Container carrier

Abstract: A plastics carrier (20) for carrying containers (34) includes container engaging portions (22, 24) which extend from a joint (26). The joint (26) is at adjacent edges (28, 30) of the container engaging portions (22, 24). The container engaging portions (22, 24) include a plurality of annular bands (33) for securely holding containers (34) therein. The joint (26) is formed by bonding the layers of plastics material between the edges (28, 30) of the container engaging portions (22, 24). The joint (26) is interrupted along its length at (44) to enable the joint (26) and container engaging portions (22, 24) to stretch when containers (34) are placed in the carrier (20). The carrier (20) may include a handle portion (48, Fig. 2) which extends from the joint (26) for carrying the completed package.

Description: This invention is generally directed to a plastic carrier for carrying containers such as bottles, cans and the like as well as to a method of making such a carrier. More particularly, the invention contemplates a plastic carrier which includes a joint between two container carrying portions. Prior art container carriers including a joint, such as the one disclosed in US-A-2,650,128, are made of a single sheet of material, usually cardboard, which is folded in half to form free moving flaps and a handle which extends between the flaps upwardly. The flaps hold the containers in shaped apertures. Since the cardboard sheet is folded in half to make the container, the handle is of a double thickness. The sides of the handle are joined together, by adhesive or staples, to deter the carrier from collapsing to a flattened position. The majority of container carriers today are preferably formed from a plastics material due to the ease and lower cost of manufacturing and the strength of the material. An example of a prior carrier is shown in US-A-4,219,117. The plastics carrier is stretched over the containers which are to be held within the carrier. The single sheet concept of US-A-2,650,128 with its glued or stapled handle is not readily adaptable to be used with a plastics material because the joint created by gluing or stapling will not withstand the stresses created by stretching the plastics material around the containers without breaking or shearing. One of the applicant's earlier patents, US-A-3,968,621 discloses a carrier according to the preamble of claim 1. The present invention is intended to overcome or minimize this problem as well as to present several new advantages. According to a first aspect of this invention, a carrier for carrying containers comprises first and second container engaging portions made of a plastics material of a predetermined thickness and including a plurality of annular bands respectively for securely holding therein a container, is characterised in that the first and second container engaging portions extend freely from a joined portion at adjacent edges of the container engaging portions and in that the joined portions are formed by merging juxtaposed surfaces of the container engaging portions together. According to a second aspect of this invention, a method of making a carrier for carrying containers comprises the steps of: providing a first sheet of plastics material and a second sheet of plastics material juxtaposed over the first sheet; bonding selected regions of the sheets together longitudinally; and, stamping a shaped carrier for carrying containers from the combined first and second sheets of plastics. Preferably the joint is formed by heat sealing or fusing adjacent surfaces of the container engaging portions preferably with a layer of plastics material between the edges of the container engaging portions to form a triple layer of thickness of plastic material at the joint. Preferably the joint is interrupted along its length to enable the carrier including container engaging portions to stretch when the carrier is applied to the containers. The carrier may include a handle portion which extends from the joint. Two embodiments of a carrier and a method in accordance with this invention will now be described with reference to the accompanying drawings, wherein like reference numerals identify like elements and, in which:- FIGURE 1 is a perspective view of a first embodiment of a container carrier which incorporates features of the present invention; FIGURE 2 is a perspective view of a second embodiment of a container carrier which incorporates features of the present invention; FIGURE 3 is a perspective view of the embodiment of the container carrier of FIGURE 2 with containers held therein; FIGURE 4 is cross sectional view of the carrier of FIGURE 2 along line 4-4; and FIGURE 5 is a simplified, schematic view of the apparatus for producing a carrier according to the present invention. In FIGURE 1, a first embodiment of a carrier 20 which incorporates features of the present invention is shown. The carrier 20 is used for carrying containers, such as bottles and the like. The carrier 20 includes body portions or container engaging portions 22, 24 a predetermined thickness. The portions are connected by a seam or joined portion 26 at 25 which forms a strong, fused joint. The seam or joined portion 26 joins the container engaging portions 22, 24 along top or adjacent edges 28, 30 of the container engaging portions 22, 24. The container engaging portions 22, 24 freely extend from the joined portion 26. The seam or joined portion 26 projects generally perpendicular to the plane of the portions 22 and 24 when the carrier 20 is assembled with containers. The container engaging portions 22, 24 include a plurality of apertures 32 defined by annular bands 33 for securely holding