Abstract:
A method for continuously forming stacked article groups, comprising the steps of supplying at least two streams of articles, each at a predetermined vertically distinct level; forming and longitudinally transporting a stream of first article groups having at least one article, at a first level; placing a support base on a top surface of each first article group; and forming a second article group, having at least one article, at a second level on top of the support base of each longitudinally moving first article group, whereby stacked article groups are formed. The stacked article groups are subsequently processed for packaging.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS, IF ANY  
       [0001]    This application is a continuation of application Ser. No. 09/338,093, filed Jun. 23, 1999, pending; which is a continuation of application Ser. No. 08/944,634, filed Oct. 6, 1997; which is a continuation of application Ser. No. 08/541,739, filed Oct. 10, 1995; which is a continuation of application Ser. No. 08/343,790, filed Nov. 24, 1994; which is a continuation of application Ser. No. 08/037,017, filed Mar. 25, 1993, which are hereby incorporated by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates, generally, to packaging methods and apparatus. More particularly, this invention relates to a continuous method of forming stacked or multiple layer article groups. The packaging method of the present invention is useable to package different types, styles and sizes of articles, in a wide range of stacked article group patterns, and into a variety of packaging media, into cartons in a fast and reliable manner.  
           [0004]    2. Background Information  
           [0005]    In the past, various machines and processes have been proposed and utilized to package selected article groups into packages. Each prior art machine and process, however, accomplishes the packaging of the article groups in a distinct manner and utilizes particular machinery. Moreover, prior art cartoners have limited adjustability, limited output capability, and have been difficult to construct and maintain due to their respective designs. And finally, no method or apparatus, insofar as is known provides continuous motion packaging of stacked or layered product groups.  
           [0006]    Prior art packaging assemblies include U.S. Pat. No. 4,802,324 to applicants&#39; assignee for a Vertical Cartoning Assembly and Method which discloses the placement and assembly of cartons over preselected article groups being moved on a conveyor. U.S. Pat. No. 5,036,644, also to applicants&#39; assignee, discloses a Packaging Sleever Assembly which transfers flat packaging sleeves directly onto preselected article groups and subsequently wraps and closes the cartons. Various end loading packaging machines have also been proposed in the art. For example, U.S. Pat. No. 3,778,959 to Langen et al. discloses an end loader which utilizes a plurality of transversely extending spaced apart fences or flights mounted on a conveyor to rake or capture a predetermined number of containers from infeed container slips. U.S. Pat. No. 4,237,673 to Calvert et al. discloses a machine also for loading container sleeves through their open ends. U.S. Pat. No. 4,936,077 to Langen et al. discloses a carton loading machine which utilizes pusher mechanisms with spring loaded pusher heads to stagger adjacent product group rows during transfer into the carton.  
           [0007]    In view of the limitations and shortcomings of prior art methods and apparatus, it is an object of this invention to provide a method of continuously and reliably forming stacked product groups at high speed. Another object of this invention is to provide a packaging method which is useable with a variety of package types, articles and stacked article group types and sizes. A particular object of the invention is to provide a method which forms stacked or multiple layer article groups via a base member disposed between a lower article sub-group and an upper article sub-group.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    The present invention provides a method for continuously forming stacked article groups, comprising the steps of: supplying at least two streams of articles, each at a predetermined vertically distinct level; forming and longitudinally transporting a stream of first article groups having at least one article, at a first level; placing a support base on a top surface of each the first article group; forming a second article group, having at least one article, at a second level at or above the support base of each longitudinally moving first article group, whereby stacked article groups are formed. The support base is preferably constructed of paperboard and has a thin, substantially flat, rectilinear configuration with a surface area substantially coextensive with that of the top surface of the first article group. The support base may have a flap member disposed along one base edge and defined by a scoreline, the flap member being foldable over one edge of the top surface of the first article group.  
           [0009]    In a preferred embodiment, the invention provides a continuous cartoning method for loading stacked article groups into packages or cartons of a type having an outer structure and an inner divider structure, comprising the steps of: supplying at least one stream of articles at a first predetermined location and a first vertical level along a longitudinally oriented axis; forming and longitudinally transporting a stream of lower article sub-groups at the first location; depositing the inner divider structure at a second predetermined location along the axis, downstream from the first location; supplying at least one stream of articles at a third location downstream from the second location, and at a second vertical level higher than the first vertical level; slidably forming, at the third location, an upper article group on each the divider structure of each the lower article sub-group, whereby stacked article groups are formed; transporting the stacked article groups along the longitudinal axis; providing a longitudinal stream of cartons, with open ends facing and synchronized with the stacked article groups, adjacent to and parallel with the article groups; and laterally moving the stacked article groups into the synchronized cartons.  
           [0010]    These and other benefits of this invention will become clear from the following description by reference to the drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING  
       [0011]    [0011]FIG. 1 is a side view of the packaging or cartoning assembly of the present invention.  
         [0012]    [0012]FIG. 2 is a top plan view of the cartoner assembly.  
