends or projects from the base 502. The backing plate 504 is appropriately positioned to contact the first end panel 314 of the blank 310 during the folding operation. For example, the backing plate 504 is approximately vertical.

In one or more examples, the pair of flap folding fingers 506 are coupled to the base 502 below or under the backing plate 504. The pair of flap folding fingers 506 also extends or projects from the base 502.

In one or more examples, the pair of flap folding fingers 506 rotate relative to the base 502 and relative to the backing plate 504 about rotation axis 530, such as an approximately horizontal axis (e.g., as shown in FIG. 29).

In one or more examples, each one of the pair of flap folding fingers 506 (e.g., identified individually as first flap folding finger 506A and second flap folding finger 506B in FIG. 30) rotates relative to the base 502, relative to the backing plate 504, and relative to the other one of the pair of flap folding fingers 506 about a respective rotation axis 570 (e.g., identified individually as rotation axis 570A and rotation axis 570B), such as an approximately vertical axis (e.g., as shown in FIG. 30).

In one or more examples, with the flap folding fingers 506 in the first rotational position (e.g., as shown in FIG. 29), the flap folding fingers 506 are spaced away from and downwardly oriented relative to the backing plate 504 such that the backing plate 504 can access (e.g., contact) the first end panel 314 of the blank 310 during the folding operation. With the flap folding fingers 506 in the second rotational position (e.g., as shown in FIG. 30), the flap folding fingers 506 are spaced away from and aligned (e.g., approximately parallel) with the backing plate 504.

The base 502, the backing plate 504, the pair of flap folding fingers 506, the first actuator 508 the second actuator 510 may have any suitable structural configuration, relative positions or mechanical layout that performs the operational movements described herein below. As such, the examples of the flap folding mechanism 472 illustrated in FIGS. 29-34 are not intended to imply structural limitations.

The first actuator 508 may be any suitable device or mechanism that is capable of or operates to drive and control rotational movement of the pair of flap folding fingers 506 between the first rotational position (e.g., a first angular orientation) and the second rotational position (e.g., a second angular orientation).

The second actuator 510 may be any suitable device or mechanism that is capable of or operates to drive and control movement of the pair of flap folding fingers 506 between the closed position and the open position.

In one or more examples, the first actuator 508 and the second actuator 510 are closed mechanical systems that do not require an external energy source or control signal to drive operation and selective control of rotation and movement of the pair of flap folding fingers 506. For example, the first actuator 508 and the second actuator 510 are driven by a cam assembly.

Referring to FIGS. 31-34, in one or more examples, the first actuator 508 includes a first cam follower 514 and a first slide mechanism 516. The first slide mechanism 516 is coupled to the first cam follower 514 and is configured to be selectively positioned relative to the pair of flap folding fingers 506 for control of rotation of the pair of flap folding fingers 506 between the first rotational position (e.g., as shown in FIG. 31) and the second rotational position (e.g., as shown in FIG. 33).

In one or more examples, the first cam follower 514 is configured to engage a drive cam 518 (e.g., as shown in FIG. 28) to selectively position the first slide mechanism 516. In one or more examples, the drive cam 518 includes or takes the form of a first cam track or other first cam surface that is dedicated to the first cam follower 514. The drive cam 518 is configured to move the first cam follower 514 relative to the base 502 (e.g., in the directions shown by directional arrow 520 in FIGS. 31 and 32) as the first cam follower 514 moves along a surface of the drive cam 518.

In one or more examples, the pair of flap folding fingers 506 is biased in the first rotational position (e.g., as shown in FIG. 31). For example, engagement of the first slide mechanism 516 with the pair of flap folding fingers 506 overcomes a bias force and upwardly rotates the pair of flap folding fingers 506 to the second rotational position (e.g., as shown in FIG. 33). Disengagement of the first slide mechanism 516 with the pair of flap folding fingers enables the bias force to automatically downwardly rotate the pair of flap folding fingers 506 back to the first rotational position.

In one or more examples, the second actuator 510 includes a second cam follower 524 and a second slide mechanism 526. The second slide mechanism 526 is coupled to the second cam follower 524 and is configured to be selectively positioned relative to the pair of flap folding fingers 506 for control of movement of the pair of flap folding fingers 506 between the closed position (e.g., as shown in FIG. 33) and the open position (e.g., as shown in FIG. 34).

