Patent Publication Number: US-8112970-B2

Title: Flexible carrier and system for application to a plurality of containers

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This Application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/079,369, filed 9 Jul. 2008 and U.S. Provisional Patent Application Ser. No. 60/998,001, filed 5 Oct. 2007. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a flexible carrier for carrying a plurality of containers such as bottles or cans and a system for applying the same. 
     2. Description of Prior Art 
     Container carriers connect two or more containers into a sturdy unitized package of containers. Carriers are generally planar arrays of rings, sometimes referred to as six-pack carriers, typically formed from a thermoplastic sheet material. Carriers are applied to containers of various sizes and shapes along various points along the sidewall or under the chime of the container. 
     Conventional carriers are arranged in aligned arrays of longitudinal rows and transverse ranks of container receiving apertures. A common arrangement is two rows of three ranks of longitudinally and transversely aligned container receiving apertures forming six total container receiving apertures and a “six-pack.” Other common configurations include two rows of four ranks forming an eight container multipackage and three rows of four ranks forming a twelve container multipackage. 
     Conventional applicating machines include a circular jaw drum used to apply carriers to individual containers. The conventional jaw drum is typically fixed into position on the applicating machine and fed with a reel or box of a generally continuous container carriers. Such conventional applicating machines typically include an infeed conveyor for supplying a plurality of containers. Additionally, a reel stand is positioned upstream of the jaw drum to supply a reel of carriers to a feed drum and then on to the jaw drum. 
     The string of carriers are then traditionally applied to the containers and, following application, cut into a desired package configuration. The resulting package is then fed into a turner-diverter that moves and/or rotates the package to a correct position for placement on a pallet or similar shipping unit. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a flexible carrier for containers which includes a flexible sheet and a plurality of container receiving apertures formed in the flexible sheet. 
     The flexible carrier in accordance with this invention is preferably used in connection with a machine for packaging multiple containers that includes a jaw assembly moveable in a reciprocating fashion to apply a carrier to a group of containers. This manner of applying flexible carriers is different from traditional methods employing a rotating drum. 
     The applicating machine according to this invention preferably includes one or more of an infeed, a conveyor positioned inline with the infeed, a carrier unwinder providing a generally continuous string of flexible carriers, and a jaw assembly positioned with respect to the conveyor to urge the flexible carrier over the plurality of containers in a reciprocating manner. 
     According to a preferred embodiment of this invention, the containers in a column are spaced relative to each other to facilitate application of the individual carriers to the desired quantity of containers. 
     The jaw assembly as described may include a plurality of fingers that engage openings within the flexible carrier to engage the flexible carrier with the plurality of containers. In addition, a cam may be connected with respect to the jaw assembly wherein the cam may be configured to generally follow a profile of each container of the plurality of containers. 
     To maintain a compact footprint and flexible manufacturing, the carrier unwinder may be connected to the conveyor. Likewise, each of the described components of applicating machine may be included within a single frame to facilitate flexibility and ease of manufacture of unitized packages. Further to this embodiment, a hinge may be connected between the carrier unwinder and the frame and/or applicating machine to permit the carrier unwinder to move between a generally horizontal position and a generally vertical position, thereby permitting ease of replacement of reels of carrier stock. 