         [0013]    [0013]FIG. 3 is a perspective view of a carton assembled by the cartoner assembly.  
         [0014]    [0014]FIG. 4 is a crossectional view of the carton taken along line  4 - 4  of FIG. 3.  
         [0015]    [0015]FIG. 5 is a detailed side view of the cartoner assembly.  
         [0016]    [0016]FIG. 6 is a detailed top plan view of the cartoner assembly.  
         [0017]    [0017]FIG. 7 is a top plan view of a portion of the cartoner assembly.  
         [0018]    [0018]FIG. 8 is a side view of selected portions of the article group selection and transport mechanism.  
         [0019]    [0019]FIG. 9 is a top view of a portion of the carton supply and transport mechanism.  
         [0020]    [0020]FIG. 10 is a side view of a portion of the carton supply and transport mechanism.  
         [0021]    [0021]FIG. 11 is a top view of the discharge end of the carton supply and transport mechanism.  
         [0022]    [0022]FIG. 12 is a side view of the discharge end of the carton supply and transport mechanism.  
         [0023]    [0023]FIG. 13 is a side view of the infeed guides of the article supply mechanisms.  
         [0024]    [0024]FIG. 14 is a side view of the carton support assembly of the carton supply and transport mechanism.  
         [0025]    [0025]FIG. 15 is a top view of the carton support assembly of FIG. 14.  
         [0026]    [0026]FIG. 16 is a left end view of the carton support assembly of FIG. 14.  
         [0027]    [0027]FIG. 17 is a right end view of the carton support assembly of FIG. 14.  
         [0028]    [0028]FIG. 18 is a top view of the crossloading mechanism.  
         [0029]    [0029]FIG. 19 is a crossectional view of the cartoner apparatus taken approximately along line  19 - 19  of FIG. 5.  
         [0030]    [0030]FIG. 20 is a crossectional view of the cartoner apparatus taken approximately along line  20 - 20  of FIG. 5.  
         [0031]    [0031]FIG. 21 is a crossectional view of the cartoner apparatus showing details of the article group selection and transport mechanism.  
         [0032]    [0032]FIG. 22 is a crossectional view of the cartoner apparatus taken along line  22 - 22  of FIG. 7.  
         [0033]    [0033]FIG. 23 is a crossectional view of the cartoner apparatus taken approximately along line  23 - 23  of FIG. 5.  
         [0034]    [0034]FIG. 24 is a crossectional view of the cartoner apparatus taken approximately along line  24 - 24  of FIG. 5.  
         [0035]    [0035]FIG. 25 is a crossectional view of the cartoner apparatus taken approximately along line  25 - 25  of FIG. 5.  
         [0036]    [0036]FIG. 26 is a top view of a loader arm assembly.  
         [0037]    [0037]FIG. 27 is a combined side and end view of a pushing face.  
         [0038]    [0038]FIG. 28 is an end view of the loader arm assembly taken along line  28 - 28  of FIG. 26.  
         [0039]    [0039]FIG. 29 is an end view of a loader arm guide.  
         [0040]    [0040]FIG. 30 is a crossectional view of a loader arm assembly operatively extended across the article group selection and transport mechanism.  
         [0041]    [0041]FIG. 31 is a detailed side view of the flight bar structures of the article group selection and transport mechanism.  
         [0042]    [0042]FIG. 32 is a top view of the loading zone of an alternative embodiment of the present invention.  
         [0043]    [0043]FIG. 33 is a side view of the embodiment shown in FIG. 32. 
     
    
     DETAILED DESCRIPTION  
       [0044]    The methods and apparatus of the present invention are for forming stacked article groups in a continuous, high speed process. As shown in the drawings, the method of this invention is implemented via a continuous motion, high-speed packaging apparatus  10 . The apparatus  10  is adjustable to provide reliable, continuous and high speed packaging of articles or products of varying types, sizes and quantities into packages of varying types and sizes. For example, the apparatus  10  is useable to load standard twelve ounce beverage cans into 24(12/12), 30(15/15) and 36(18/18) pack stacked combinations. Moreover, the process of loading beverage containers into paperboard cartons, for example, is accomplished quickly and reliably, under typical industry tolerances for both container and carton construction. The resultant filled cartons output by the apparatus  10  are of high quality and consistency, having maximized squareness and tautness for improved storage qualities and transportability. Although the embodiments disclosed load stacked article groups into paperboard cartons, its within the purview of this invention to process the stacked article groups in a variety of ways subsequent their formation, including side loading, shrink wrapping, banding or having paperboard or other material formed around them.  
         [0045]    Referring to FIGS. 1 and 2, the continuous motion cartoner assembly  10  generally comprises a carton supply and transport mechanism or stream  11 , an article group selection and transport mechanism or stream  12 , a pair of article supply mechanisms or streams  13  and  14 , a divider placement mechanism  15 , and an article group transfer or cross loading mechanism  16 . These mechanisms are shown to be supported by a unitary frame structure  17 , although if aligned properly, separate support structures may be utilized consistent with the teachings of this invention.  