In one or more examples, the second cam follower 524 is configured to engage the drive cam 518 (e.g., as shown in FIG. 28) to selectively position the second slide mechanism 526. In one or more examples, the drive cam 518 includes or takes the form of a second cam track or other second cam surface that is dedicated to the second cam follower 524. The drive cam 518 is configured to move the second cam follower 524 relative to the base 502 (e.g., in the directions shown by directional arrow 528 in FIGS. 33 and 34) as the second cam follower 524 moves along a surface of the drive cam 518.

In one or more examples, the pair of flap folding fingers 506 is biased in the closed position (e.g., as shown in FIG. 33). For example, engagement of the second slide mechanism 526 with the pair of flap folding fingers 506 overcomes a bias force and moves (e.g., opens) the pair of flap folding fingers 506 to the open position (e.g., as shown in FIG. 34). Disengagement of the second slide mechanism 526 from the pair of flap folding fingers 506 enables the bias force to automatically move (e.g., close) the pair of flap folding fingers 506 back to the closed position.

Referring now to FIGS. 31-33, movement (e.g., linear movement) of the first cam follower 514 relative to the base 502 and as driven by the drive cam 518 translates to movement (e.g., linear movement) of the first slide mechanism 516 relative to the base 502 and relative to the pair of flap folding fingers 506. For example, movement of the first cam follower 514 and, thus, the first slide mechanism 516 in a first direction positions the first slide mechanism 516 in engagement with the pair of flap folding fingers 506, which results in upward rotational movement of the pair of flap folding fingers 506 (e.g., from the first rotational position to the second rotational position). Movement of the first cam follower 514 and, thus, the first slide mechanism 516 in a second direction, opposite the first direction, positions the first slide mechanism 516 out of engagement with the pair of flap folding fingers 506, which results in downward rotational movement of the pair of flap folding fingers 506 (e.g., from the second rotational position to the first rotational position).

Referring now to FIGS. 33 and 34, movement (e.g., linear movement) of the first cam follower 514 relative to the base 502 and as driven by the drive cam 518 translates to movement (e.g., linear movement) of the first slide mechanism 516 relative to the base 502 and relative to the pair of flap folding fingers 506. For example, movement of the first cam follower 514 and, thus, the first slide mechanism 516 in a first direction positions the first slide mechanism 516 in engagement with the pair of flap folding fingers 506, which results in upward rotational movement of the pair of flap folding fingers 506 (e.g., from the first rotational position to the second rotational position). Movement of the first cam follower 514 and, thus, the first slide mechanism 516 in a second direction, opposite the first direction, positions the first slide mechanism 516 out of engagement with the pair of flap folding fingers 506, which results in downward rotational movement of the pair of flap folding fingers 506 (e.g., from the second rotational position to the first rotational position)

Referring again to FIGS. 29-34, the first slide mechanism 516 may include any suitable structure or combination of features and elements. In one or more examples, the first slide mechanism 516 includes a first linear slide rail, such as a first linear guide 532 and a first carriage 534 (e.g., bearing) that moves along the first linear guide 532. In one or more examples, the first linear guide 532 is coupled to the base 502 and the first carriage 534 is coupled to the first cam follower 514, such that movement of the first cam follower 514 moves the first carriage 534 along the first linear guide 532.

In one or more examples, the first slide mechanism 516 includes a linkage 540 that is coupled to the first carriage 534 at a first end and that is coupled to the base 502 at a second end, opposite the first end. The linkage 540 is linearly movable relative to the base 502 and relative to the flap folding fingers 506 in response to linear movement of the first carriage 534 along the first linear guide 532. In one or more examples, the linkage 540 is rotationally movable about rotation axis 544 (e.g., as shown in FIG. 30), such as an approximately horizontal axis, relative to the base 502 at the second end in response to linear movement of the first carriage 534 along the first linear guide 532.

In one or more examples, the first slide mechanism 516 includes a guide bar 542 (e.g., as shown in FIGS. 29 and 30) that is coupled to the linkage 540 proximate (e.g., at or near) the second end of the linkage 540. The guide bar 542 is appropriately positioned and is configured to engage the pair of flap folding fingers 506 and to drive rotational movement of the pair of flap folding fingers 506 in response to linear movement of the first carriage 534 along the first linear guide 532.

