Patent Publication Number: US-10766644-B2

Title: Apparatus and method for forming a carton

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 13/589,485, filed Aug. 20, 2012, which claims the benefit of U.S. Provisional Application No. 61/575,354, which was filed on Aug. 19, 2011. 
     INCORPORATION BY REFERENCE 
     U.S. patent application Ser. No. 13/589,485, which was filed Aug. 20, 2012, and U.S. Provisional Application No. 61/575,354, which was filed on Aug. 11, 2011, are hereby incorporated by reference for all purposes as if presented herein in their entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to article packaging apparatus, machines, and methods. More specifically, the present disclosure relates to apparatus and methods for forming a carton containing a group of articles such as beverage containers. 
     SUMMARY OF THE DISCLOSURE 
     In general, one aspect of the disclosure is directed to an apparatus for forming a carton containing a group of articles. The apparatus comprises an article positioning system for positioning articles into a plurality of groups of articles and moving the groups of articles along a processing path. A blank handling apparatus is for conveying a plurality of carton blanks towards the plurality of groups of articles. The blank handling apparatus comprises a presser assembly for pressing a respective carton blank of the plurality of carton blanks onto the tops of articles in a respective group of articles of the plurality of groups of articles as the respective carton blank engages the tops of the articles. A folding mechanism is downstream of the blank handling apparatus for folding a portion of the ends of each respective carton blank downwardly around the respective group of articles, the folding mechanism comprising at least one leading lug for folding a leading end portion of the carton blank against the respective group of articles and at least one trailing lug for folding a trailing end portion of the carton blank against the respective group of articles. 
     In another aspect, the disclosure is generally directed to a method of forming a carton containing a group of articles. The method comprises positioning a plurality of articles into a plurality of groups of articles and moving the groups of articles along a processing path. The method comprises moving a plurality of carton blanks towards the plurality of group of articles and pressing a respective carton blank of the plurality of carton blanks onto the tops of articles in a respective group of articles of the plurality of groups of articles and engaging the respective carton blank with the tops of the articles. The method comprises folding a respective carton blank around the respective group of articles. The folding comprises folding a leading end portion of the carton blank downwardly against the respective group of articles and folding a trailing end portion of the carton blank downwardly against the respective group of articles. 
     In other aspects, the disclosure is generally directed to various other features of the apparatus for forming the carton as shown and/or described herein. 
     In other aspects, the disclosure is generally directed to various other features of the method of forming the carton as shown and/or described herein. 
     Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure. 
         FIG. 1  is a side view of an apparatus for forming a carton according to one embodiment of the disclosure. 
         FIG. 2  is a side view of a portion of the apparatus of  FIG. 1  showing a portion of a blank handling apparatus of one embodiment of the disclosure. 
         FIG. 2A  is a detail plan view of one embodiment of a carton blank suitable for use in the apparatus of the present disclosure. 
         FIG. 3  is a schematic view of a portion of the apparatus of  FIG. 1  showing a portion of the blank handling apparatus of one embodiment of the disclosure. 
         FIG. 3A  is a detail perspective of a carton blank removed from the blank handling apparatus and showing the detail of a portion of the blank handling apparatus engaging the carton blank. 
         FIG. 4  is a schematic view of a portion of the apparatus of  FIG. 1  showing a portion of an article positioning system of one embodiment of the disclosure. 
         FIG. 4A  is a schematic view of a portion of the article positioning system with some of the bottles removed to show details of the article positioning system. 
         FIG. 5  is a schematic view of a portion of the blank handling apparatus. 
         FIG. 6  is a schematic view of a portion of the blank handling apparatus with a carton blank being pressed onto a top of a group of articles and a portion of a folding mechanism. 
         FIG. 7  is a schematic view similar to  FIG. 6  but showing detail of the folding mechanism. 
         FIG. 8  is a schematic view showing further detail of the folding mechanism. 
         FIG. 9  is a schematic view showing further detail of the folding mechanism as the group of articles advances in the carton forming apparatus. 
         FIG. 10  is a view similar to  FIG. 9 . 
         FIG. 11  is a schematic view of a top portion of the folding mechanism that is above the path of travel of the group of articles. 