         [0046]    The carton supply mechanism  11  is shown to be disposed proximate an input end  18  of the assembly  10 . Carton sleeves or blanks  25  are subsequently transported in a linear fashion to an output end  21  of the apparatus  10 . The article supply mechanisms  13  and  14  are also shown to be disposed at the input end  20  of the apparatus  10 . A first portion of each article supply mechanism  13  and  14  is disposed spacially parallel to the article group selection and transport mechanism  12 , and a second portion merges, at a predetermined angle, with the article group selection transport mechanism  12  to supply streams of product or articles  20  to two separate positions along the article group selection and transport mechanism  12 . These merging mechanisms  12 - 14  are further constructed and arranged to meter individual articles  20 , via a fixed flight bar arrangement, into predetermined stacked article groups  21  and  22  on the mechanism  12 .  
         [0047]    The stacking function of the device  10  is accomplished by forming a first group  21  at a low level, placing a separator or divider sheet  24  on the lower group  21  via the divider sheet placement mechanism  15 , and then simultaneously forming a second group  22  downstream at a higher level and allowing the upper group  22  to slide across the divider sheet  24  by the action of the flight bars of the article group selecting mechanism  12 . In an alternative embodiment, the second group is formed on an upper dead plate and dropped or otherwise deposited onto the divider sheet.  
         [0048]    The article group selection and transport mechanism  12  is disposed adjacent and parallel to the carton supply and transport mechanism  11  and extends downstream, in a linear orientation. Merged or combined article groups  23  are transported downstream thereon in a spaced and metered fashion, each group  23  being aligned with a carton  25  traveling on the carton supply and transport mechanism  11 . The crossloading mechanism  16  is disposed adjacent to and parallel with the second portion of the article group selection and transport mechanism  12 , extending and traveling longitudinally with respect to the apparatus  10 . The crossloading mechanism  16  has a plurality of loading arms which extend transversely or perpendicularly with respect to the transport mechanisms  11 ,  13  and  14 , to move product groups  23  on the article group selection transport mechanism  12  into aligned cartons  25  traveling on the carton transport mechanism  11 , thereby loading the cartons  25  with product groups  23 . Preferably, each of the aforementioned mechanisms  11 - 14  and  16  has a conveyor type structure with an endless chain or belt configured about rotatable drive and idler end means and moving longitudinally with respect to the input (upstream) and output (downstream) ends  18  and  19  of the apparatus  10 . The movement of each mechanism is further synchronized with one another, for example by a common drive and/or gearing means.  
         [0049]    Referring to FIGS. 3 and 4, the method of this invention is useable to construct carriers or cartons  26  containing cans  20  or other articles which are disposed on top of one another or stacked. The paperboard carrier blank or sleeve  26  is comprised of leading and trailing side panels  40  and  41  foldably connected to top panel  42  and to a bottom panel  43 . End panels  44  connect the top, bottom and side panels  40 - 43 . As shown, the carrier  26  contains a bottom layer or sub-group  21  of articles, shown for purpose of illustration as beverage cans  20 , and an upper layer or sub-group  22  of cans in stacked relationship. The lower ends of the upper cans  22  are supported on a thin, paperboard divider sheet  24  (also referred to as a base or support sheet) with the bottom cans  21  resting on the bottom panel  43 . An extension tab located on the medial edge of the sheet  24 , and which folds down via a perforation or scoreline is preferably provided to help stabilize the divider sheet  24 . The extension tab provides a means for holding the sheet  24  stable while the upper layer of cans  22  are pushed onto the separator sheet  24 . Once the cans  23  have been all properly positioned the sheet  24  is held in place by guides on the apparatus  10 . The top panel  42  is disposed closely adjacent, and preferably is in contact with, the top chimes  43  of the upper level  22  of cans to provide for a tight fit between the cans  20  and the carrier  25 . Although the apparatus  10  shown in the drawings is utilized in a beverage can cartoning operation with paperboard carrier sleeves, modifications consistent with the teachings of this invention may be made to package various other stacked containers or articles in various carrier configurations or to package the article groups via shrink wrapping, banding or the like.  
         [0050]    Referring also to FIGS. 5, 6,  20  and  22 , the carton supply and transport mechanism  11  is preferably a rotary type carton placer  49 , such as that disclosed in U.S. Pat. No.  4 , 530 , 686  owned by Applicants&#39; assignee. The carton erecting apparatus  49  is supported above the input end of the carton transport mechanism  11  by a vertically adjustable frame structure  50 , and basically transfers flat carton blanks or sleeves  25  from a power magazine  51  to the conveyance surface of the mechanism  11 , simultaneously opening the blank  25  so that it assumes a four-sided configuration with opposing open ends bounded by at least one flap  44  each. Importantly, the partially erected carton  25  is placed in a transverse or lateral orientation so that its ends are open to the sides of the carton transport mechanism  11  for loading purposes.  