     In addition, the applicating machine may include a container indexer positioned inline with the conveyor to index a desired quantity of containers for the jaw assembly. Further, a set of pneumatic clamps may be positioned with respect to the jaw assembly to grasp the containers as the jaw assembly is raised from the 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 top elevational view of a container carrier according to one preferred embodiment of this invention; 
         FIG. 2  is a top elevational view of a container carrier and a plurality of containers prior to application according to one preferred embodiment of this invention; 
         FIG. 3  is a top elevational view of a container carrier and a plurality of containers during application according to one preferred embodiment of this invention; 
         FIG. 4  is a top elevational view of a container carrier and a plurality of containers following application according to one preferred embodiment of this invention; 
         FIG. 5  is a side perspective view of a machine according to one preferred embodiment of this invention; 
         FIG. 6  is a side perspective view of a machine according to one preferred embodiment of this invention; 
         FIG. 7  is front perspective view of a machine according to one preferred embodiment of this invention; 
         FIG. 8  is a top view of the machine shown in  FIG. 7 ; 
         FIG. 9  is a side perspective view of a machine according to one preferred embodiment of this invention; 
         FIG. 10  is a side perspective view of an opposite side of the machine shown in  FIG. 9 ; 
         FIG. 11  is a side view of the machine shown in  FIG. 7 ; 
         FIG. 12  is a side perspective view of carrier stock traveling through a plow according to one preferred embodiment of this invention; 
         FIG. 13  is a top schematic view of sleeve applicator machine used in connection with one preferred embodiment of this invention; and 
         FIG. 14  is a package according to one preferred embodiment of this invention. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIGS. 1-4  show various preferred embodiments of flexible carrier  10  and package  15  according to this invention. Flexible carriers  10  generally include a plurality of container receiving apertures  25  that are each stretched around container  50  to form a unitized package  15  of containers  50 . 
       FIG. 1  illustrates flexible carrier  10  according to a preferred embodiment of this invention. As described in more detail below, portions of flexible carrier  10  are stretched a sufficient amount to permit a tight, gripping engagement with containers  50 . This tight, gripping engagement also maximizes the amount of material of the flexible carrier  10  positioned in the vertical plane, i.e., in contact with the sidewalls of containers  50 . 
       FIG. 1  illustrates one preferred structure for flexible carrier  10  of the invention. The illustrations are exemplary, and the invention is not limited to the flexible carriers  10  or packages shown. Likewise, the applicating machine described in more detail below may operate in connection with flexible carrier  10  as shown or with variations of such flexible carrier  10 . Each flexible carrier  10  preferably includes flexible sheet  20  defining a plurality of container receiving apertures  25 , each for receiving a container  50 . Flexible sheet  20  includes bands or rings of material, termed container receiving portions  30  herein, that surround each container receiving aperture  25 . Such container receiving portions  30  stretchingly engage or grip the respective containers to form a unitized package of containers  50 . 
     As shown in the figures, each flexible carrier  10  according to this invention features an array of container receiving apertures  25 . For example, as shown in  FIGS. 1-4 , the array of container receiving apertures  25  in flexible carrier  10  includes a two rows of three ranks of container receiving apertures  25  totaling six container receiving apertures  25 . Other suitable configurations are contemplated by this invention including two rows of two ranks, two rows of four ranks and/or any other desirable configuration of container receiving apertures  25 . 
     As shown in  FIGS. 2-4 , flexible carrier  10  is applied to a plurality of containers  50  to create a package  15  that, following application, includes an aligned array of container receiving apertures whereby each container receiving aperture is aligned longitudinally and transversely with each adjacent container receiving aperture. In the prior art, a container will generally contact a longitudinally adjacent container (within the same row) and a transversely adjacent container (within the same rank). However, as described in more detail below, according to a preferred embodiment of this invention, and as shown in  FIGS. 2-4 , immediately prior to application of flexible carrier  10  to the plurality of containers  50 , each container  50  in a column of containers  50  is preferably spaced longitudinally from each adjacent container  50 . 
     The containers, such as those shown in packages in  FIGS. 2-4 , are preferably cans. Although cans are shown in  FIGS. 2-4 , bottles or any other commonly unitized container may be used with flexible carrier  10  according to this invention. The containers are preferably like-sized within a single flexible carrier  10 . 
     As shown in  FIG. 1 , flexible carrier  10  may further include an integral handle  60  extending generally upwardly from package  15 . According to this embodiment of the invention, one or more handle apertures  65  are positioned between handle  60  and the remainder of flexible sheet  20 . Handle aperture  65  both provides a void within which to grasp resulting package and permits a flexible interface between handle  60  and remainder of flexible sheet  20 . 