         FIG. 12  is a schematic view similar to  FIG. 9 . 
         FIG. 12A  is a detail of the partially formed carton removed from the apparatus and configured as shown in  FIGS. 9, 10, and 12 . 
         FIG. 13  is a schematic illustrating additional features of the folding mechanism as the group of articles advances in the carton forming apparatus. 
         FIG. 13A  is a detail of the partially formed carton removed from the folding mechanism illustrated in  FIG. 13 . 
         FIGS. 13B  thru  13 C are details of the partially formed carton that is further formed from the view of  FIG. 13A . 
         FIGS. 13D and 13E  are details of the formed carton that is further formed from the view of  FIG. 13C . 
         FIG. 14  is an enlarged detail view of a leading lug of the folding mechanism overhead to one illustrated embodiment. 
         FIG. 15  is an enlarged detail view of a presser assembly of the blank handling apparatus according to one illustrated embodiment. 
         FIG. 16  is a partially exploded perspective illustrating one end of a portion of the folding mechanism. 
         FIG. 17  is a detailed perspective view of a second end of the portion of the folding mechanism of  FIG. 16 . 
         FIG. 18  is a detailed perspective view of a portion of the folding mechanism of  FIG. 16  including a trailing lug of one embodiment of the disclosure. 
         FIG. 19  is a detailed perspective view similar to  FIG. 18 . 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     The present disclosure generally relates to apparatus and methods for forming cartons that contain articles such as containers, bottles, cans, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, aluminum and/or other metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof. 
     Cartons formed by apparatus or methods according to the present disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes beverage containers (e.g., plastic beverage bottles) as disposed within the carton embodiments. In this specification, the terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected and upright cartons. 
     Referring now in more detail to the drawing figures, wherein like reference numerals indicate like parts throughout the several views,  FIG. 1  illustrates an apparatus  11  for forming a carton  3  ( FIG. 13E ) from a carton blank  5  ( FIG. 2A ). The carton  3  and blank  5  shown in the illustrated embodiments are exemplary of the type of carton or blank that can be used in the apparatus  11  of the present disclosure, as the carton and/or blank could be otherwise shaped, arranged, configured, etc. without departing from the disclosure. The apparatus  11  can be referred to as a packaging machine and is used to form the carton  3  around a group of articles, such as beverage containers C ( FIG. 13E ). In the illustrated embodiments, the packaging machine  11  has features for attaching the blank  5  to a group of articles or containers C and folding portions of the blank around the articles to form the carton attached to the containers. 
     In one embodiment, the packaging machine  11  comprises a frame  12  configured to surround and support components of the machine. The machine  11  has an upstream end  13 , a downstream end  14 , with a processing path P extending from the upstream end to the downstream end. The apparatus  11  comprises a blank handling apparatus  16  that is disposed at the upstream end  13 , and an article positioning system  20  for positioning articles C into a plurality of groups of articles and conveying the groups of articles at a precise rate along the processing path P from the upstream end  13  of the machine to the downstream end  14  of the machine. The blank handling apparatus  16  is configured to attach a respective blank  5  to a respective group of articles C formed by the article positioning system  20  with the attached blank and group of articles being further conveyed in the machine  11  for further forming the carton  3 . In the illustrated embodiment, the article positioning system  20  groups the containers C into a group of four containers arranged in a 2×2 arrangement, but the article positioning system could be configured to arrange the containers in other than a 2×2 arrangement (e.g., 2×3, 2×4, 1×3, 1×4, 3×3, 3×4, etc.) without departing from the disclosure. The apparatus  11  includes a folding mechanism  45  downstream from the blank handling apparatus  16  that folds the blank  5  that is attached to the group of articles C to form the carton  3 . Adhesive or glue can be applied to one or more flaps or panels of the blank  5  during the folding by the folding mechanism  45  or by other suitable mechanisms. After the carton  3  is formed in the apparatus  11 , the carton is discharged at an exiting end  26  of the processing path P for further handling. 
       FIG. 2A  illustrates an exemplary blank  5  that can be handled in the apparatus  11  of the present disclosure. The blank  5  is illustrated in further detail in U.S. patent application Ser. No. 12/971,297, filed Dec. 17, 2010, the entire disclosure of which is incorporated by reference herein for all purposes. 