         [0051]    The carton transport conveyor  52  receives cartons or other carriers  25  from the carton supply placer  49  and transports them linearly downstream with respect to the overall apparatus  10 . The downstream transport of cartons  25  is synchronized with the article group selection and transport mechanism  12  and with the crossloading mechanism  16 , as described further below, to effectuate carton  25  loading. Importantly, the carton transport conveyor  52  is adjustable to accommodate cartons  25  of varying types and sizes. Referring also to FIGS. 9, 10 and  22 - 25  in particular, the carton transport conveyor  52  basically comprises a plurality of flight lugs  56  which are connected to a pair of flight chains  181  and  182 , the flight chains  181  and  182  being connected to and revolving about drive and idler ends  53  and  54 . Although a pair of lugs  56  is shown, the number of lugs  56  per carton  25  may be varied for alternative carton configurations. The lugs  56  are shown to serve a dual purpose in that they are disposed anterior with respect to a particular carton  25  for control and stabilization purposes, while the pair  56  which is disposed posterior to the carton urges the carton  25  forward on the conveyor mechanism  52 . The lugs  56  are preferably constructed of nylon or a similar material. The lugs  56  are attached to the flight chains  181  and  182  via lug bases. The flight chains  181  and  182  are supported at the top or forward run of the conveyor  52  by chain guides  183 . The chain guides  183  are connected to the main frame  17  via guide supports  184 . An elongated, longitudinally extending return guide  185  is disposed along the bottom run of the conveyor  52  and mates with a notch in each lug  56  to stabilize their return during high speed operation. Additionally, a longitudinally oriented slide rail (not shown) may be disposed between the flight chains  181  and  182 , level with the horizontal plane of the chain guides  183 , and with a low-friction top surface to support the bottom of each carton  25  on the conveyor  52 . The width-wise or transverse spacing between lugs  56  on the parallel, side-by-side chains is preferably variable via a transverse lug adjustment mechanism. Although a single pair of flight lugs  56  is shown, an alternative structure may be constructed with phase adjustable leading and trailing flight lugs, as is known in the art. This phase adjustment is desirable to permit the apparatus  10  to be used with various carton configurations to allow for adjustment of carton spacing between, for example, 6 and 12 inch, on center arrangements to convert the apparatus  10  from 6 to 36 pack processing.  
         [0052]    Referring to FIGS. 5, 10 and  14 - 17 , the apparatus preferably includes a carton stabilization structure  28  which supports the tops of the relatively tall, bi-level cartons  25  traveling on the carton supply and transport mechanism  11 , particularly during the loading phase of operation. The carton stabilization structure  28  basically comprises a pair of overhead rails  191  and  192  connected to vertical and horizontal support members  193  and  194  which are linked via adjustment mechanism  195  supported by posts  196 . A carton sleeve set up guide assembly  197  is also preferably disposed anterior to the carton stabilizer  28  and immediately downstream of the point of initial placement of the sleeve on the conveyor  52  by placer  49 .  
         [0053]    Referring to FIGS. 5, 6 and  13 , the first or low article supply mechanism  13  provides a plurality of input individual articles  20  to the apparatus  10  at a first predetermined level or height and at a predetermined point on the article group selection and transport mechanism  12 . The mechanism  13  is shown to comprise a conveyor  60  disposed about a drive sprocket/shaft assembly  61  and an idler sprocket/shaft assembly  62 . The conveyor  60  preferably consists of a unitary, belt. Articles  20  transported on the top, forward run of the conveyor  60  are separated into a plurality of single file paths by lane separators  63 . Each lane separator  63  is shown to be an upstanding plate of a height sufficient to guide the flow of one or more containers  20  on the conveyor  60 , and which is suspended above the conveyor  60 . The lane separators  63  form product conveyance lanes which angle towards the article group selection and conveyance mechanism  12 . An approach angle of approximately 20-25 degrees with respect to the longitudinal axis of the mechanism  12  has been found to provide optimal product group selection results. The conveyor  60  is disposed parallel with and immediately proximate to the article group selection and transport conveyor  12  to allow for article movement thereinbetween. A low friction, dead plate having angled lane grooves which correspond with the lane separators  63  is preferably interposed at the interface between the conveyor  60  and the transport mechanism  12 . Each lane separator  63  has a terminal portion  64  of a predetermined length, such that it extends into the path of the article group selection and transport mechanism  12  a distance approximately equal to one-third the width of the mechanism  12  conveyance path. Each terminal portion  64  is constructed such that it allows longitudinally transported flight structures  74  (described further below) of the article group selection and transport mechanism  12  to pass through the angled conveyance lanes. As the flight bars  74  mesh with and pass through the lane separator end portions  64 , they engage articles  20  disposed in lanes and rake them onto the longitudinal conveyance path of the mechanism  12  and between adjacent flight bars  74 .  