     Flexible sheet  20  of material is preferably cut, using means known to those skilled in the art, such as a stamping die, to form a plurality of container receiving apertures  25  in flexible sheet  20 , such as shown in  FIG. 1 . Container receiving apertures  25  are preferably formed in a rectangular shape having rounded or radiused corners and extending longitudinally across flexible carrier  10  to sufficiently engage and retain a respective container. 
     Container receiving apertures  25  preferably extend lengthwise or longitudinally along flexible sheet  20  so that a length of each rectangular container receiving aperture  25  is aligned longitudinally along flexible sheet  20  and a width of each rectangular container receiving aperture  25  is aligned transversely along flexible sheet  20 . Flexible sheet  20  may include other configurations of container receiving apertures  25  depending on the size of package and/or the number of containers desired. 
     Flexible carrier  10  is preferably manufactured so that raw carrier stock includes a generally continuous roll of flexible sheet  20  having a plurality of adjacent flexible carriers  10  that are punched and then wound onto a reel or spool having several thousand flexible carriers  10 , each flexible carrier  10  attached to each adjacent flexible carrier  10 . Flexible carriers  10  are later applied to containers to form packages and, during such process, are preferably unwound from the reels, stretched over the containers, detached at selected points to separate and then separated from each other to form individual packages. 
     Specifically, each flexible carrier  10  is attached to each adjacent flexible carrier  10  along a series of perforations  75 . According to a preferred embodiment of this invention, end straps  80  along a portion of carrier receiving portions  30  defining container receiving apertures  25  of each adjacent flexible carrier  10  are connected along two sets of perforations  75 , each set of perforations separating a respective end strap  80  from an end strap  80  of an adjacent flexible carrier  10 . A generally straight edge section  85  separates each set of perforations  75  along each end of flexible carrier  10 . 
     As shown in  FIG. 1 , perforations  75  are formed between each adjacent flexible carrier  10  such that a cut is formed in a periphery of flexible sheet  20  thus encouraging separation between each adjacent flexible carrier  10 . Such a perforation pattern in not feasible in conventional carrier design because the drum style application techniques require that adjacent carriers remain attached with respect to each other up to an including application onto containers  50 . 
     The containers to be inserted in container receiving apertures  25  may be bottles or cans having varying shapes and diameters. Carrier receiving portions  30  are installed around the respective containers while stretched, and are allowed to retract or recover to provide a snug fit around the rib, chime or outside sidewall surface of the respective containers. 
     The flexible sheet  20  used to form the flexible carrier  10  is desirably a polymeric or plastic sheet, which can be formed by an extrusion process and then cut to form flexible carrier  10 . The flexible sheet  20  has a thickness which provides sufficient structural integrity to carry a desired number of containers. For instance, each flexible carrier  10  may be designed to carry four, six, eight or more containers of a desired product having a specific weight, volume, shape and size. For most applications, the flexible sheet  20  may have a thickness of about 3-50 mils, suitably about 5-30 mils, commonly about 10-20 mils. 
       FIGS. 2-4  show one preferred system and method of engagement of flexible carrier  10  with containers  50 . As shown, flexible carrier  10  is preferably engaged with applicating machine  110  and then stretchingly engaged with a plurality of containers  50  to form package  15 . Such system, method and apparatus is described in more detail below. 
       FIGS. 2-14  show a system and machine for packaging multiple containers in a carrier according to one preferred embodiment of this invention. As shown in  FIGS. 5-12 , carrier stock  115  moves through machine  110 , specifically through jaw assembly  140 , where it is applied to containers and then separated into individual, unitized packages. Carrier stock  115  may comprise a plurality of flexible carriers  10 , as described above, connected end to end. Therefore, the machine  110  for packaging multiple containers according to this invention permits the use of a single machine in combination with a variety of sizes of containers, sizes of packages and configurations of packages. Traditional machines are typically fifteen or more feet long and six or more feet wide, however, the machine as described herein includes a small footprint, particularly beneficial for small bottling operations, such as craft brewers. 