     In one embodiment, the blank  5  has a longitudinal axis L 1  and a lateral axis L 2 . The blank  3  comprises a top panel  111  foldably connected to a first end panel  113  at a lateral fold line  114 , and a second end panel  115  foldably connected to the top panel at a lateral fold line  116 . A first side panel  117  is foldably connected to the top panel  111  at a longitudinal fold line  119 , and a second side panel  121  is foldably connected to the top panel  10  at a longitudinal fold line  123 . In one embodiment, the blank  5  comprises four openings  125  that at least partially define the side panels  117 ,  121 , end panels  113 ,  115  and top panel  111 . In one embodiment, the apparatus  11  of the present disclosure is used to fold the end panels  113 ,  115 , and side panels  117 ,  121  relative to the top panel  111  to at least partially form an interior of the carton  3  that contains the group of articles C. 
     In the illustrated embodiment, the top panel  111  comprises four receptacles  127  that receive a respective top portion of a respective container C of the group of containers that are contained in the carton  3 . In one embodiment, the features of each receptacle  127  comprise four retention flaps  141 ,  143 ,  145 ,  147  that frame a respective opening  151  in the top panel  11  of the blank  5 . Each of the retention flaps  141 ,  143 ,  145 ,  147  has free edges that engage a respective container C to restrain the container from removal from the blank  5  or carton  3 . The retention flaps  141 ,  143 ,  145 ,  147  could be otherwise shaped, arranged, or configured without departing from the disclosure. 
     In one embodiment, the blank  5  comprises four gussets  139  that connect a respective one of the side panels  117 ,  121  to a respective one of the end panels  113 ,  115 . Each of the gussets  139  comprises a first gusset panel  142  foldably connected to a respective end panel  113 ,  115  at an oblique fold line  144  and further defined by an oblique cut line  146 . The gussets  139  each comprise a second gusset panel  152  foldably connected to the first gusset panel  142  at longitudinal fold line  154 . The second gusset panel  152  is at least partially defined by a cut line  156  extending from an edge of a respective opening  125 . The second gusset panel  152  is foldably connected to a respective side panel  117 ,  121  by the portion of the blank  5  that is adjacent the end of the cut line  156 . The cut line  156  at least partially defines an adhesive portion at each end of a respective side panel  117 ,  121 . 
     In one embodiment, the blank  5  has outermost edges  191 ,  193  at the longitudinal ends of the blank corresponding to the free edges of the end panels  113 ,  115  that are spaced a farther distance from the laterally-extending centerline CL of the blank than the edges  195 ,  197  of the side panels  117 ,  121  at the longitudinal ends of the blank. In one embodiment, the outermost edges  191 ,  193  of the end panels  113 ,  115  are spaced apart from the edges  195 ,  197  of the side panels  117 ,  121  by a distance D 1 . In one exemplary embodiment, the distance D 1  is at least approximately ⅝ inch (approximately 16 mm), but the distance D 1  could be more or less without departing from the scope of the disclosure. As shown in  FIGS. 3, 3A, and 5  and discussed in detail below, the blank handling apparatus  16  can have spacing pins  31  that engage the end panels  13 ,  15  to move the blanks in the downstream direction in the packaging machine  11 . The spacing of the edges  191 ,  193  from the edges  195 ,  197  facilitates engagement of the blanks  5  and the pins  31  to convey the blank in the packaging machine  11 . 
     In the illustrated embodiment, the blank handling apparatus  16  comprises a picker assembly  18  that is configured to pick carton blanks  5  from a carton magazine  17  ( FIG. 2 ) that contains a stack  27  of carton blanks. The picker assembly  18  transfers the carton blanks  5  one-at-a-time from the stack  27  in the magazine  17  to a carton chute  19  ( FIG. 3 ) that is located below and downstream from the picker assembly. As shown in  FIG. 1 , the carton chute  19  angles downwardly toward the path P of moving bottle groups C moving along the article conveyor assembly  20 . The carton chute  19  transfers blanks  5  to a presser assembly  21  that is angled downwardly and has features for attaching the blanks  5  to a respective group of articles C. 
