Patent Abstract:
A carrier for receiving and restraining a container against rotation during an automated filling and capping operation includes an array of modular container housings. A bumper is disposed below the housing and projects outwardly to cushion the carrier against impact. The bumper is supported by a base. Structure extends from the housing through the bumper and into the base to secure the carrier. One housing module includes a recess having container abutment surfaces and angled surfaces at the opening to guide a container into engagement with the abutments. One housing module includes a recess having ribs separated by relief vents to relieve air pressure as a container is loaded into the carrier. One housing module includes a container holder having a pair of upright supports separated by side openings. The bumper and the base each including a weight positioned at a selected location to uphold the filled container.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority under 35 U.S.C. 119(e) and 37 C.F.R. 1.78(a)(4) based upon copending U.S. Provisional Application Ser. No. 61/596,697 for CONTAINER HANDLING SYSTEM filed Feb. 8, 2012, the entirety of which is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure is broadly concerned with product container carriers. More particularly, it is concerned with a carrier for receiving a container from an assembly line and supporting it in an upright position and secured against rotation for filling and capping. 
       BACKGROUND 
       [0003]    Automated bottling and packaging systems make it possible to handle, fill and cap a wide variety of containers at high speed. These systems may also provide product identification, verification and package labeling. These latter functions enable automated handling systems to be used by regulated industries such as pharmaceutical distribution and dispensing, for example, by mail order pharmacies. In general, these automated systems include structures for loading containers onto a transporting conveyor which delivers them to a series of stations at which they are filled, sealed with a cap or the like, and eventually deposited into a receiving container such as a tote or bin. 
         [0004]    The conveyor may be equipped with a series of larger container carriers, or pucks that receive the containers to be filled and support them in an upright position as they are transported along the conveyor. The pucks may be equipped with data elements such as radio frequency identification (RFID) devices or tags having read-write memory. The containers may be labeled with optically readable data such as bar codes. Association of the RFID tag on the puck with the bar code on the container enables computer verification of the contents of the container. In some industries, such as pharmaceutical distribution, the RFID tag may contain both information associated with the bar code on the container as well as information from a stored database regarding the patient and the order number. Where collection totes used in an automated system, they may also include an RFID tag that is associated with the RFID tag on the puck and the bar code on the container. The RFID tag and/or bar code are read along the assembly line and verified by the stored database. If verification of a container fails, it is diverted to a verification station for further processing. Alternatively, it may be shunted to a rejection tote or bin. 
         [0005]    The Poison Prevention Packaging Act currently requires prescription pharmaceuticals and medications as well as certain non-prescription drugs, medications, and dietary supplements, household chemical and cosmetic products to be packaged in child-resistant containers unless an exception is claimed. Virtually all such containers employ some form of screw type cap in which threading or one or more radially expanded flanges at the opening or on the neck of the container engage complementary threading, a groove or slot in the cap. The screw capping operation in automated systems involves engaging the complementary threading or the slot in the cap with the flanges and rotating the cap until it is snugged against the container at a preselected torque. Automated capping systems such as the KAPS-ALL® packaging systems, generally use a pair of side belts to capture the puck during the capping operation. These systems may experience some slippage problems in capturing and holding currently available cylindrical pucks. In addition, these systems are not well-suited to receiving or handling irregularly shaped containers such as the triangular bottles used for some popular liquid medications. In particular, the triangular, oval and other non-cylindrical containers tend to be difficult to align and introduce into a container carrier. They also tend to rotate within the carrier during the capping operation. Missed container insertion (no container), slippage and internal rotation can each trigger shut down of the assembly line and result in product waste. 
         [0006]    Movement of the container carriers through such automated systems can generate substantial noise. The carriers are generally constructed of a hard synthetic resin material so that they will be durable and can be easily cleaned and sterilized if product spillage occurs. The container carriers are accumulated for use in an accumulating or staging area, where collisions between their hard surfaces produce noise. Some systems employ a vibratory mechanism to align and move the carriers along, which causes them to slap against each other. Some systems employ one or more pneumatic cylinders to push the carriers to various stations along the production line. Such cylinders strike the external surface of the carrier, causing noise. The carriers also generate noise when they transition from one conveyor to another, as well as along the production line when they collide as they are stopped for filling or other operations. High volume automated bottling and packaging systems employ extremely large number of container carriers, which may generate unacceptable levels of occupational noise exposure for their workers. 
