Abstract:
A carrier and method of manufacture for a carrier that results in a package of containers includes a plastic sheet having an array of container apertures and an inner web. The inner web includes a flap that impinges into each container aperture thus creating a carrier that may be consistently applied to produce a desirable package.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This Application claims priority to Provisional Patent Application Ser. No. 60/922,212, filed 6 Apr. 2007. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to a carrier used to unitize a plurality of containers such as cans or bottles. 
   2. Description of Prior Art 
   Container carriers, such as the carrier according to this invention, are used to unitize a plurality of containers. Typical containers are bottles, cans and other containers having a sidewall and a chime or raised rib around an upper portion of the container. Much of the prior art in this area, specifically container carriers constructed from polymeric materials, comprises devices that engage the chime or rib around the upper portion of the container. Another style of container carrier is the sidewall-applied carrier wherein the carrier engages the sidewall of the container. 
   Regardless of the style of container carrier, one challenge in the art is to provide a container carrier that can be used with a variety of containers, including different container diameters and containers having sidewalls with different qualities. In addition, such container carriers should promote a consistent application to a variety of containers resulting in a package that is tight and compact and thus desirable to the consumer. 
   SUMMARY OF THE INVENTION 
   A carrier according to one preferred embodiment of this invention is constructed from a generally flexible plastic sheet that is preferably generally transparent and includes an array of container apertures, each container aperture in the array for engaging a container. The container apertures are preferably arranged in transversely adjacent pairs. 
   An inner web is preferably formed between each transversely adjacent pair of container apertures. The inner web preferably includes a flap extending into each container aperture. The flap is preferably a generally curved portion that extends across a central portion of an inner edge of each container aperture. 
   A line of weakness also preferably extends across a center of the inner web. The inner web is preferably symmetrical about the line of weakness, which may comprise a series of perforations or slits. 
   As a result of the described configuration of the carrier, a consistent package of containers is created because the inner web consistently forms in a “V” shape and resists skewing or inverting. Such skewing or inverting may occur in conventionally designed carriers when the carrier is applied to smaller diameter containers. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above-mentioned and other features and objects of this invention will be better understood from the following detailed description taken in conjunction with the drawings wherein: 
       FIG. 1  is a side elevational view of a container carrier according to one preferred embodiment of this invention; and 
       FIG. 2  is a front perspective view of a package of containers according to one preferred embodiment of this invention. 
   

   DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIG. 1  shows a representative carrier for carrying an array of containers and  FIG. 2  shows a resulting package according to various preferred embodiments of this invention. The physical configuration of carrier  10  and package  50  is merely illustrative and may be varied without departing from the principles of this invention. 
   In a manner similar to the types of multi-package carriers described above, carrier  10  according to one preferred embodiment of this invention is constructed from a thermoplastic material, preferably an extruded low- to medium-density polyethylene sheet material, or plastic sheet  20  having a generally smooth surface. Plastic sheet  20  is preferably generally transparent. As is common in plastic extrusion, plastic sheet  20  is extruded such that a longitudinal direction of plastic sheet  20  is in a machine direction, by definition the direction of the extrusion that is perpendicular to the face of an extrusion die, and the lateral dimension of plastic sheet  20  is in a transverse direction, the direction of the extrusion that is parallel with the extrusion die. 
   Plastic sheet  20  is preferably die-cut to form a plurality of apertures  25 , each aperture  25  capable of receiving container  60 . Apertures  25  are preferably arranged in an array of lateral rows and longitudinal ranks. As shown in  FIGS. 1 and 2 , a preferable array is an arrangement of two lateral rows and three longitudinal ranks to form carrier  10  for holding six containers  60 . Accordingly, rows of apertures  25 , although extending lengthwise across plastic sheet  20 , are counted laterally across a width of plastic sheet  20  and ranks of apertures  25 , although extending widthwise across plastic sheet  20 , are counted longitudinally along a length of plastic sheet  20 . It should be noted, however, that although  FIGS. 1 and 2  show carrier  10  for holding six containers  60 , the invention is not intended to be so limited and carrier  10  may contain any feasible array of apertures  25 . 
   Apertures  25  may comprise any suitable opening, preferably, though not necessarily, an elongated opening having an elongation in the longitudinal direction. As shown in  FIG. 1 , apertures  25  are narrower in the lateral direction than in the longitudinal direction. According to one preferred embodiment of this invention, each container aperture  25  further comprises two generally straight edges  27  extending in a transverse direction of plastic sheet  20 . 
   As shown and described, container apertures  25  are preferably formed in plastic sheet  20  in transversely adjacent pairs with inner web  30  positioned between each transversely adjacent pair of container apertures  25 . Inner web  30  preferably includes flap  35  extending into each container aperture  25  of each adjacent pair of container apertures  25 . As shown in  FIG. 1 , flap  35  is preferably a generally curved portion that extends across a central portion of an inner edge of each container aperture  25 . 
   Line of weakness  40  extending across a center of inner web  30 . As shown in  FIG. 1 , inner web  30  is preferably symmetrical about line of weakness  40 . According to one preferred embodiment of this invention, the line of weakness  40  comprises a perforation, however, line of weakness  40  may comprise any suitable arrangement of perforations, slits, scores, a reduction in thickness of flexible sheet  20  or any other similar line of weakness  40  known to those having ordinary skill in the art. 
   Handle  45  preferably extends from one longitudinal edge of plastic sheet  20 . Handle  45  may be integrally formed with flexible sheet  20  or may be separately formed and attached relative to flexible sheet  20 . Handle  45  may comprise one or more elongated apertures  47  positioned within handle  45  or may comprise a similar configuration that provides an ample area for a consumer to grasp by inserting his hand through and still maintain the purpose and integrity of package  50 . 
   When the preceding embodiment of carrier  10  is assembled into a package  50 , the plurality of interconnected bands formed around container apertures  25  within plastic sheet  20  are positioned along the sidewalls of respective containers  60 , for instance, approximately 1.5″ from a top of each container  60 . 
   Carrier  10  will therefore unitize groups of containers having a range of diameters and a range of sidewall characteristics, including smaller container diameters that require overstretching carrier  10  in both the machine and transverse directions. Carrier  10  according to this invention will permit a single carrier  10  to engage a relatively broad range of existing and conceivable containers. 
   As described, carrier  10  is preferably engaged and applied to containers  60  by sets of moveable jaws (not shown). These moveable jaws typically engage carrier  10  within container apertures  25  and then stretch carrier  10  for application onto containers  60 . As a result of the described embodiment, flap  35  promotes consistent contact with the sidewalls of containers  60 , and container apertures  25  are slideable relative to the sidewalls of the respective containers  60  until carrier  10  is applied to containers  60  and jaws are released from container apertures  25 . Container apertures  25  are then released into engagement with containers  60  thereby providing a tight engagement relative to the sidewalls. This results in a package having containers  60  tightly and firmly maintained within carrier  10 . 
   Flap  35  preferably permits inner web  30  to form in the shape of a “V” due to the friction created by the extra material comprising flap  35 . Absent the “V” shaped inner web  30 , inner web  30  tends to invert following some applications giving package  50  a skewed appearance. By consistently applying carrier  10  having flap  35  in this manner, a desirable looking package  50  is consistently created. 
   While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the apparatus is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.