     As shown in  FIG. 2 , the picker assembly  18  includes the carton magazine  27  and vacuum cups  29  attached to articulating arms  30  that pick a single carton blank  5  from the stack  27  of blanks and rotate and move the blanks downwardly as indicated by arrow  28  to place the carton blanks on the carton cute  19 .  FIG. 3  shows the carton chute  19  with carton blanks  5  having been placed therein by the picker assembly  18 . The carton chute  19  has side walls  25  and a pair of endless chains  27  to which are attached spacing pins  31  that are moved in the downstream direction indicated by arrow  32  by movement of the chains. Only one of the side walls  25  and endless chains  27  are visible in  FIG. 3 . The spacing pins  31  engage end panels  113 ,  115  of the carton blanks  5  and thereby move the blanks in a predetermined spaced relationship (determined by the spacing of the pins) along and down the carton chute  19 . While the carton blanks  5  are shown in spaced apart single file configuration in  FIG. 3 , this may not necessarily be the case. The spacing pins  31  can be otherwise position as needed to accommodate blanks of varying size or alternative configuration, in which case adjacent blanks may well overlap. The arrangement of the spacing pins  31  and chains  27  provides versatility of the blank handling apparatus  16  so that larger and smaller articles and groups of articles of various configurations can be handle with the same apparatus or with slight modification and/or adjustment to the blank handling apparatus.  FIG. 3A  shows a detail view of a blank  5  removed from the blank handling apparatus  16  but showing the engagement of the spacing pins  31  of the carton chute  19  with the end panels  113 ,  115 . The arrangement of the end panels  113 ,  115  of the blank  5  with the spacing of the edges  191 ,  193  from the edges  195 ,  197  by a distance D 1  facilitates engagement of the blank with the pins  31 . The spacing pins  31  engage the blank  5  to move the blank in the direction of travel indicated by arrow  35 . 
       FIG. 4  illustrates a first portion  43  of the article positioning system  20  for conveying beverage bottles along the processing path P in the downstream direction of the machine  11 . The article conveyor assembly  20  has an endless conveyor belt (not visible) upon which the beverage bottles C are supported, and upstanding guide plates  37  that confine and organize the bottles on the belt. The conveyor belt moves the bottles C downstream until they encounter starwheel assemblies  34  on each side of the processing path P. As illustrated in  FIG. 4 , the starwheel assemblies  34  are rotated in opposite directions (the near wheel being rotated in direction  36  and the far wheel being rotated in direction  40 ) by suitable drive mechanisms (not shown). The top portion  42  of the starwheel assemblies  34  have article receiving surfaces  44  that are shaped to conform to the shape of the container C to capture the containers and meter the conveying rate of the containers. The containers C are conveyed from the first portion  43  of the article positioning system  20  downstream, where they are grouped as described in more detail below by a gripper assembly  50  ( FIG. 4A ). A dead plate (not shown) is disposed between the starwheels and the gripper assembly  50  so that the star wheel assemblies  34  push the bottles across the deadplate to the gripper assembly  50 . 
       FIG. 4A  illustrates the gripper assembly  50  of the article positioning system  20  and shows it as having an endless belt  67  upon which the bottles C rest and ride. The belt  67  is flanked by moving gripper belts  68  that move in synchronization with the endless belt below. The gripper belts  68  are formed with article-receiving recesses  69  sized to caress a beverage bottle C and position it precisely with respect to adjacent bottles of a group. The starwheel assemblies  34  meter the bottles C to the gripper assembly  50  such that groups of bottles separated by spaces are captured by the gripper assembly and moved along the processing path P. The starwheel assemblies  34  can be controlled to create groups of 2×2, 2×4; 2×6, or any other numbers of bottles as needed. The gripper assembly  50  is synchronized with the chains or belts  27  of the carton chute  19  above such that each group of bottles C moves in precise vertical alignment with and in precise synchronization with a corresponding carton blank  5  moving down the carton chute above. In one embodiment, the gripper belts  68  and bottom belt  67  are configured to accelerate movement of the containers C such that the speed of movement of the group of containers that are discharged from the gripper assembly  50  is greater than the speed of movement of the group of containers that are discharged from the first portion  43  of the article positioning system  20 . Since the carton chute  19  is angled downward along the path of travel P as described, the carton blanks  5  progressively approach their aligned bottle groups below. The article positioning system  20  could be otherwise shaped, arranged, and/or configured without departing from the disclosure. 