         [0054]    The combination of forces exerted by the flight bars  74 , lane ends  64 , and conveyors  60  and  12  serve to select and meter individual articles  20  into predetermined article groups  21  which are fully merged onto the article group selection and transport mechanism  12 . The size, orientation and dimensions of the resultant product groups  21  is dependent upon the number of infeed lanes, product dimensions, and the configuration and spacing of the flight bars  74 . For example, in the instant embodiment, six (6) lanes of product are active, and the flight bars  74  are spaced such that the resultant product group  21  is selected of eighteen (18) articles in three rows of six cans each. Lanes may be blocked off by closure means  67  to alter the group  21  size and/or orientation. The lane separators  63  and the flight bars  74  are adjustable to provide full variability of product group parameters.  
         [0055]    The low article supply mechanism  13  is shown to terminate at its infeed end  18  for mating with a complementary external apparatus, for example an additional infeed conveyor or conveyors. Alternatively, such infeed conveyor may be integrated with the apparatus  10 . Further, although this embodiment utilizes conveyance lanes which are initially oriented parallel with the remaining elements of the apparatus  10  and subsequently angle towards the article group selection transport mechanism  12 , it is possible to provide an infeed conveyor that is entirely angled as such.  
         [0056]    The article group selection and transport mechanism  12  selects article groups  21  and  22  from the first or low article supply mechanism  13  as set forth above and from the second or high article supply mechanism  19  discussed below, and transports them linearly downstream with respect to the overall apparatus  10 . The downstream transport of article groups  21  and  22  is synchronized with the carton supply and transport mechanism  11  and with the crossloading mechanism  16 , as described further below, to effectuate carton  25  loading. Referring also to FIGS. 7, 21 and  22 , the article group selection and transport mechanism  12  generally comprises a conveyor  73 , a plurality of flight bar assemblies  74  fixed to and longitudinally transported on the conveyor  73 , and a plurality of slide plates  75 , which are disposed on the conveyor  73  between the spaced flight bars  74 .  
         [0057]    The conveyor  73  runs at a predetermined speed and includes a drive procket/shaft assembly  76  and an idler sprocket/shaft assembly  77 , a pair of parallel endless conveyor chains  78  which are connected to and revolve about the sprocket/shaft assemblies  76  and  77 , forming a longitudinally extending forward or top run  79  and a return or bottom run  80 . Idler assembly  77  is disposed ust anterior to the area where the first or low article supply mechanism  13  merges with the article group selection and transport mechanism  12 , and marks the beginning of the conveyor  73 . The drive sprocket/shaft assembly  76  is disposed adjacent the end of the crossloading mechanism  16  and marks the end of the conveyor  73 . The conveyor chains  78  are each supported by top and bottom longitudinally extending chain guides  81 , which in turn are connected to the main frame  17  via upstanding conveyor supports  82 .  
         [0058]    Referring also to FIG. 31, the flight bar assemblies  74  are each shown to include a top rail member  83  and a bottom rail member  84  which are connected to one another by vertical spacers  85 . The top and bottom members  83  and  84  are shown disposed parallel to one another and spacially separated by the spacers  85 . Each top and bottom member  83  and  84  further has an angled front end  150  and an elongated, rectilinear body  151  terminating in a flat back end. The front end  150  slants or angles inwardly from its leading edge to its trailing edge to enable the flight bars  74  to select individual articles  20  disposed in the article infeed lanes and to separate them from the closely spaced nearest upstream article  20 .  
         [0059]    As is best shown in FIG. 7, a pair of fixed slide plates  152  and  153  are connected to each flight bar  74  assembly. Both the flight bars  74  and the slide plates  152  and  153  are connected to the flight chains  78  via connection brackets  86 . The slide plates  152  and  153  are thin, flat structures with a low friction top surface which support the lower article groups  21  and further permit sliding movement thereon. Additionally, slotted slide plates  154  are disposed between adjacent flight bar assemblies  74 , each plate  154  including a laterally oriented slot  155 .  
         [0060]    The height of the flight bar  74  (i.e., the separation distance between the top and bottom members  83  and  84 ) is a function of the container and container group size and configuration. For example, taller cans (12 oz.) require greater flight bar  74  height than a short can (10 oz.), for proper selection and transport. The width of the top and bottom members  83  and  84  is a function of the desired dimensions of the product groups  21  and  22  formed. It is within the purview of this invention that the flight bar  74  height and width be fully adjustable to accommodate various container and group parameters.  
         [0061]    As is best shown in FIGS. 7, 8 and  21 , a group stabilization structure  161  including a pair of longitudinally oriented upper and lower guide rails  162  and  163 , and lateral adjustment structures  163  is disposed on the outer or lateral side of the article group selection and transport mechanism  12 . The lower guide rail  162  extends from the upstream end of the mechanism  12  to a point anterior to a point on the mechanism  12  at which the upper group  22  is formed. The upper guide rail  162  extends throughout the region on the article group selection and transport mechanism  12  at which the upper group  22  is formed. The upper and lower rails  162  and  163  are disposed at predetermined vertical levels, between the upper and lower members  83  and  84  of the flight bars  74 , to contact the base and upper article sub-groups  21  and  22  respectively. The lateral extension distance of the rails  162  and  163  is adjustable by means of the lateral adjustment structures  164  for varying article group  23  sizes.  