Referring briefly to FIG. 29, in one or more examples, each one of the flap folding fingers 506 includes a front portion 546, a central portion 548 that extends from the front portion 546, and a rear portion 550 that extends from the central portion 548, opposite the front portion 546. In one or more examples, rearward movement of the first slide mechanism 516 (e.g., rearward movement of the first carriage 534 along the first linear guide 532 and, thus, rearward movement of linkage 540 relative to the base 502) moves the guide bar 542 over the central portion 548 of the flap folding fingers 506 from the front portion 546 toward the rear portion 550, thereby pushing the rear portion 550 downwardly and rotating the flap folding fingers 506 from the first rotational position (e.g., as shown in FIG. 29) to the second rotational position (e.g., as shown in FIG. 30).

Referring briefly to FIG. 32, in one or more examples, the front portion 546 of each one of the flap folding fingers 506 has an approximately U-shape in order to accommodate a portion of the backing plate 504 and to accommodate folding of the first flap 372 relative to the first end panel 314. For example, the front portion 546 of each one of the flap folding fingers 506 includes a first portion 552 that is coupled to and extends at a non-zero angle (e.g., oblique or approximately perpendicular) from the central portion 548, a second portion 554 that is coupled to and extends at a non-zero angle (e.g., oblique or approximately perpendicular) from the first portion 552, and a third portion 556 that is coupled to and extends at a non-zero angle (e.g., oblique or approximately perpendicular) from the second portion 554. With the flap folding fingers 506 in the second rotational position (e.g., as shown in FIG. 33), the third portion 556 of the front portion 546 of each one of the flap folding fingers 506 is spaced away from and is aligned with (e.g., approximately parallel to) the backing plate 504.

Referring again to FIGS. 29-34, the second slide mechanism 526 may include any suitable structure or combination of features and elements. In one or more examples, the second slide mechanism 526 includes a second linear slide rail, such as a second linear guide 536 and a second carriage 538 (e.g., bearing) that moves along the second linear guide 536. In one or more examples, the second linear guide 536 is coupled to the base 502 and the second carriage 538 is coupled to the second cam follower 524, such that movement of the second cam follower 524 moves the second carriage 538 along the second linear guide 536.

In one or more examples, the second slide mechanism 526 includes a yoke 558 that is coupled to the second carriage 538 at a first end. A second end of the yoke 558, opposite the first end, is positioned proximate the rear portion 550 of each one of the flap folding fingers 506. In one or more examples, the yoke 558 is linearly movable relative to the base 502 and relative to the flap folding fingers 506 in response to linear movement of the second carriage 538 along the second linear guide 536. In one or more examples, forward movement of the second slide mechanism 526 (e.g., rearward movement of the second carriage 538 along the second linear guide 536 and, thus, rearward movement of yoke 558 relative to the base 502) moves the front end of the yoke 558 into engagement with the rear portion 550 of each one of the flap folding fingers 506 to bring the rear portion 550 of each one of the flap folding fingers 506 together and, thus, moving the front portion 546 of each one of the flap folding fingers 506 away from each other.

Referring briefly to FIG. 29, in one or more examples, the front end of the yoke 558 includes a pair of finger guides 560 (e.g., identified as first finger guide 560A and second finger guide 560B in FIG. 29) that correspond to the pair of flap folding fingers 506. The finger guides 560 are angularly oriented at a non-zero angle (e.g., oblique) relative to each other (e.g., forming a generally Y-shaped yoke). In one or more examples, each one of the flap folding fingers 506 includes a follower 562 coupled to the rear portion 550 thereof. In one or more examples, forward movement of the yoke 558 engages each one of the finger guides 560 with the follower 562 of a corresponding one of the flap folding fingers 506 to urge the rear portion 550 of each one of the flap folding fingers 506 together and, thus, move the flap folding fingers 506 from the closed position to the open position.

In one or more examples, the first carriage 534 and the second carriage 538 share a common linear guide (e.g., the first linear guide 532 and the second linear guide 536 are the same structure).

Referring briefly to FIG. 31, in one or more examples, the base 502 includes a third cam follower 564 that is coupled (e.g., fixed) to the base 502. The third cam follower 564 is configured to selectively position the base 502 relative to the blank 310, such as to selectively position the backing plate 504 relative to the first end panel 314 during the folding operation.