therein containers, such as bottles, cans and the like. For example, as shown in FIGURE 3, the containers 34 are a plurality of bottles which are securely held within the apertures 32 in the carrier 20 by the resiliently stretched bands 33. Each bottle 34 includes a side wall 36, a bottom wall 38 and a top or cap 40. Alternatively, the carrier 20 may be used to carry typical beverage cans. The carrier 20 is made of a suitable flexible, resilient, stretchable material, such as plastic. Preferably, the carrier 20 is made of a low density polyethylene so that the carrier 20 can be stretched over the containers 34 and conform to the side walls 36 of the containers 34. The carrier 20 may be applied to the containers 34 by known means, for example, by the machines disclosed in US-A-4,250,682 or US-A-3,204,386. It is noted that when the carrier 20 is stretched over the containers 34 the individual bands 33 are stretched and the overall length of the carrier is increased. As explained in detail herein-below with reference to FIGURE 5, the joined portion 26 is formed by extruding a strip or layer of resilient, stretchable material 42, such as plastic, preferably the same low density polyethylene material that forms the carrier 20, between the edges 28, 30 of the container engaging portions 22, 24. Thus, a triple layer of plastic material forms the joined portion 26. The three layers of plastic material (the container engaging portions 22, 24 and the layer of extruded plastic 42) are sufficiently melted and merged together by known means, preferably by heat sealing and fusing the layers together, to form a strong, integral bond. When the layers 22, 24, 42 of plastic material are merged together by heat sealing, the layers 22, 24, 42 are no longer distinguishable from each other and become one mass having a thickness greater than the combined thickness of the layers 22 and 24 alone. The seam or joined portion 26 extends along the edges 28, 30 of the container engaging portions 22, 24. In order to permit the region 25 to react longitudinally to stresses created when the carrier 20 is applied to the containers 34, the joined portion 26 is interrupted along its length by cutouts 44 which form apertures between the container engaging portions 22, 24. The cutouts 44 allow the container engaging portions 22, 24 and the joined portion 26 to easily stretch transversely and in a longitudinal direction with respect to the seam or joined portion 26 and to conform to the containers 34 when the carrier 20 is applied to the containers 34. Segments of the seam 26 which are initially spaced apart by the cutouts 44, are spread longitudinally of the carrier 20 when the bands 33 are stretched over the containers 34 with the result that the overall length of the carrier 20 is increased in the final package. Since the joined portion 26 is formed by fused material and preferably by a triple layer of plastic material, the bond created is sufficiently strong to prevent the joined portion 26 from shearing or breaking when the carrier 20 is stretched during application to the containers 34. Preferably, the carrier 20 of the present invention is formed by joining two separate sheets of plastic material together at the seam or joined portion 26. However, it is within the scope of the invention that a single sheet of plastic material may be used to form the carrier 20 by folding the sheet in half and applying a layer of plastic or otherwise fusing the sheets together to form the joined portion 26. The second embodiment of the carrier 20a, as shown in FIGURE 2, is identical to the first embodiment of the carrier as shown in FIGURE 1, except for the differences noted herein-below. The components of the carrier 20a which are identical to the carrier 20 are identified with the same numerals but with an "a" after the numeral. The carrier 20a as shown in FIGURE 2 includes a handle portion 46 which extends upwardly from the centre of the carrier 20a. When the carrier 20a is applied to the containers 34, the top 48 of the handle portion 46 may extend upwardly from the top of the containers 34, or alternatively, as shown in FIGURE 3, the top 48 of the handle portion 46 may lie even with the top of the containers 34. If the carrier 20a is made of two separate sheets of plastic material, which is the preferred embodiment, the handle portion 46 also includes the two separate sheets of plastic material. Alternatively, if the carrier 20a is made out of a single sheet of plastic material, the handle portion 46 is formed when the sheet is folded in half. In either method, the handle portion 46 includes two sides portions 50, 52. The joined portion 26a is formed at the base 54 of the handle portion 46 and at the top edge 28a, 30a of the container engaging portions 22a, 24a and the handle portion 46 extends upwardly from the joined portion 26a. A bond 56, preferably formed by heat sealing, is provided along an upper portion of the handle portion 46 to prevent the side portions 50, 52 of the handle portion 46 from separating thereby making the handle portion 46 easy to grasp by a consumer. The bond 56 merges the two layers of plastic material together to form a double thickness of material along the bond 56 as clearly shown in FIGURE 4. It is within the scope of the invention that the handle portion 46 may be formed by extruding a layer of plastic material to create a triple thickness identical to that of the joined portion 26a. The thicknesses of the heat sealed joined portion 26a and the bond 56 are illustrated in FIGURE 4 and have been somewhat exaggerated for a better understanding of the description herein. Thus, the double thickness in the plastic material formed by the bond 56 in the handle