Packaging of rectangular articles

Arranging a group of articles to be packaged so as to include a space for the insertion of a different article. All the articles except one are arranged in upright position. The one article is positioned on its side, between other articles. This creates a space above the one article into which a different article is inserted prior to packaging the articles in a multipack carton.

FIELD OF THE INVENTION 
This invention relates to the packaging of rectangular articles, such as 
aseptic cartons. More particularly, it relates to the packaging of such 
articles in a multipack arrangement in which one of the articles is 
different from the others. 
BACKGROUND OF THE INVENTION 
Aseptic cartons are used for packaging liquids such as fruit juice or milk. 
They are normally formed of paperboard which has been coated or otherwise 
treated to make it liquid-tight. Each carton is conventionally in the 
shape of a rectangular block, which enables a number of cartons to be 
tightly abutted in a multipack arrangement. 
It is sometimes desirable for marketing purposes to include a bonus or gift 
in the multipack carton. This is usually done by omitting one of the 
aseptic cartons and replacing it with the gift package. For example, in a 
multipack carton holding eight aseptic cartons, the aseptic cartons are 
arranged as if nine cartons were being packaged in three abutting rows, 
each containing three cartons. The space normally occupied by the center 
carton in such an arrangement is instead filled by a gift carton 
containing something other than the liquid in the aseptic carton. This 
arrangement, however, creates packaging problems. The aseptic cartons are 
normally moved along a first path to a loading station while the gift 
items are moved along another path to the same station. This means that 
the aseptic cartons must be segregated into the final grouping of eight 
and moved into position while retaining intact the gap reserved for 
insertion of the gift. The gift must then be moved into position and 
inserted into the gap, after which the final grouping of aseptic cartons 
and gift carton is inserted into a multipack carton. These maneuvers 
require complicated product queuing and gift insertion machinery which, in 
addition to creating additional maintenance problems, tends to limit the 
speed with which multipacks can be formed. 
It would be desirable to be able to simplify the task of grouping and 
moving the aseptic cartons as well as the task of inserting the gift and 
the final grouped cartons into a multipack carton. 
BRIEF DESCRIPTION OF THE INVENTION 
The invention has to do with the arrangement of the packaged articles 
within the multipack carton. Articles of substantially the same 
rectangular shape and size are arranged in a substantially rectangular 
group so that the bottom of each article except one is in contact with a 
support surface. The latter article is arranged at right angles to the 
other articles, with one side in contact with the support surface, so as 
to form a space between its opposite side and the top of an adjacent first 
article. Each article in the group abuts an adjacent article. A different 
article, such as a gift item, is then inserted into the space and the 
group of articles is packaged in a multipack carton. 
This procedure creates a space for receiving the different article but 
maintains the structural integrity of the group. Thus, when the group is 
pushed along the support surface toward a loading station, the articles do 
not move with respect to each other and the space reserved for the 
different article is maintained at its original size. This reduces 
difficulties in forming and moving the group of articles and in 
subsequently introducing the different article into the group. 
These and other features and aspects of the invention will be readily 
ascertained from the following detailed description of the preferred 
embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
FIG. 1 more clearly illustrates the prior art method of including a 
different article with other similar articles in a multipack arrangement. 
Eight aseptic cartons A are grouped on a support surface S in a 
rectangular configuration made up of four perimeter rows of three each, so 
that the middle carton in each row is spaced from the opposite middle 
carton, thereby forming a space 10 in the center of the group of the same 
size as a carton A. This group of eight cartons is moved to a loading 
station L where the articles are inserted through the open end of the 
multipack carton C, after which the glue flaps 12 and the end flaps 14 of 
the carton are folded into place and glued to complete the formation of 
the final carton C. Prior to loading the aseptic cartons into the carton C 
a gift package G is inserted into the space 10. It can be appreciated that 
arranging the aseptic cartons in the pattern illustrated and then moving 
them toward the loading station so that the space 10 remains intact can 
present problems. Use of a pusher bar to move the group of cartons, for 
example, tends to push the middle carton in the upstream row toward the 
space 10. Even if such movement is slight, the dimensions of the space are 
reduced, making it more difficult to insert the gift package. 
The solution provided by the present invention is illustrated in FIGS. 2, 3 
and 4, which shows a group of eight aseptic cartons arranged in a 
different manner. The cartons A are arranged in three perimeter rows which 
are similar to the perimeter rows in the prior art grouping. Instead of 
stanching upright, however, the middle carton A' in the fourth row is 
supported on its side, so that it extends toward the middle carton in the 
opposite row. This creates an elongated opening or space 16 into which the 
gift package can be inserted. Because this arrangement does not create a 
space extending down to the support surface S, the space 16 cannot be 
distorted by a pusher bar pushing against the upstream perimeter row of 
the group. The space 16 is the same shape and size as the space 10 of the 
prior art, except that it is oriented differently. After insertion of the 
gift package G, the group of cartons is loaded into the open-ended 
multipack carton C and the end panels of the carton are then formed as in 
the prior art practice, resulting in the package illustrated in FIG. 5. 
For the purpose of illustration, the gift G is shown as being inserted 
downwardly into the space 16. It will be appreciated, however, that since 
the space is open to one side of the group, the gift could just as readily 
be inserted from the side. 
Although the carton C is illustrated as being a sleeve-type carton, the 
invention obviously is not limited by the type of multipack carton in 
which the aseptic cartons are packaged. Nor is the invention limited by 
the type of gift package or other item introduced into the space provided 
in the aseptic carton grouping. 
As best shown in FIGS. 3 and 4, the height of the aseptic cartons A 
illustrated in the drawing is twice their width. With this arrangement the 
inner end of the carton lying on its side abuts the side of the opposite 
carton and the outer end of the carton is aligned with the outer sides of 
the other cartons in the same perimeter row. The resulting solid 
arrangement of abutting cartons requires simpler machinery for queuing the 
cartons and inserting the gift package into the space provided, and also 
eliminates the prior art tendency of the cartons adjacent the space in the 
grouping to move into the space. The invention may be employed with 
cartons of other dimensions, but the height of such cartons cannot be 
greater than the width of the rectangular group of cartons. Otherwise the 
carton lying on its side would extend beyond one side of the group of 
cartons and would not be conducive to packaging in the larger multipack 
carton. 
Although the invention has been described in connection with the packaging 
of aseptic cartons, it may also be used in connection with the packaging 
of any type of article which is rectangular in transverse cross section 
where it is desired to introduce a different article into the space 
created in the group. 
The invention need not be limited to the packaging of an item with a group 
of eight similar articles as illustrated. Other arrangements made up of a 
different number of articles, but with a space created by one of the 
articles lying on its side, may also be employed as long as the maximum 
allowable height of the article referred to above is not exceeded. 
Although the invention could be carried out by hand, it is contemplated 
that elements of a packaging machine would form the articles into a group, 
push the group of articles downstream, insert a package into the space 
created in the group and load the group into a carton. The design and 
operation of such machinery is well within the scope of current packaging 
technology and is not necessary to an understanding of the invention. 
It is contemplated that the invention need not necessarily be limited to 
all the specific features of the preferred embodiment, but that changes 
which do not alter the overall basic function and concept of the invention 
may be made without departing from the spirit and scope of the invention 
defined in the appended claims.