In one or more examples, the third cam follower 564 is configured to engage the drive cam 518 (e.g., as shown in FIG. 28) to selectively position the base 502. In one or more examples, the drive cam 518 includes or takes the form of a third cam track or other third cam surface that is dedicated to the third cam follower 564. The drive cam 518 is configured to move the third cam follower 564 (e.g., in the directions shown by directional arrow 566 in FIG. 31) as the third cam follower 564 moves along a surface of the drive cam 518.

In one or more examples, the movement of the base 502 and the pair of flap folding fingers 506 is synchronized with the flow rate of the group of articles B and the blank 310 such that the backing plate 504 and the pair of flap folding fingers suitably engage the blank 310 to fold the first flap 372 into the folded position as the group of articles B and the blank 310 pass along the flap folding mechanism 472.

In one or more examples, the flap folding mechanism 472 (e.g., the base 502) moves relative to the drive cam 518 to initiate and control operational movement of the base 502, the first actuator 508 and the second actuator 510 as the first cam follower 514, the second cam follower 524 and the third cam follower 564 move along a respective cam surface of the drive cam 518.

Alternatively, in one or more examples, the flap folding mechanism 472 (e.g., the base 502) is fixed and the drive cam 518 moves relative to the flap folding mechanism 472 to initiate and control operational movement of the base 502, the first actuator 508 and the second actuator 510 as the a respective cam surface of the drive cam 518 moves along a respective one of the first cam follower 514, the second cam follower 524 and the third cam follower 564.

Referring again to FIG. 28, in one or more examples, the system 404 includes a plurality of flap folding mechanisms 472 and a drive 568, such as a continuous chain and drive mechanism, a carousel and the like. Each one of the plurality of flap folding mechanisms 472 is coupled to the drive 568. The drive 568 is configured to move the plurality of flap folding mechanisms 472 along a continuous path (e.g., as shown by directional arrow 571 in FIG. 28).

In one or more examples, the movement of the flap folding mechanisms 472 is synchronized with the flow rate of the group of articles B and the blank 310 such that each flap folding mechanism suitably engage the blank 310 to fold the first flap 372 into the folded positions as the group of articles B and the blank 310 pass along the flap folding mechanism 472.

In one or more examples, the drive cam 518 is incorporated in or is coupled to the drive 568. For example, as the flap folding mechanism 472 moves along the continuous path, the first cam follower 514, the second cam follower 524 and the third cam follower 564 move along a respective cam surface of the drive cam 518 to initiate and control operational movement of the base 502, the first actuator 508 and the second actuator 510, as described above and illustrated in FIGS. 29-34.

In one or more examples, the movement of the flap folding mechanism 472 is synchronized with the flow rate of the group of articles B and the blank 310 such that the backing plate 504 and the pair of flap folding fingers suitably engage the blank 310 to fold the first flap 372 into the folded position as the group of articles B and the blank 310 pass along the flap folding mechanism 472.

In other examples, the first actuator 508 and/or the second actuator 510 may include other types of actuation devices, such as, but not limited to, linear actuators (e.g., hydraulic, pneumatic, mechanical), drive motors (e.g., servo motors) and power transmitting components, and the like, without departing from the scop of the present disclosure.

Referring now to FIGS. 35-48, which schematically illustrate examples of different stages of the flap folding mechanism 472 during the folding operation (e.g., as shown in FIGS. 22-24). The following portion of the present disclosure describes an example of the folding operations for the first flap 372 using the flap folding mechanism 472 (e.g., first flap folding mechanism 472A as shown in FIG. 26). However, the operations of the flap folding mechanism 472 illustrated in FIGS. 35-48 are similarly applicable to folding the second flap 376. For example, an example of the folding operations for the second flap 376 using the flap folding mechanism 472 (e.g., second flap folding mechanism 472B as shown in FIG. 26) is substantially the same of the example of the folding operations for the first flap 372.

In FIGS. 36, 38, 40, 42, 44, 46 and 48, the articles B have been omitted for the purpose of clarify of illustration.

FIGS. 35 and 36 depict a first stage of a method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, the group of articles B and the blank 310, applied to the group of articles B, and the flap folding mechanism 472 are appropriately positioned relative to each other such that the first end structure 322 is facing the flap folding mechanism 472. As described herein above, the first and second side panels 318, 320, the first end panel 314, the first and second corner panels 360A, 360B and the first and second securing panels 364A, 364B have already been folded in the folded position. The base 502, the backing plate 504 and the flap folding fingers 506 are spaced away from the blank 310. The flap folding fingers 506 are in the first rotational position and in the closed position.