       FIG. 5  illustrates a portion of the carton chute  19  with carton blanks  5  being moved down the carton chute by the spacer pins  31  attached to the endless chains  27 . As the carton blanks  5  move down the chute  19 , they are discharged from the chute and received by a presser assembly  21  that is adjacent the carton chute. The carton presser assembly  21  comprises an array of spaced endless belts  38  having lower flights that move in synchronization with the adjacent carton blanks below. Further, the endless presser belts  38  are spaced apart such that they straddle a respective row of beverage bottles C of a group of articles being conveyed in synchronization with each carton blank  5  below the presser assembly  21 . Thus, the carton blanks  5  are conveyed in synchronization with corresponding underlying groups of beverage bottles C and are held down as they approach the groups of bottles by the endless presser belts  38  of the presser assembly  21 . The presser assembly  21  presses each carton blank  5  onto the tops of the containers C and causes the receptacles  127  of each blank to engages the tops of the containers of a group of containers. As illustrated in  FIG. 6 , the discharge of the presser assembly  21  is below the tops of the containers C to cause the tops of the containers to extend through the receptacles  127  so that the flaps  141 ,  143 ,  145 ,  147  of each receptacle engage a rim R of the container that is inserted through the top panel  111  of the blank  5 . The carton blanks  5  are thus held in place on the top of a group of bottles C by the mechanical locking action of the flaps  141 ,  143 ,  145 ,  147  that engage the rim R of the container C. As the carton blanks  5  that are now attached to the group of articles C are moved past the presser assembly  21 , the attached carton blanks encounter the folding mechanism  45  that further folds the panels and flaps of the blank. 
       FIGS. 7 and 8  illustrate the upstream end of the folding mechanism  45  that comprises an overhead lug assembly  46 . The lug assembly  46  has a support frame  50  that carries a pair of endless chains  58  ( FIG. 8 ). An array of leading lugs  47  are secured at intervals to one of the endless chains  58  and an array of trailing lugs  61  are secured at intervals to the other one of the endless chains  58 . The leading lugs  47  and trailing lugs  61  move sequentially in front of and behind each group of articles C and attached carton blank  5  as the attached blank and article groups move along the processing path P. The leading lugs  47  are for folding a leading end portion (e.g., side panel  117 ) of the attached blank  5  such that a respective leading lug folds down a respective side panel  117  of the attached blank  5 . The trailing lugs  61  are for folding a trailing end portion (e.g., side panel  121 ) of the attached blank  5  such that a respective trailing lug folds down a respective side panel  121  of the attached blank. As described in more detail below, the leading and trailing lugs  47 ,  61  are pivotally attached to their respective chains  58  so that they can rotate or pivot with respect to the direction of movement of the chain to fold the respective portions of the blanks  5  in an efficient and effective manner. 
     To facilitate and control this rotational or pivotal movement of the lugs  47 ,  61 , the lugs are provided with outer cam followers (outer follower  51  being visible in  FIGS. 7 and 14 ) and inner cam followers (inner cam follower  82  being visible in  FIGS. 7 and 14 ) that ride in strategically configured outer and inner cam tracks  56 ,  57  ( FIG. 8 ) formed in cam plates  49 . In this way, the lugs  47 ,  61  can be pivoted to move almost directly downwardly in front of or behind a group of bottles C rather than rotating in an arc corresponding to the movement of the chains  58  on respective end sprockets in front of or behind the group. The downward movement of the lugs  47 ,  61  allows closer spacing of the bottle groups C and thus higher throughput of the apparatus  11 . The process is illustrated in  FIG. 7  where leading lug  47  is seen to have been pivoted downwardly by its cam followers  51 ,  82  moving in the respective outer and inner cam tracks  56 ,  57  until it is oriented substantially parallel to the direction of movement of its endless chain  58  around its sprocket. Thus, rather than rotating in a wide arc around the sprocket, the leading lug  47  moves virtually straight down as indicated by arrow  52  until it engages the leading flap  117  of the carton blank  5  attached to a moving group of bottles C. The leading lug  47  thus presses or folds the leading flap  117  downwardly in front of the group of bottles C. As the leading lug  47  rounds its sprocket, cam followers  51 ,  82  cooperating again with the adjacent cam tracks  56 ,  57 , progressively rotates or pivots the lug to keep it engaged with the front of the bottle group and hold the leading flap  117  in place against the bottles C. 