         [0007]    Container carriers are frequently designed to accommodate more than one size or type of container. This reduces the need for additional carriers and minimizes changeover time for dispensing different products on the same line. However, taller product containers have a higher center of gravity, which subjects them to tipping when filled with liquids or other heavier products. 
         [0008]    Accordingly, there is a need for an improved product container carrier that enables a container to be easily loaded into a carrier, that centers the container on the vertical axis of the carrier, that prevents rotation of the container within the carrier, that enables a capper to capture the carrier and prevent slippage or rotation of the carrier, as well as the product container, during cap placement and torque down, that includes effective noise damping features, and that can be configured with a selected weight distribution to accommodate product containers having any of various shapes and weights so as to maintain the product container in an upright position during an automated filling and capping operation. 
       SUMMARY 
       [0009]    An improved product container carrier includes a radially expanded base and an upstanding container holder with a recess for receiving a container. The external surface of the carrier includes a series of abutment surfaces to facilitate gripping the container and holding it in place. The internal surface of the container holder includes a plurality of abutment surfaces to facilitate loading and gripping of the container. A plurality of beveled surfaces assist in guiding the container into position at the center of the carrier and into contact with the abutment surfaces. 
         [0010]    The carrier may also include a data element such as an RFID tag and/or bar coding. The base and the container holder may be constructed separately and secured together, or they may be of unitary construction. The base may include one or more recesses for receiving the container holder and/or data element. 
         [0011]    In one embodiment, the carrier includes a housing module, a bumper and a base. The housing module may include a platform member that supports a product holder. A plurality of lugs depend from the platform member for reception within apertures in the bumper and bottom cap to receive fasteners that join the components together. In one aspect, the bottom cap is recessed to include a data element and a weight, and the bumper is recessed to include a weight. In another aspect, a data element and a weight are formed into the bottom cap and a weight is formed into the bumper. 
         [0012]    The housing module may include a holder having a plurality of container abutment surfaces and angled surfaces at the opening to guide a container into engagement with the abutments. 
         [0013]    The housing module may include a holder having a plurality of spaced container abutment surfaces. The abutment surfaces are separated by relief vents to enable air to escape when the carrier receives a container within the holder. 
         [0014]    The housing module may include a holder having a pair of upright support members, which may be supported by a connecting base. Lateral openings between the upright supports permit engagement of the exposed side areas of the container by belts or other means. 
         [0015]    A housing module may be selected in accordance with the type of container to be carried. The housing module is connected with the bumper and base by structure that extends between the housing and the base and passes through apertures in the bumper. This structure secures the parts of the carrier together. The bumper and the base may each include a weight positioned at a location selected to raise or lower the center of gravity to uphold the filled container within the carrier. 
         [0016]    Various objects and advantages of this product container carrier will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this container carrier. 
         [0017]    The drawings constitute a part of this specification, include exemplary embodiments of the carrier, and illustrate various objects and features thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of a product container carrier with a triangular-type container in place; 
           [0019]      FIG. 2  is a top plan view of the sleeve of  FIG. 1  with a product container carrier in place of  FIG. 1 ; 
           [0020]      FIG. 3  is a perspective view of the product container carrier of  FIG. 1  with the container removed; 
           [0021]      FIG. 4  is a perspective view of the base shown in  FIG. 1 ; 
           [0022]      FIG. 5  is a perspective view of the sleeve shown in  FIG. 1 ; 
           [0023]      FIG. 6  is a top plan view of the sleeve of  FIG. 3  with the container removed; 
           [0024]      FIG. 7  is a perspective view of product container carriers including a bumper shown in line formation on a production line conveyor; 
           [0025]      FIG. 8  is an exploded perspective view of an embodiment of a product container carrier with triangular container; 
           [0026]      FIG. 9  is a perspective view of the product container carrier of  FIG. 8  with the container removed; 
           [0027]      FIG. 10  is a sectional view taken along line  10 - 10  of  FIG. 9 ; 
           [0028]      FIG. 11  is a perspective view of an exemplary product container carrier with upright support members, showing a container in position for reception within the carrier; and 
           [0029]      FIG. 12  is a perspective view of an exemplary product container carrier with spaced interior abutment surfaces forming relief vents, showing a container in position for reception within the carrier. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    As required, detailed embodiments of the product container carrier are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the device, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the apparatus in virtually any appropriately detailed structure. 