FIGS. 37 and 38 depict a second stage of the method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, with the pair of flap folding fingers 506 in the first rotational position, the base 502 moves (e.g., linearly forward) relative to the blank 310 in a first direction to position the backing plate 504 in contact with an exterior surface of the first end panel 314 of the blank 310 such that the first end panel 314 is positioned between the backing plate 504 and the group of articles B.

FIGS. 39 and 40 depict a third stage of the method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, with backing plate 504 in contact with the first end panel 314 and the pair of flap folding fingers 506 in the closed position, the pair of flap folding fingers 506 is rotated from the first rotational position to the second rotational position to fold the first flap 372 of the blank 310 relative to the first end panel 314 of the blank 310 such that the first flap 372 and the first end panel 314 are positioned (e.g., sandwiched) between the pair of flap folding fingers 506 (e.g., the third portion 556 of the front portion 546 of each one of the flap folding fingers 506) and the backing plate 504.

As illustrated in FIG. 40, during and/or after folding the first flap 372 and with the pair of flap folding fingers 506 in the closed position and in the second rotational position, a pair of wing portions 378 of the first flap 372 are in a non-coplanar relationship with a central portion 380 of the first flap 372.

FIGS. 41 and 42 depict a fourth stage of the method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, with the backing plate 504 in contact with the first end panel 314 and the pair of flap folding fingers 506 in the second rotational position and in the closed position, the pair of flap folding fingers 506 is moved from the closed position to the open position to fold the pair of wing portions 378 into an approximately coplanar relationship with the central portion 380.

FIGS. 43 and 44 depict a fifth stage of the method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, with the backing plate 504 in contact with the first end panel 314 and the pair of flap folding fingers 506 in the second rotational position, the pair of flap folding fingers 506 is moved from the open position back to the closed position. With the backing plate 504 in contact with the first end panel 314, the pair of flap folding fingers 506 in the second rotational position and in the closed position, and the first flap 372 and the first end panel 314 positioned (e.g., sandwiched) between the pair of flap folding fingers 506 and the backing plate 504, the base 502 and, thus, the backing plate 504 and the pair of flap folding fingers 506, moves (e.g., linearly rearward) relative to the blank 310 in a second direction, opposite the first direction, to pull the first end structure 322 in the folded position slightly away from the group of articles B to confirm that the first end structure 322 is locked together, for example, to confirm that the locking tabs of the first and second securing panels 366A, 366B are received in the receiver formed by the cut line in the first end panel 314 and that the detents of the first end panel 314 are received in the apertures of the first and second securing panels 366A, 366B.

FIGS. 43 and 44 depict a sixth stage of the method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, with the backing plate 504 in contact with the first end panel 314, the pair of flap folding fingers 506 in the second rotational position and in the closed position, and the first flap 372 and the first end panel 314 positioned (e.g., sandwiched) between the pair of flap folding fingers 506 and the backing plate 504, the base 502 and, thus, the backing plate 504 and the pair of flap folding fingers 506, moves (e.g., linearly forward) relative to the blank 310 in the first direction to position the assembled first end structure 322 back in the folded position.

FIGS. 45 and 46 depict a seventh stage of the method (e.g., one of the operational steps) for folding the first flap 372 using the flap folding mechanism 472. In one or more examples, with the backing plate 504 in contact with the first end panel 314, the pair of flap folding fingers 506 in the second rotational position and in the closed position, and the first flap 372 and the first end panel 314 positioned (e.g., sandwiched) between the pair of flap folding fingers 506 and the backing plate 504, the pair of flap folding fingers 506 are rotated (e.g., downwardly) from the second rotational position to the first rotational position to position the first flap 372 between the first end panel 314 and the group of articles B (e.g., adjacently disposed articles B). With the pair of flap folding fingers 506 removed, the first flap 372 is held in position by the group of articles B.

The flap folding mechanism 472 then returns to an initial position (e.g., as shown in FIGS. 35 and 36) and the folding process is repeated on a subsequent blank 310 as a subsequent group of articles B and subsequent blank 310 moves along the packaging path.

In one or more examples, the blank 400 is formed from a sheet of suitable substrate. As used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that any number of (e.g., one or more) blanks 400 may be employed where suitable, for example, to provide and/or form one or other numbers of cartons 402 (e.g., carrier structures) described in more detail below.