         [0062]    Referring to FIGS. 5 and 19, the divider placement mechanism  15  deposits a divider sheet  24  on the top surface of lower or base article group  21  formed and traveling on the article group selection and transport mechanism  12 .  
         [0063]    The divider placement mechanism  15  is shown to be disposed above the article group selection and transport mechanism  12  at a predetermined point downstream from where the base article group  21  is first fully formed. The divider placement mechanism  15  preferably comprises a rotary placer mechanism  92  of the type manufactured and sold by Applicants&#39; assignee and having a pair of apex positions with vacuum control members  94 . A power magazine  93  is shown operatively connected to the placer  92  to provide a continuous supply of divider sheets  24  thereto. Although a rotary-type placer is preferred for divider sheet placement, other placement means may be substituted to practice the basic method of this invention.  
         [0064]    Referring again to FIGS. 7, 8 and  21 , a divider hold down assembly  168  including a pair of medial and lateral rails  169  and  170  and adjustment structures  171  is disposed above a segment of the article group selection and transport mechanism  12 , extending downstream from a point immediately posterior to the point of placement of the divider sheet  24  by the placer  92 . The medial rail  169  has a anterior segment which includes a top member  169  with an upturned forward lip  174  and a side member  173  with a plow configuration, and a rail shaped posterior segment  175 . This configuration is designed to engage and fold down the medial flap on the divider sheet  24 , formed by a perforation or scoreline, and to hold the flap down over the medial edge of the lower article sub-group  21  to stabilize the position of the divider sheet  24  during downstream transport and lateral movement of the upper article sub-group  22  across the divider sheet  24  top surface. The lateral rail  170  extends a predetermined distance downstream to stabilize the lateral edge region of the divider sheet  24  prior to lateral merging of the upper group  22  across the divider sheet  24 . The structure of the divider hold down assembly  168  has been shown to yield a substantially flat divider sheet  24  for improved article group  22  merging thereacross, especially in paperboard divider sheets  24  constructed with recycled materials which tend not to lay flat when unstabilized.  
         [0065]    Referring again to FIGS. 5, 6 and  13 , the second or high article supply mechanism  14  provides a plurality of input individual articles  20  to the apparatus  10  at a second predetermined level or height and at a predetermined point downstream from the low article supply mechanism  13 . The mechanism  14  is also shown to comprise a pair of conveyors  100  and  101 , each being disposed about a drive sprocket/shaft assembly and an idler sprocket/shaft assembly. The conveyors  100  and  101  may consist of a plurality of individual tracks or paths or alternatively a unitary, wider path or belt. Articles  20  transported on the top, forward run of the conveyors  100  and  101  are separated into a plurality of single file paths by lane separators  102 . Each lane separator  102  is shown to be an upstanding wall of a height sufficient to guide the flow of one or more containers  20  on the conveyors  100  and  101 , and which is suspended above the conveyors  100  and  101 . The lane separators  102  form product conveyance lanes which angle towards the article group selection and conveyance mechanism  12  at an approach angle of approximately 20-25 degrees with respect to the longitudinal axis of the mechanism  12 . The conveyors  100  and  101  are disposed parallel with the article group selection and transport conveyor  12 . Conveyor  101  is further disposed immediately adjacent the article group selection and transport conveyor  12  to allow for article  20  movement thereinbetween. A dead plate region is also preferably utilized. Each lane separator  102  has a terminal portion  103  of a predetermined length, such that it extends into the path of the article group selection and transport mechanism  12  a predetermined distance. Each terminal portion  103  is constructed such that it allows the longitudinally transported flight structures  74  of the article group selection and transport mechanism  12  to pass through the angled conveyance lanes. As the flight structures  74  mesh with and pass through the lane separator end portions  103 , they engage articles  20  disposed in lanes and rake them onto the longitudinal conveyance path of the mechanism  12 .  
         [0066]    The combination of forces exerted by the flight bars  74 , lane ends  103 , and conveyors  100 ,  101  and  73  serve to select and meter individual articles  20  into predetermined upper article groups  22  which are merged onto the divider sheet  24  on top of the lower or base article group  21  traveling on the article group selection and transport mechanism  12 . The size, orientation and peripheral dimensions of the resultant upper product groups  22  is dependent upon the number of infeed lanes, product dimensions, and the configuration and spacing of the flight bars  74 . The divider sheet  24  provides a low friction base surface upon which the upper group  22  is transversely, slidably moved to form a stacked group  23 . Lanes may be blocked off by closure means  104  to alter the group  22  size and/or orientation. The lane separators  103  and the flight bars  74  are adjustable to provide full variability of product group parameters.  