portion 46 is shown. The triple thickness in the plastic material formed at the joined portion 26 by the container engaging portions 22a, 24a and the extruded layer 42 of plastic is also shown. Now that the specifics of the carriers 20, 20a which incorporate features of the present invention have been described, a general description of the method for making the carrier 20a will be described. The method for making the carrier 20a is schematically illustrated in FIGURE 5 in a simplified form. The same method is used for making the carrier 20 except for the differences noted herein. The carriers 20a are formed in a continuous method as described herein-below and as illustrated in FIGURE 5. Preferably, a first sheet 58 of plastic material and a second sheet 60 of plastic material are used. The first sheet 58 and the second sheet 60 are combined together. At the combining step, a layer or strip of plastic 42, preferably low density polyethylene, is continuously extruded between the sheets 58, 60 by an extruder 61 of known construction and by known methods to create a bond 62 between the sheets 58, 60. The combined sheets 58, 60 of plastic material are then stamped by a stamping die 64, of known construction, to form a continuous strip of carriers 20a. The stamping die 64 punches both sheets 58, 60 simultaneously to form the carrier 20a and the apertures 32. To form the carrier 20 the stamping die 64 does not stamp a handle portion 46. In either embodiment, a plurality of lines of cutouts creating apertures for container receiving portions and/or handles can be formed simultaneously. The carrier 20a is then heat sealed along the bond 62 to form the triple layer of thickness of material at the top edge 28a, 30a of the container engaging portions 22a, 24a. The handle portion 46 is also heat sealed at this time to create the double layer of thickness of material. The continuous web of carriers 20a are then rolled or otherwise appropriately stored until they are to be applied to the containers 34 by known methods. The structure and process of this invention thus provides degrees of manufacturing flexibility to produce integral carriers having features not capable of being created using existing technology. The heat sealing may be done by conventional, known methods, such as by heated rollers 66. It is within the scope of the invention that the stamping step and the heat sealing step may be interchanged. It should also be recognized that regions 26, 26a and 56 can be created by fusing the carrier material directly together without the additional extrusion 42 or alternatively in some cases a strip of heat sensitive or pressure sensitive adhesive may be inserted at desired locations between sheets 58 and 60.

Claims: A carrier (20) for carrying containers (34) comprising first and second container engaging portions (22, 24) made of a plastics material of a predetermined thickness, the container engaging portions (22, 24) including a plurality of annular bands (33) respectively for securely holding therein a container (34) characterised in that the first and second container engaging portions (22,24) extend freely from a joined portion (26) at adjacent edges of the container engaging portions (22, 24), and in that the joined portion (26) being formed by merging juxtaposed surfaces of the container engaging portions together. A carrier as defined in claim 1, wherein the joined portion (26) is interrupted along its length to form apertures (44) between the bands (33) to enable the joined portion (26) to stretch when containers (34) are placed within the bands (33). A carrier as defined in claim 1 or 2, wherein the joined portion (26) extends generally transverse to the plane of the container engaging portions (22, 24) when the carrier (20) is applied to containers (34). A carrier as defined in any one of the preceding claims, wherein the joined portion (26) is formed by heat sealing the juxtaposed surfaces of the container engaging portions (22, 24). A carrier as defined in any one of the preceding claims, further including an initially separate layer (42) of plastics between the juxtaposed surfaces of edges of the container engaging portions (22, 24) which form the joined portion (26) so as to form a triple thickness of plastics material at the joined portion (26). A carrier as defined in any one of the preceding claims, further including a handle portion (46) extending freely from the joined portion (26). A carrier as defined in any one of the preceding claims, wherein the container engaging portions (22, 24) are formed by first and second sheets (58, 60) of plastics material joined together by said joined portion (26). A method of making a carrier (20) for carrying containers (34) comprising the steps of: providing a first sheet (58) of plastics material and a second sheet (60) of plastics material juxtaposed over the first sheet (58); bonding selected regions (62) of the sheets (58, 60) together longitudinally; and, stamping (64) a shaped carrier (20) for carrying containers (34) from the combined first (58) and second (60) sheets of plastics. A method as defined in claim 8, wherein the stamping step includes forming a carrier (20) comprising a body portion (22, 24) having annular bands (33) for holding the containers (34) and a handle portion (48) extending from the body portion (22, 24). A method as defined in claim 8 or 9, further including the step of heat sealing the combined first (58) and second (60) sheets along the handle portion (48) to form a second bond (56).

Inventors: BROSKOW JAMES A, BROSKOW, JAMES A.
Applicants: ILLINOIS TOOL WORKS, ILLINOIS TOOL WORKS INC.
Application year: 1995
Main classification: B65D71
IPC codes: B65B17, B65D71