Abstract:
A method to package stacked article groups utilizing packaging sleeves having a divider or base member mounted therein. At least one open end of each packaging sleeve is exposed during travel on a conveyor whereby a stream of articles within reach of the moving packaging sleeves are directed below and above the divider members of the open ended sleeves before closure.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to the packaging of stacked articles to form stacked article units. Particularly, this invention relates to methods of packaging stacked articles utilizing a multilevel carton packaging process wherein packaging cartons are provided having a divider member mounted therein. 
     The packaging of stacked articles, such as beverage and food containers and the like, has been found to be an economical and well accepted means to distribute products. These benefits extend to both the distributor and to the consumer. The primary limitation to the distribution of stacked articles, such as stacked beverage cans, has been the ability to form and package such stacked article groups in a fast and economical manner. The methods of this invention utilize multilevel packaging cartons having a divider sheet mounted therein to provide such stacked article groups. 
     SUMMARY OF THE INVENTION 
     The present invention provides a method of packaging stacked articles utilizing multilevel packaging cartons having a divider sheet mounted therein. The method comprises providing a supply of packaging cartons, each having at least one divider or base member mounted therein. The packaging cartons are positioned on a moving conveyor so that at least one end of the packaging cartons is exposed to provide access to the carton interior and to expose the divider member. Simultaneously, first and second streams of articles are provided within reach of the opened packaging cartons so that the articles may be directed below and above the divider member in each carton structure. Finally, the packaging cartons are closed to provide a stream of stacked article packages. 
     These and other benefits will become clear from the following description by reference to the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1 and 2 are flow diagrams showing the method of this invention; 
     FIG. 3 is a flow diagram showing an alternate method of this invention; 
     FIG. 4 is a flow diagram showing another method of this invention; 
     FIGS. 5 and 6 are flow diagrams further showing the methods of this invention; 
     FIG. 6d shows a carton to be filled by the method. 
     FIG. 7 is a perspective process flow diagram showing another method of the invention; and 
     FIG. 8 shows another perspective diagram of a packaging method of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 shows a flow diagram of the packaging method of the present invention wherein a supply of multilevel packaging cartons 12 are provided having a divider member 15 mounted therein. The packaging cartons 12 are provided in a magazine 11, for example, wherein a plurality of flat and folded packaging cartons or sleeves 12 are positioned above or within reach of conveyor 23. The flat and folded packaging cartons 12 are removed from the magazine 11 and positioned onto moving conveyor 23 whereby the open ends of the sleeve are faced outwardly or perpendicular to the direction of travel of the conveyor 23. 
     As shown in FIGS. 2 and 3, first and second streams of preselected article groups 21 and 22 are moved on conveyors 29 and 24 which are positioned adjacent the conveyor 23 providing the packaging cartons 12. The article group conveyors 24 and 29 are positioned vertically and spacially apart whereby the first stream of article groups 26 is adjacent the bottom 18 of the cartons 12 and the second stream of article groups 25 is adjacent the divider base 15 of the cartons 12. Alternately, the first and second streams 21 and 22 of article groups 26 and 25 are directed into the packaging cartons 12 through its open ends. It is preferred that the first stream 21 is directed into the carton sleeves so that the divider sheet 12 is supported to subsequently receive the second stream 22 of article groups 25. Finally, the packaging cartons 12 are closed via a gluing step or a carton locking step, as is known in the art. 
     FIG. 3 particularly shows the method wherein the first and second streams of article groups 26 and 25 are provided on opposite sides of conveyor 23 and whereby the respective streams are directed into the carton structures 12 from opposing sides and into the open ends of the cartons 12. In other words, the spacially positioned first and second streams of article groups 26 and 25 are directed adjacent the opposing sides of conveyor 23 which moves the open ended cartons 12. As shown, pushing mechanisms 27 and 28 are utilized to perpendicularly and sequentially move the article groups 26 and then the article groups 25 into the cartons 12. Alternatively, the conveyors 25 and 26 may be positioned on one side of the carton conveyor 23 whereby the conveyor 25 is positioned above conveyor 26. 
     FIG. 4 shows a stream 30 of multilevel carrier cartons 12 on conveyor 23 whereby a stream of articles 31 is directed angularly into the open sides of the cartons 12. Alternatively, a plurality of streams 31 may be utilized in this process whereby opposing, adjacent and streams at various heights may be used to direct articles or article groups angularly into the passing open sided carton structures 12. The tangential or angular movement of articles into carton sleeve ends is known in the packaging art and may utilize movable flight bar ends and cooperating guide rail structures 36. 
     FIGS. 5 and 6 show the multilevel carton structures 12 being placed on conveyor 23 from a carton source 11. The carton structures 23 are shown positioned between flight bars 13 and 15 and although the multilevel cartons 12 are shown to have a single divider base 15 to define the levels within carton 12, a plurality of such divider bases may be utilized in the processes of this invention. As further shown in FIG. 6, the conveyors 29 and 26, which travel at different elevations with respect to the carton conveyor 23, move article groups 26 and 25, respectively, and which are moved and slid into the open cartons 12 by means of pushing devices 27 and 28. Thereafter, the flaps 37 and 38 are closed by known means to form a completed stacked article carrier 39. 
     FIG. 7 shows a method of loading multilevel carton structures 12 by utilizing starwheels 40 and 41. As shown, a stream of carton structures 12 are moved on conveyor 23 adjacent to which starwheels 40 and 41 are positioned. A stream of articles 32 is shown having an upper level and a lower level of articles which are, respectively, entrapped by upper pockets 42 and lower pockets 43 of the starwheels which separate the stream of articles 32 into upper article groups 44 and lower article groups 25. The pockets 42 and 43 of the respective starwheels have predetermined dimension whereby a single layer of articles, as shown, is placed into the multilevel cartons 12. As known in the art, stripper bars are provided for use with the starwheels to ensure proper entry of the article group layers 44 and 45 into the cartons 12. Subsequent to filling the multilevel cartons 12, the packages are closed via known means to provide a stream of completed stacked article carriers 39. It is within the purview of this invention to also utilize and operate the starwheels in a vertical rather then a horizontal manner whereby the article layers 44 and 45 may be dropped into the tops of the opened cartons 12. 
     FIG. 8 shows a method of loading multilevel carton structures 12 whereby the starwheels 40 and 41 are positioned on opposite sides of the stream of opened carton structures transported on conveyor 23. Opposing streams of articles 32 are shown to be divided into upper and lower article groups 44 and 45 by the pockets 42 and 43 of starwheels 40 and 41 and which simultaneously feed the respective article groups from opposing sides into the multilevel cartons 12. 
     In summary, a plurality of means may be utilized to guide or move articles or article groups into multilevel carton structures. Whereas FIGS. 2 and 3 show the upper and lower article groups 25 and 26 being directed by means of a pushing and sliding process of the respective groups into the carton ends, FIG. 4 shows article groups being guided into the carton sleeve structures. Further, the first and second streams may be moved in the same plane while the conveyor or conveyor moving the open ended carton sleeve structures may have two distinct vertical levels of travel, the first being aligned with the first stream of article groups and the second being aligned with the second stream of article groups. 
     As many changes are possible to the processes of this invention utilizing the teachings thereof, the descriptions above, and the accompanying drawings should be interpreted in the illustrative and not the limited sense.