       FIG. 8  further illustrates the above-described features of the leading lug  47  rotating around the end of the lug assembly  46  and engaging the leading flap  117 . The leading lug  47  is pivotally attached to one of the pair of endless chains  58 , which is being driven in the direction indicated by arrow  60 . An extender plate  59  projects from the leading lug  47  and carries the outer cam follower  51  and an inner cam follower  82 . The outer cam follower  51  rides in the outer cam track  56  and the inner cam follower  82  rides in inner cam track  57 . Two cam tracks  56 ,  57  and two cam followers  51 ,  82  are used to rotate the leading lug  47  at an extreme angle relative to the direction of its endless chain  58 . The first portion of this rotation is controlled by the outer cam follower  51  riding in the outer cam track  56 . When the angle of rotation nears the limit of control capable by the configuration of the outer cam follower  51  (e.g., too steep an angle with respect to the direction of the chain  58 ), then the inner cam follower  82  riding in the inner cam track  57  causes the leading lug  47  to further rotate through the remainder of the required angle in order for the leading lug to be driven downward in the direction of arrow  52  toward the leading flap  117 . At locations where the outer cam follower  51  and outer cam track  56  are controlling rotation of the leading lug  47 , the inner cam track  57  is widened such that the inner cam follower  82  is not operative. Similarly, at locations where the inner cam follower  82  and inner cam track  57  are controlling rotation of the leading lug  47 , the outer cam track  56  is widened so that the outer cam follower  51  is not operative. In this way, only one cam follower  51 ,  82  and cam track  56 ,  57  are operating at any one time to avoid binding or interference that can cause intermittent movement of the leading lug  47 . In the illustrated configuration, the leading lug  47  is rotated until it is oriented virtually along the direction of movement of the chain  58  as the chain rounds its sprocket. The leading lug  47  thus moves in a downward direction as indicated by arrow  52  rather than swinging through a large arc as it would do if it remained oriented at a right angle relative to its endless chain. It thus slips down at the appropriate orientation in front of an oncoming group of articles C to fold the leading flap  117  of the carton blank  5  down against the leading side of the group of articles. Such downward movement of the leading lug  47  results from the configuration of the cam followers  51 ,  82  and cam tracks  56 ,  57  that rotate the leading lug relative to the chain  58 . 
     Once the leading lug  47  rotates in front of the group of articles C, the trailing lug  61  rotates downwardly in a similar manner (guided by the cam tracks  56 ,  57  and inner and outer cam followers) behind the group of articles to fold down the trailing flap (e.g., side panel  121 ) of the carton blank  5  against the trailing end of the group of articles C.  FIGS. 9 and 10  illustrate the trailing lug  61  in position after folding down the trailing flap  121  and positioned behind the group of articles holding the trailing flap against the group. The leading flap  117  is also shown being held against the leading end of the group of articles by the leading lug  47  as described above. The lugs  47 ,  61  and the group of articles are moving together along the processing path P. Significantly, it has been found that the cam followers of the leading and trailing lugs can be used at this stage of the process to move the leading and trailing lugs into tight engagement with group of articles and the carton flaps using cam tracks or cam surfaces that interact with the cam followers. While slightly visible in  FIG. 9 , and more apparent in  FIG. 18 , the trailing lug  61  has a face  96  that is formed with forwardly curved ends  97  that wrap slightly around the group of bottles when the trailing lug engages them. This causes the trailing gussets  139  of the carton to begin to wrap around the sides of the group as shown. A static rail  66  is positioned to engage a respective end flaps  113 ,  115  of the carton blank  5  to raise and hold it up to allow the leading and trailing gussets  139  to be folded completely inwardly against the sides of the group of bottles C, as detailed below. Only one static rail  66  is shown that engages end flap  113 , but it is understood that a second static rail can be provide on the opposite side of the attached carton blank  5  to position the end flap  115  in a similar manner. As shown in  FIG. 10 , the next successive leading lug  47  is being moved downward as described above to contact the leading flap  117  of the next attached blank  5  and group of bottles to repeat the process. In this way, groups of bottles C are packaged continuously and sequentially as they move along the processing path P. 