         [0031]    Referring now to the drawing figures, an exemplary product container carrier  10  is illustrated in  FIG. 1  in association with an exemplary container  12 . The carrier  10  includes a housing  14  having a base  16  supporting a container holder or sleeve  18 . 
         [0032]    As best shown in  FIGS. 4 and 5 , the base  16  has an approximately cylindrical external overall shape presenting an external sidewall  20 . A shorter internal sidewall  22  is positioned in axial spaced relation to the external sidewall. The internal sidewall  22  circumscribes an aperture, cavity or recess  24  in the base for receiving the sleeve  18 . The sleeve  18  has an approximately cylindrical external overall shape that is generally more elongate than the base and includes an external sidewall  26  and a coaxial internal sidewall  28 . The sleeve internal sidewall  28  circumscribes a bore, cavity or recess  30  for receiving a container  12  through an upper opening  31  ( FIG. 6 ). While the base and sleeve are each illustrated to have an approximately cylindrical external overall shape, any suitable external shape may be employed, including generally multilateral, oval, or multi-curved or combinations thereof. It is also foreseen that the base  16  and sleeve  18  may have the same outer diameter and/or surface configuration as, for example, a cylinder or oval, so that delineation of the base is not apparent from the external geometry of the carrier  14 . It is further foreseen that the carrier  14  may be constructed as if bored through, so that the sleeve  18  is contiguous with the base  16 . The sleeve  18  and base  20  may be constructed as separate pieces, or they may be of unitary construction. 
         [0033]    The surfaces of the external and internal sidewalls  20  and  22  of the base  16  each include a series of respective abutment or gripping surfaces  32  and  34 . The surface of the external sidewall  26  of the sleeve  18  also includes a series of abutment surfaces  36 . The abutment surfaces  32 ,  34  and  36  are depicted in the drawing figures as generally vertically oriented flattened surfaces. It is foreseen that these surfaces may also be knurled, swaged, crenate, scalloped or configured in any other suitable manner or combination of manners to provide the sidewalls  20 ,  22  and  26  with a series of gripping surfaces. Where the sleeve  18  and base  16  are constructed as separate components, the internal abutment surfaces  32  and  34  of the sleeve and base aid in mutual engagement and gripping of the surfaces. This provides a friction fit for seating and holding the sleeve  18  in the recess  24  of the base during use, and also allows for quick and easy manual disengagement of the parts. Such construction enables substitution of different sleeve and base components or modules. It is also foreseen that the base internal sidewall  22  may be configured to include a smooth surface to facilitate application of an adhesive substance for permanently securing the sleeve  18  in the recess  24 . 
         [0034]    The surface of the sleeve internal sidewall  28  includes a series of container abutment or gripping surfaces  38 . Preferably, the surface  38  is broached, molded, swaged or otherwise configured to provide a series of internal grooves that serve to position the container  12  at the center of the sleeve  18  and prevent slippage and/or rotation. The grooves are generally axially oriented and distributed so as to provide a plurality of container-contacting surfaces. In one example, the grooves are generally evenly distributed along the sleeve inner sidewall  28 . As best shown in  FIG. 3 , the upper portion of the surfaces  38  may also include a series of bevels or chamfers  40  that are angled inwardly and serve to facilitate or ease the entry of the container  12  through the opening  31  and into the center of the sleeve  18 . It is also foreseen that the surface  38  may have a configuration similar to surfaces  32 ,  34  and  36 . The container abutment surfaces  38  may be of integral construction with the sleeve  18 , or they may be independently formed as a bushing or insert, which may be removable or secured in place. Independently formed abutment surfaces may be constructed from a resilient material such as a silicone polymer or other suitable composition. The abutment surfaces  38  may also take the form of a smooth-walled tubular insert or bushing constructed of a resilient material. In such construction, the resiliency of the material would enable the insert to engage the container surface(s). The insert or bushing may be removable, or it may be secured in place by an adhesive composition or fasteners. 