       FIG. 5  shows applicating machine  110  for applying flexible carrier  10  to a plurality of containers provided from infeed  130 . Applicating machine  110  is preferably supported on frame  112  and, according to a preferred embodiment of this invention is generally self-contained on frame  112 . As such, applicating machine  110  may be moved in a single step without the requirement that multiple adjacent components be disassembled and reassembled inline. 
     Infeed  130  preferably accommodates the generally continuous passage of containers into applicating machine  110 . For example, according to one preferred embodiment of this invention, conveyor  125  is positioned inline with infeed  130 . As used herein, the term “inline” means that the respective jaw assembly is positioned to receive and apply carrier stock  115  to containers. As such, conveyor  125  preferably supplies a preferred column or columns of containers. In a traditional “six pack” arrangement of containers, conveyor  125  preferably provides two generally continuous columns of containers for placement into an appropriate carrier, as described here. 
     According to a preferred embodiment of this invention, and as shown in  FIGS. 2-4 , a plurality of spacers  95  are positioned relative to each column of containers  50  positioned in the applicating machine  110 . Spacers  95  are preferably positioned to space each container  50  from each adjacent container  50  within a column of containers that are positioned beneath jaw assembly  140  of applicating machine  110 . 
     Carrier stock  115  preferably moves through applicating machine  110  from carrier unwinder  150  where individual, separable carriers are dispersed in a generally continuous string of carrier stock  115  and ultimately to packages  15  where each carrier  10  is separated into a unitized package  15 , each package  15  containing a plurality of generally uniform containers  50 . As described above, a typical configuration for a package is a six-pack containing two longitudinal rows of containers in three transverse ranks. Additional desired packages such as four-packs, eight packs and twelve packs may be unitized using applicating machine  110  according to this invention, and such additional sizes of packages are limited only by the consumer market for such additional sizes. 
     One or more operative components of machine  110  are preferably adjustable to permit packaging of containers having different sizes, such as heights and diameters, carriers having different sizes, packages having different sizes, such as six-packs and twelve-packs, and packages having different configurations, namely rim-applied carrier (RAC) configurations and side-applied carrier (SAC) configurations. In each of these different applications, multiple components of machine  110  may be adjusted, replaced and/or interchanged to permit application of carrier stock  115  to containers  50 . Several of these components are described in more detail below. 
     As shown in  FIGS. 5-11 , carrier unwinder  150  provides a generally continuous string of flexible carriers, such as flexible carrier  10  described above. Carrier unwinder  150  preferably comprises a spindle or similar apparatus to accommodate reel  153  onto which a generally continuous string of container stock  115  is wound. Carrier unwinder  150  is preferably integrated within applicating machine  110 , for instance, positioned on or within frame  112  of applicating machine  110  and directly adjacent conveyor  125  and/or infeed  130 . As shown in  FIG. 5 , carrier unwinder  150  may provide a generally continuous string of flexible carriers arranged in a generally vertical orientation. 
     Carrier unwinder  150  is preferably positioned to accommodate reel  153  of carrier stock  115  in a generally horizontal position. According to a preferred embodiment of the invention, hinge  155  is connected with respect to carrier unwinder  150  to permit carrier unwinder  150  to move between a generally horizontal position and a generally vertical position. Movement between a generally horizontal position and a generally vertical position permits a machine operator to load a new reel  153  of carrier stock  115  onto carrier unwinder  150  following exhaustion of the previous reel  153 . As such, carrier unwinder  150  is shifted from a horizontal operating position to a vertical refilling position to permit an operator to easily lift and position reel  153  onto carrier unwinder  150  and then return carrier unwinder to the horizontal operating position using hinge  155 . 
     According to one preferred embodiment of the invention, best shown in  FIGS. 9 and 11 , plow  160  is positioned between carrier unwinder  150  and jaw assembly  140 . Plow  160  is preferably positioned and arranged to spread each carrier of the plurality of carriers in carrier stock  115  for placement onto jaw assembly  140 . Specifically, for carrier stock  115  having a center weld, container apertures  25  are generally positioned through two layers of material. As such, plow  160  preferably separates the two layers of material to provide two preferably coplanar sets of apertures  25  for placement on containers. Such a result is best shown in  FIG. 12  whereby container stock  115  enters plow  160  in a single plane and exits plow  160  configured into two planes, including a plane of material containing an array of apertures  25 . Plow  160  may alternatively be used to configure carrier stock  115  into any other desirable configuration prior to placement onto or into jaw assembly  140 . 