         [0067]    Referring to FIGS. 32 and 33, a portion of an alternative embodiment of the stacked article cartoning apparatus  205  is shown wherein upper article sub-groups  206  are deposited on the top surface of divider sheet  207  on lower article sub-group  200  to form a stacked article group  209 . In this embodiment, an upper stream  210  of article sub-groups  206  is disposed above and in longitudinal alignment with a lower stream  211  of article sub-groups  208 . The upper stream  210  is shown to include a dead plate  212  across which the upper article sub-groups  206  are moved by the action of upper pusher bars  213 . The lower stream  211  includes a conveyor  214  and flight bars  215 . As shown, the upper article sub-groups  206  are dropped directly, vertically on top of the divider sheet  207  as they move over the terminal edge  216  of the dead plate. Longitudinal movement of the upper and lower article sub-groups  206  and  208  is synchronized.  
         [0068]    The article group lateral transfer or crossloading mechanism  16  is synchronized with the aforementioned apparatus  10  elements to move completed, stacked article groups  23  traveling on the article group selection and transport conveyor  12  into aligned cartons  25  traveling on the carton supply and transport conveyor  11 . Referring to FIGS. 7, 18,  22  and  26 - 30 , the crossloading mechanism  16  basically comprises a plurality of loader arm assemblies  110 , a flight chain and guide tube assembly  111  to which the loader arm assemblies  110  are attached at predetermined intervals, and which provides a longitudinal movement component thereto, and a control cam assembly  112  which provides a predetermined transverse motion component to the loader arm assemblies  110 .  
         [0069]    The flight chain and guide tube assembly  110  has a forward or top run  113  and a return or bottom run  114  and comprises drive and idler sprocket/shaft assemblies  115  and  116  and a pair of spacially parallel flight chains  117  and  118  which are connected to and revolve about the sprocket/shaft assemblies  115  and  116 . The flight chains  117  and  118  are maintained in a rectilinear configuration on both the top and bottom runs  113  and  114  by chain guides  119  and  120 , which are linked to the frame  17  via vertical support members  121 .  
         [0070]    Pairs of elongated guide tubes  122  are disposed at predetermined intervals along the flight chains  117  and  118 , each guide tube  122  being directly connected at one end to the outer flight chain  118 , and at its opposite end to the inner flight chain  117  so that they are oriented transversely with respect to the axis of the apparatus  10  and to the downstream or forward run of the crossloader  16 . The guide tubes  122  have a low friction exterior surface to provide slidable support of the loader arm assemblies  110 . The pairs of closely spaced tubes  122  increase the stability of transverse movement of the arm assemblies  110 . Further stability is attained by the guide blocks  123  (connected to the inner ends of the guide tubes  122  via set screws) traveling in a longitudinally oriented guide rail  124  which is linked to the frame  17  via a support  125 . As best shown in FIG. 29, lateral retainers  126  are mounted on the top of each guide block  123  to guide the transversely moving arm assemblies  110 . The spacing between successive sets (pairs) of tubes  122  corresponds to the spacing between the flight bars  74  of the article group selection and transport conveyor  12  and of the flight lugs  56  of the carton transport conveyor  11  so that the arm assemblies  110  are aligned to push product groups  23  from between the flight bars  74  into the cartons  25 .  
         [0071]    The loader arm assemblies  110  are movably mounted on the guide tubes  122 , and in a transverse orientation with respect to the axis of the apparatus  10 . The arm assemblies  110  are conveyed in a downstream, longitudinal direction while they simultaneously reciprocate in a transverse direction under the control of a cam mechanism  112  described below. Each loader arm assembly  110  basically comprises an elongated, rectilinear base plate  127  and a loading head  128  located at one end of the base plate  127 . The base plate  127  is shown to have a rigid, flat, elongated structure which is oriented horizontally. A rigid stiffing bar  129  is connected to the top surface of the base plate  127 , vertically oriented, to increase the rigidity and strength of the arm assembly  110 . Preferably, a plurality of bores are disposed in the stiffing bar  129  to reduce its weight. The inwardly disposed end of the base plate  127  is slidably supported by the lateral retainers  126  of the guide block  123 . A first or outer bushing block  130  is connected to the bottom of the base plate  127  at its opposite end. The first bushing block  130  has a pair of apertures, including bushings, through which the guide tubes  122  are slidably extended. A second or inner bushing block  131  is similarly connected to the base plate  127  and interfaces with the guide tubes  122  a short distance from the first bushing block  130 . The bushing blocks  130  and  131  are further connected by a spreader bar  132  which is oriented and rides in the space between the guide tubes  122 . A rotatable cam follower  133  is connected to the bottom of the spreader bar  132 . The longitudinally traveling cam follower  133  cooperates with the cam guide assembly  112  to cause the arm assembly  110  elements to transversely reciprocate on the guide tubes  122  and through the lateral retainers  126  of the guide block  123 .  