In one or more examples, the blank 400 and, thus, the carton 402 are formed from a sheet material, such as a paperboard substrate. The paperboard substrate may be, for example, a solid bleached sulfate (SBS) substrate, an uncoated natural kraft (UNC) substrate, or a coated natural kraft (CNK) substrate. The paperboard substrate may be formed from virgin fibers, recycled fibers, or combinations thereof.

In one or more examples, the blank 400 and, thus, the carton 402 are formed from a sheet material such as paperboard, which may be made of materials or coated with materials to increase its strength. An example of such a sheet material is tear resistant NATRALOCK® paperboard made by WestRock Company. In one or more examples, the tear resistant materials are provided by more than one layer to help improve the tear-resistance of the carton 402.

In one or more examples, the blank 400 includes at least a paperboard substrate. The material of the paperboard substrate may be selected from any conventional paperboard, for example, ranging in weight upwardly from about 10 pt., preferably from about 16 pt. to about 28 pt. (0.028″/˜0.7 mm). An example of such a substrate is a 27-point (pt.) SBS board (solid bleached sulfate paperboard coated on one side, trade name PrintKote®) or CNK® board (Coated Natural Kraft®—an unbleached kraft paperboard having a clay coating on one side, trade name CarrierKote™) manufactured by WestRock® Company. The paperboard substrate may be a bleached or unbleached board. The board may be coated on at least one side, optionally the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and board composition.

In one or more examples, one surface of the sheet material has different characteristics to the other surface. For example, the surface of the sheet material that faces outwardly from a finished carton 402 may be particularly smooth and may have a coating, such as a clay coating or other surface treatment, to provide good printability. The surface of the sheet material that faces inwardly may, on the other hand, be provided with a coating, a layer, and/or a treatment or be otherwise prepared to provide properties such as one or more of tear-resistance, good glue-ability, heat sealability, or other desired functional properties.

In one or more examples, the blank 400 may include a tear resistant layer laminated to the paperboard layer. It optionally includes an adhesive layer between the paperboard substrate and the tear resistant layer. The tear resistant layer may be disposed over the uncoated side of the paperboard substrate and may be formed of polymeric material and secured to the substrate. The tear resistant layer imparts toughness to the laminate structure. Suitable tear resistant materials may include, but not be limited to, tear resistant laminated sheet material, e.g., NATRALOCK®, which may include a layer of an n-axially oriented film, e.g. MYLAR®, which is a bi-axially oriented polyester, oriented nylon, cross-laminated polyolefin or high-density polyolefin. The orientation and cross-laminated structure of these materials contribute to the tear resistant characteristic. Also, tear resistance may be attributed to the chemical nature of the tear resistant material such as extruded metallocene-catalyzed polyethylene (mPE).

Alternatively, in one or more examples, the tear resistant layer may be a layer of linear low-density polyethylene (LLDPE). In examples where linear low-density polyethylene (LLDPE) or mPE is used, it is not necessary to incorporate an adhesive layer. Other suitable materials having a high level of tear resistance may also be used. The adhesive layer may be formed of polyolefin material such as a low-density polyethylene (LDPE). The adhesive layer may be placed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

The preceding detailed description refers to the accompanying drawings, which illustrate specific examples of the disclosed packaging system and method described by the present disclosure. It will be understood that the disclosed examples are merely exemplary embodiments of the way in which certain aspects of the of the disclosed packaging system and method can be implemented and do not represent an exhaustive list of all of the ways the of the disclosed packaging system and method may be embodied. Other examples having different structures and operations do not depart from the scope of the present disclosure.

Well-known components, materials or methods are not necessarily described in detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not meant to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Like reference numerals may refer to the same feature, element, or component in the different drawings. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components.

Throughout the present disclosure, any one of a plurality of items may be referred to individually as the item and a plurality of items may be referred to collectively as the items. Moreover, as used herein, a feature, element, component, or step preceded with the word “a” or “an” should be understood as not excluding a plurality of features, elements, components or steps, unless such exclusion is explicitly recited.

Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided above. Reference herein to “example” means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” “one or more examples,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.