     One such additional configuration would apply to flexible carrier  10  as shown in  FIG. 1 . Such a flexible carrier  10  includes a single layer of material which is thereupon stretched over and around individual containers as shown in  FIGS. 2-4 . 
       FIGS. 2-4  show the process of application of flexible carrier  10  to containers  50 . As shown in  FIG. 2 , prior to application, each container  50  in a column of containers  50  is spaced from each adjacent container and jaw assembly  140  engages flexible carrier  10  above a spaced plurality of containers  50 .  FIG. 3  shows applicating machine  110  during application of flexible carrier  10  to containers  50 . As shown, each of four end straps  80  overlap a top edge of each corner container lid in the plurality of containers  50 . Jaw assembly  140  is then urged downward to engage flexible carrier  10  with the plurality of containers  50  as shown in  FIG. 4 . Jaw assembly  140  then preferably released from package  15  as described in more detail herein. 
     As best shown in  FIG. 9 , jaw assembly  140  is preferably positioned with respect to infeed  130  to urge a carrier, such as flexible carrier  10 , over the plurality of containers  50 , preferably in a reciprocating manner. Specifically, according to this preferred embodiment, jaw assembly  140  reciprocates in an up and down motion as containers are provided beneath or within jaw assembly  140 . According to one preferred embodiment of the invention, jaw assembly  140  includes a plurality of fingers  145  that engage openings, such as container apertures  25 , within carrier  10  to engage carrier  10  with the plurality of containers  50 . 
     Fingers  145  are preferably configured to grip carrier stock  115  with a pair of fingers  145  engaged through each transverse pair of container receiving apertures  25  in carrier stock  115 . The circumferential spacing between adjacent fingers  145  is preferably approximately equal to a pitch of carrier, i.e., the distance between adjacent centers of container receiving openings. The lateral spacing between each pair of fingers  145  is preferably slightly less than a width between transverse pairs of container receiving apertures  25 . Carrier stock  115  is engaged with fingers  145  of jaw assembly  140  immediately prior to application to containers. 
     As fingers  145  reciprocate within jaw assembly  140 , container receiving apertures  25  within carrier stock  115  stretch to accommodate a container  50 , such as shown in  FIG. 2 . According to one preferred embodiment of this invention, best shown in  FIG. 3 , immediately prior to application containers  50 , end straps  80  of flexible carrier  10  are positioned over a top portion of a respective container  50  and pulled downward to expand around the respective container  50 . Flexible carrier  10  in a stretched condition is positioned over a plurality of containers  50  so that each container receiving aperture  25  engages with one container  50 , such as shown in  FIG. 4 . Upon engagement with the containers, carrier stock  15  is released from jaw assembly  40  and grips a perimeter of container, either around a chime in a rim-applied carrier (RAC) configuration or, more preferably in bottle applications, around a sidewall in a sidewall-applied carrier (SAC) configuration. 
     Cam  143  may be connected with respect to jaw assembly  140  such as shown in  FIGS. 9-11 . Cam  143  is preferably configured to generally follow a profile of each container of the plurality of containers thereby permitting consistent and predictable application of carrier stock  115  over the plurality of containers  50 . In addition, cam  143  may be replaceable and/or adjustable to permit application of carrier stock  115  to containers having different sizes, diameters and configurations and additionally to permit RAC or SAC packages. For instance the downward travel of jaw assembly  140  may be adjusted to permit application of carrier stock  115  around a general mid-section of container, thereby resulting in a SAC package such shown in  FIG. 9 . 