     The entire overhead lug assembly  46  of the folding mechanism  45  can be raised and lowered, and the endless chains  58  can be moved apart and together and phased relative to each other to accommodate other carton blank configurations and/or other bottle group formations. In this way, the same packaging machine  11  can be converted to apply cartons to groups of bottles of various configurations. For example, 2×4 groups of bottles and 2×6 groups of bottles, as well as groups of bottles of different sizes can be accommodated by appropriate adjustment of the overhead lug assembly and perhaps replacement of the lugs with lugs sized for the particular size and configuration of the groups of bottles being packaged.  FIG. 12  is another view showing the leading and trailing flaps  117 ,  121  of the carton blank  5  being held against the group of articles C with the leading and trailing lugs  47 ,  61  as described above.  FIG. 12A  shows the attached carton blank  5  and bottles C removed from the apparatus of  FIG. 12  with the leading and trailing side panels  117 ,  121  downwardly folded and being held in the position of  FIG. 12  by the leading and trailing lugs  47 ,  61 . The end panels  113 ,  115  of the attached carton blank  5  are shown as positioned in the folding mechanism  45  of  FIG. 12  just prior to engagement with the static rail  66 . 
     After having been captured between the lugs  47 ,  61  as described, the attached carton blank  5  and group of bottles C move downstream to a tucking wheel  71 , shown in  FIG. 13 , which folds or tucks the leading and trailing gussets  139  of the attached carton blank  5  inwardly against the sides of the group of bottles C. More specifically, the tucking wheel  71  is a generally circular relative thin plate that is rotated by a belt  73  and sheave  72  in the direction indicated by the arrow  74  in  FIG. 13 . The tucking wheel  71  is rotated at a rate such that its outer peripheral surface moves faster than the speed of the groups of articles B with attached carton blanks  5  traveling along the adjacent processing path P. The tucking wheel  71  is formed with a gap  70  at a predetermined location around its circumference, and the rotation of the tucking wheel is timed such that the gap  70  engages the trailing gusset  139  of a carton blank  5  attached to the group of articles C as the attached blank and articles are moved adjacent the tucking wheel to fold the gusset inwardly against the side of the bottle group. As a group of bottles with attached blank  5  reaches the tucking wheel  71 , the leading gusset  139  encounters the edge of the wheel, which although rotating, acts as a static plow or stop that folds the leading gusset back against the side of the group when the advancing attached blank  5  comes into contact with the tucking wheel. As the trailing gusset  139  reaches the tucking wheel  71 , the gap  70  aligns with it so that the gusset falls into the gap. Further rotation of the tucking wheel  71  in the indicated direction  74  urges the trailing gusset  139  inwardly in the downstream direction against the side of the group of bottles. This results in improved positioning and placement of the gussets  139  with respect to the end flaps  113 ,  115  and side flaps  117 ,  121  so that when the end flaps are folded down and glued to the folded gussets, the flap is precisely aligned with the gussets. This contrasts with simply folding the gussets  139  with a static rail or plow, which can skew their positions through friction and result in a less pleasing alignment of the end flaps  113 ,  115 , side flaps  117 ,  121 , side flap and the gussets in the formed carton  3 . A similar tucking wheel (not shown) as the tucking wheel  71  is provide on the opposite side of the processing path P to fold the gussets  139  on the opposite side of the attached blank  5  in the same manner.  FIGS. 13A  thru  13 E illustrate the attached blank  5  removed from the folding apparatus  45  and being formed into the carton  3  by having the gussets  139  inwardly folded by the tucking wheel  71  and the end panels  113 ,  115  downwardly folded. 