It is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular example described herein. Thus, for example, those skilled in the art will recognize that certain examples may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

It should be appreciated that, when used to modify a structure, an element, an item, a component or a feature described herein, the terms “front,” “back,” “rear,” “bottom,” “top,” “left,” “right,” “side,” “end,” “upper,” “lower,” “inner,” “outer,” “interior,” “exterior,” as well as similar terms or other forms of such terms, are relative and refer to an example of a spatial relationship between structures, elements, items, components or features. As such, examples of the blanks and the cartons, described herein and illustrated in the figures, are not intended to be limited by the specific relative terms used to describe any structure, element, item, component or feature thereof.

As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed, a hinged connection can be formed from two or more fold lines wherein each of the two or more fold lines may be either straight/linear or curved/curvilinear in shape. When linear fold lines form a hinged connection, they may be disposed parallel with each other or be slightly angled with respect to each other. When curvilinear fold lines form a hinged connection, they may intersect each other to define a shaped panel within the area surrounded by the curvilinear fold lines. A typical example of such a hinged connection may include a pair of arched or arcuate fold lines intersecting at two points such that they define an elliptical panel therebetween. A hinged connection may be formed from one or more linear fold lines and one or more curvilinear fold lines. A typical example of such a hinged connection may comprise a combination of a linear fold line and an arched or arcuate fold line which intersect at two points such that they define a half moon-shaped panel therebetween.

As used herein, the term “fold line” may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cutline, a line of aligned slits, a line of scores and any combination of the aforesaid options.

It should be understood that hinged connections and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cutline, an interrupted cutline, slits, scores, embossed lines, debossed lines, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

As used herein, the phrase “in registry with” and similar terms or variations of such term refer to the alignment of two or more elements in an erected carton, such as an aperture formed in a first of two overlapping panels and a second aperture formed in a second of two overlapping panels. Those elements in registry with each other may be aligned with each other in the direction of the thickness of the overlapping panels. For example, when an aperture in a first panel is “in registry with” a second aperture in a second panel that is placed in an overlapping arrangement with the first panel, an edge of the aperture may extend along at least a portion of an edge of the second aperture and may be aligned, in the direction of the thickness of the first and second panels, with the second aperture.

As used herein, the terms “rotate,” “rotating,” “rotation,” and similar terms refer to movement of a body around an axis and includes a condition in which the axis extends through a center of mass of the body (e.g., rotate), a condition in which the axis extends through the body, but not through the center of mass of the body (e.g., gyrate or pivot), and a condition in which the axis does not extend through the body (e.g., revolve).

Conditional language such as, among others, “can” or “may,” unless specifically stated otherwise, are otherwise understood within the context as used in general to convey that certain examples include, while other examples do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more examples or that one or more examples necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular example.

Unless otherwise indicated, the terms “first,” “second,” “third,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.

Those skilled in the art will appreciate that not all elements described and illustrated in FIGS. 1-48 need be included in every example and not all elements described herein are necessarily depicted in each illustrative example. FIGS. 1-48, referred to above, may represent functional elements, features, or components thereof and do not necessarily imply any particular structure. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Additionally, those skilled in the art will appreciate that not all elements, features, and/or components described and illustrated in FIGS. 1-48, referred to above, need be included in every example and not all elements, features, and/or components described herein are necessarily depicted in each illustrative example. Accordingly, some of the elements, features, and/or components described and illustrated in FIGS. 1-48 may be combined in various ways without the need to include other features described and illustrated in FIGS. 1-48, other drawing figures, and/or the accompanying disclosure, even though such combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the examples presented, may be combined with some or all of the features shown and described herein. Unless otherwise explicitly stated, the schematic illustrations of the examples depicted in FIGS. 1-48, referred to above, are not meant to imply structural limitations with respect to the illustrative example. Rather, although one illustrative structure is indicated, it is to be understood that the structure may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Furthermore, elements, features, and/or components that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of FIGS. 1-48, and such elements, features, and/or components may not be discussed in detail herein with reference to each of FIGS. 1-48. Similarly, all elements, features, and/or components may not be labeled in each of FIGS. 1-48, but reference numerals associated therewith may be utilized herein for consistency.

Further, references throughout the present specification to features, advantages, or similar language used herein do not imply that all of the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar language used throughout the present disclosure may, but do not necessarily, refer to the same example.

The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. One skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, although various examples of the system, flap folding mechanism and method have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

SYSTEMS AND METHODS FOR PACKAGING ARTICLES WITHIN A CARTON

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