         [0072]    The loading head  128  is shown to have two fixed, flat face members  134  and  135 . As the arm assemblies  110  move forward, the face members  134  and  135  push the article groups forward from the article group selection transport conveyor  12  into the cartons  25 . A support roller  144  is disposed on the bottom of the head  128  to provide support when the head  128  is extended across the article group selection and transport mechanism  12 . Additionally, a t-shaped guide pin  145  is disposed on the bottom of the base plate  127  of the arm assembly  110  to mate with the slot  155  in slide plate  154  to laterally stabilize the arm member  110  during high speed operation. The loading head  128  configuration is variable to interface with a wide range of product group  23  configurations. Although in the instant embodiment the head  128  is configured for use with a stacked configuration, the head  128  can be modified for cartoning various other product and product group arrangements, including non-stacked configurations. Head  128  modification is accomplished by changes in the configuration of the face members  134  and  135 . A transition conveyor  29 , shown in FIGS. 2 and 22, is disposed between the crossloading mechanism  16  and the carton transport mechanism  12  to provide a moving base for the movement of the article groups  23  into the longitudinally conveyed cartons  25 . A fixed dead plate may alternatively be used. The bottom member  84  of the flight bars  74  is elongated to extend across the top run of the transition conveyor  29  to guide or funnel article groups  23  across the conveyor  29  and into the cartons  25 , between the carton end panels  44 .  
         [0073]    The loader control cam assembly  112  controls the transverse, reciprocal motion of the arm assemblies  110 . The loader control cam assembly  112  is generally oriented longitudinally with respect to the overall crossloading mechanism  16 , and has a top or forward run  136  and a bottom or return run  137  corresponding to the revolving arm assemblies  110 . The top run  136  basically comprises an inwardly sloping approach segment  137 , an apex  138 , and an outwardly sloping return segment  139 . In the approach segment  137 , the cam follower  133  is urged inwardly, and drives each arm assembly  110  into moving engagement with a product group  23  until it is loaded in a carton  25 . A lag segment  146  of decreased slope is disposed at a predetermined point where the loading head  128  first contacts the article group  23  to provide gentle, even pressure at this initial contact point. In the return segment  139 , the face  128  is retracted from the carton  25  prior to its being reset in the return run  137  of the cam assembly  112 . The forward run  136  of the cam assembly  112  comprises an outer rail  140  and an inner rail  141  which is spaced from the inner rail  140  a distance equivalent to the diameter of the cam follower  133 . The follower  133  is disposed in a cam pathway formed between the outer and inner rails  140  and  141  to effectuate transverse, inward motion to the arm assemblies  110 . Preferably, the outer rail  140  is connected to a pivot point  142  at one end and to a release mechanism, such as a pressure release cylinder and piston  143  proximate its opposite end. The release mechanism  143  is controlled by a sensing mechanism, for example, a photoeye or capacitive proximity sensor, such that if an excessive force is placed on the outer rail  140 , for example due to a jamming of the arm assembly  110 , the release mechanism  143  will be actuated releasing the outer rail  140  which pivots about point  142 .  
         [0074]    The bottom or return run  136  of the cam assembly  112  includes circular guide plates  148  and  149 , and a bottom cam rail  147  which contacts the cam follower  133  to further retract and reset the loader arms  110  for further loading cycles. Since the loader arms  110  are substantially extended when they revolve around sprocket/shaft assembly  115 , it is critical that they be stabilized by the guide pin  145  in slide plate  154  groove  155  during high speed operation.  
         [0075]    As shown in FIGS. 2, 6,  7 ,  9  and  23 , lateral and medial flap tuckers  30  and  31  are disposed adjacent each side of the carton transport mechanism  11 , one anterior to the loading region to provide a closed carton backside against which the loaded containers may nest, and one posterior to the loading region to allow article group  23  ingress to the carton  25  through its open, unglued end flaps  44 .  
         [0076]    Referring to FIGS. 1 and 12, an overhead carton squaring station  33  is shown disposed immediately downstream of glue stations  37 , immediately above the carton supply and transport mechanism  12 , and extending a predetermining longitudinal distance downstream. The overhead station  33  assists in maintaining the squareness of the loaded cartons. The overhead compression station preferably comprises an endless chain  201  with a plurality of vertical lugs  202  having a bottom downstream run of a predetermined longitudinal distance and being disposed a predetermined vertical distance above the article transport conveyor  12 . The vertically disposed lugs  202  have a predetermined configuration such that they aid in maintaining the squareness of the cartons  26 . One or more compression belts (not shown) may additionally be added for package control purposes.  
         [0077]    As shown in FIGS.  1 ,  6 , 24  and  25 , gluing, side compression and discharge mechanisms  32  and  37 ,  34  and  35  are disposed consecutively, further downstream and adjacent the carton supply and transport mechanism  11  to complete the carton flap securement process.  
         [0078]    As many changes are possible to the embodiments 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. The descriptions above and the accompanying drawings should be interpreted in the illustrative and not the limited sense. While the invention has been disclosed in connection with the preferred embodiment or embodiments thereof, it should be understood that there may be other embodiments which fall within the scope of the invention as defined by the following claims. Where a claim, if any, is expressed as a means or step for performing a specified function it is intended that such claim be construed to cover the corresponding structure, material, or acts described in the specification and equivalents thereof, including both structural equivalents and equivalent structures, material-based equivalents and equivalent materials, and act-based equivalents and equivalent acts.