     After the gussets  139  are folded inwardly, adhesive is applied, and the end panels  113 ,  115  are urged downwardly and inwardly by a static rail or plow (not shown) into engagement with the folded gussets  139  to complete the wrapping of the carton  5  around the upper portion of the group of articles C. The wrapped group of articles C then moves beyond the overhead lug assembly  46  and between the moving compression belts  24  ( FIG. 1 ), which hold the side flaps against the gussets until the adhesive is cured. The packaged group of bottles C then moves beyond the packaging machine  11  to downstream locations for further handling. 
       FIG. 14  shows one possible embodiment of a leading lug  47  according to the disclosure and as seen from the back side to illustrate the cam follower arrangement thereon. The leading lug  47  includes a chain mount  76  that is securable to the endless chain  58  associated with the leading lug. The arm  77  of the lug is pivotally mounted to the chain mount with a pivot pin  79  so that it can rotate with respect to the chain mount and the chain. The arm  77  terminates in a paddle-like head  78  having a face that is substantially planar. An extender plate  81  projects from the base of the lug  47  and carries the inner cam follower  82  and the outer cam follower  51  that ride in respective inner and outer cam tracks  57 ,  56  to rotate the lug as described above. The lug  47  can be made of any suitable material such as plastic, nylon, aluminum or the like and it will be understood that lugs of different sizes and configurations can be substituted according the shape, configuration, and size of articles being packaged. 
       FIG. 15  illustrates one embodiment of the presser assembly  21  that presses carton blanks  5  onto the tops of bottle groups C as described. The presser assembly  21  includes a drive shaft  86  that drives a set of sheaves  87  for moving endless belts  38  in a downstream direction and downwardly toward the processing path P. The endless belts  38  ride on belt guides  88  to keep them in proper position for pressing carton blanks  5  onto groups of bottles C. The belts  38  are spaced to move between the tops of bottles C in the respective rows of each bottle group or outboard of the side bottles of the group so that they can move below the tops to press the carton blanks onto the tops as described above. The presser assembly  21  could be otherwise shaped, arranged, and/or configured without departing from the disclosure. 
       FIG. 16  shows the upstream end of the overhead lug assembly  46  and illustrates the cam plate  49  with inner cam track  57  and outer cam track  56 . As discussed above, the outer cam track  56  acts on the outer cam follower  51  for part of the rotation of a leading lug  47  until the inner cam track  57  and inner cam follower  82  take over. It can be seen in  FIG. 16  that the outer cam track  56  is widened at locations where the inner cam track  57  is controlling rotation so that only one cam follower  51 ,  82  is operational at any one time during rotation of the leading lug  47  relative to its chain  58 . 
       FIG. 17  illustrates a downstream end of the overhead lug assembly  46  showing a pair of lugs  47 ,  61  rotating back up on the return flight of the assembly to be carried back to the upstream end for another cycle. The leading lug  47  is held in an upright orientation by cam track  93 . The trailing lug  61  is seen to have a face with forwardly curved end portions for initiating folding of the trailing gussets  139  as described above. 
       FIG. 18  is a detailed view of one embodiment of a trailing lug  61  according to one embodiment of the disclosure. The trailing lug  61  has an arm  98  to which a chain mount  99  is attached for mounting the lug to its endless chain  58 . The lug  61  is pivotally connected to the chain mount  99  with a pivot pin  101  so that it can rotate or pivot relative to the direction of movement of the endless chain  58 . A cam follower (not visible in  FIG. 18 ) on the arm  98  projects into a cam track  104  to control the orientation of the lug with respect to the chain to which it is attached. The trailing lug  61  is formed with a head having a face  96  with end portions  97  that are forwardly curved for starting the folding of trailing gussets as previously described. The trailing lug  61  can be made of any appropriate material such as plastic, nylon, metal, or the like and lugs with different configurations can be substituted depending upon the configuration and size of the bottle groups being packaged.  FIG. 19  is a view of the trailing lug  61  from a different perspective illustrating the forwardly curved end portions  97  of the lug face. Alternatively, the trailing lug  61  can have an inner cam follower  82  and outer cam follower  51  similar or identical to the cam followers as described above for the leading lug  47 . 
     The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections. 
     In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. 
     As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. 
     The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place. 
     The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments that are within the scope of the claims. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.