     According to one preferred embodiment of the invention, container indexer  170  is positioned inline with conveyor  125  to index a desired quantity of containers for jaw assembly  140 . Container indexer  170  may include a plurality of pockets or similar device for positively capturing, containing and/or moving a desired quantity of containers. Such pockets may be formed within a pair of generally parallel sidewalls positioned on either side of the plurality of containers. Such pockets and/or sidewalls may be adjustable relative to each other to permit a variety of sizes and configurations of containers. 
     According to one preferred embodiment of the invention, scanner  210  may be positioned upstream of jaw assembly  140 , such as between jaw assembly  140  and carrier unwinder  150 . Scanner  210  is preferably used to count container receiving apertures  25  and/or other measure of length of carrier stock  115  to determine a proper length of carrier stock  115  to provide to jaw assembly  140 . Scanner  210  may be used in connection with a means for drawing or unspooling an amount of carrier stock  115  until scanner  210  arrives at a predetermined length and/or count to halt the advance of additional carrier stock  115 . In such a manner, multiple flexible carriers  10  may be provided simultaneously to jaw assembly  140  for application. 
     According to one preferred embodiment of this invention, such as shown in  FIG. 10 , a clamp or set of pneumatic clamps  180  is positioned with respect to jaw assembly  140  to grasp the containers as jaw assembly  140  is raised from the containers. Clamps  180  are preferably arranged and configured to minimize or eliminate any effect on containers as they are grasped for removal of jaw assembly  140 . In this manner, unitized bottles remain together and inline within applicating machine  110  as jaw assembly  140  is pulled away from container stock  115  and the containers  50 . 
     Accordingly, in a method of packaging multiple containers in unitized packages, a plurality of containers are presented to applicating machine  110  preferably to infeed  130 . A generally continuous carrier stock  115  is likewise moved through applicating machine  110 , generally at a similar rate as the plurality of containers. Carrier unwinder  150  is preferably integrated within applicating machine  110  to unwind the generally continuous string of carrier stock  115  through applicating machine  110 . 
     A predetermined quantity of containers is next preferably separated from the plurality of containers, for example, a quantity of six containers. The predetermined quantity of containers may then be indexed to a position below jaw assembly  140 , such as with container indexer  170  as described. 
     Carrier stock  115  is then presented to jaw assembly  140  which is lowered to position the carrier over the containers to form unitized package  15 . Finally, according to a preferred embodiment of this invention, unitized package  15  is grasped, such as with clamp  180 , jaw assembly  140  is raised to a position clear of unitized package  15  and unitized package  15  is advanced from beneath jaw assembly  140 . 
     Following application to containers, carrier stock  115  is divided into individual carriers using a cut-off wheel, knives or similar device resulting in individually unitized packages  15  of a desired size which are then dispersed to a case packer (not shown). Alternatively, for example when using flexible carrier  10  as described above, each flexible carrier  10  is separated from carrier stock  115  along perforations  75  positioned between adjacent end straps  80  by virtue of the application process. Specifically, as each one or more flexible carriers  10  is loaded into jaw assembly  140 , each flexible carrier  10  is separated from an adjacent flexible carrier  10  as a result of the engagement with jaw assembly  140 . Perforations  75  as described above are preferably extend into a periphery of flexible sheet  20  so as to permit the free separation of each adjacent flexible carrier  10  from carrier stock  115 . 
     According to a preferred embodiment of this invention, machine  110  is capable of packaging approximately sixty containers per minute or ten “six packs” per minute. This contrasts with the approximately 1500 and 1800 containers per minute possible on conventional packaging equipment, however, in lower volume operations such lower capacity may be desirable. 
     Additional equipment, such as sleeve applicator machine  200  shown in  FIG. 13 , may be used in connection with the resulting package  15 .  FIG. 14  shows one embodiment of package  15  including carrier and sleeve  190  or similar band around a perimeter of the unitized containers. Such a sleeve  190  may assist in providing a tighter, sturdier package while also providing additional billboard space for packaging graphics and related consumer information. 
     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 purpose of illustration, it will be apparent to those skilled in the art that carrier  10  and the related method of manufacture are 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.