         [0035]    As shown in  FIGS. 1 and 2 , the exemplary container has a body  42 , including an upstanding neck  44 , which may be tapered. The body  42  includes three walls  46  that meet at acute angles to form corners  48 , imparting a generally triangular shape when viewed from above. The upper portion of the neck  44  includes a plurality of outstanding flanges  50  for reception within corresponding tracks or grooves in a cap. The abutment surfaces  38  on the internal sidewall  38  of the sleeve receive the container corners  48  and grip them in place when a cap is inserted over the container neck and rotated to engage the flanges  50 . This construction prevents the container from rotating within the sleeve  18  along with the cap as it is tightened to a predetermined torque. While the exemplary container described and shown in  FIGS. 1 and 2  presents a generally triangular cross section, it is foreseen that the product container carrier  10  can be used to prevent rotation within the carrier of a container having virtually any construction capable of engagement by the abutment surfaces  38 . It is also foreseen that the angular orientation of the abutment surfaces  38  may be specially configured to maximize gripping contact with the sidewalls of virtually any container. 
         [0036]    Any of the previously described components of the container carrier  10  may be constructed of any known or hereafter developed synthetic resin, rubber, metal or other suitable material or combination thereof. The carrier components may be of solid construction, or they may be generally or partially hollow with internal support ribs. A nonslip coating composition may be applied to any or all of the abutment surfaces  32 ,  34 ,  36 ,  38  to facilitate gripping. 
         [0037]    In a method of manufacture of the container carrier  14 , the base  16  and sleeve  18  are constructed separately. The base  16  is constructed so that the internal sidewall  22  and recess  24  are axially oriented in the base. A data element such as an RFID unit  39  may be molded in or otherwise installed in the base  16 , either in the recess  24  or any other suitable location, or in the sleeve  18 . An adhesive substance such as, for example, a glue, epoxy, fusion weld are applied to one or more of the bottom surface of the sleeve  18  the lower portion of the sleeve exterior sidewall  26 , the internal sidewall  22  of the base and the portion of the base recess  24  adjacent the internal sidewall  22 . The base and sleeve are connected by sliding the sleeve  18  into the recess  24  in a press fit. The puck  14  may be constructed of a synthetic resin material or any other suitable material, including but not limited to a metal or organic material. 
         [0038]    Alternatively, the base  16  and sleeve  18  may be of unitary construction with the sleeve  18  positioned coaxial on the base  16 . A data unit  39  may be installed on or in the base portion  16  or on or in the sleeve  18 . 
         [0039]    In another embodiment shown in  FIGS. 8-12 , a modular container carrier includes a noise-damping base with a variety of selectable container housing modules designed to accommodate various types of containers. An exemplary product container carrier  100  is illustrated in  FIG. 8  in association with an exemplary container  112 . The container carrier  100  includes a base or bottom cap  116  supporting a bumper element  118 , and a housing module  120 . 
         [0040]    The base  116  is approximately disc-shaped, with an upper or top surface  122 , a lower or bottom surface  124  and a circumscribing sidewall  126 . The lower surface  124  may be substantially planar, or it may include a recess  128  to receive a data element  130 , which may also be molded in place during formation of the base  116 . Optically readable data may also be inscribed on or applied to the base sidewall  126  or to the sleeve sidewall  166 . A weight unit or element  132  is molded into a recess  123  in the upper surface  122  of the base. The weight  132  may also rest or be attached to the upper surface  122  so that it is captured between the base upper surface  122  and the bumper  118 . The weight may be constructed of a metal, such as lead, steel or other ferrous metal, aluminum, or any other suitable material. It may be in the shape of a disc, as shown in  FIG. 8 , or it may have any other suitable configuration, such as an apertured washer or multilateral body. Multiple weight elements may also be arranged in axial spaced relation or in axial and vertical spaced relation. The upper surface  122  includes an axial expansion groove  134  to facilitate snugging the upper surface of the base  122  against the lower surface of the bumper. The base  116  includes a plurality of spaced apertures to receive fastener structure for connecting the base, bumper and housing module, as will be described. 
         [0041]    The bumper  118  includes upper and lower surfaces  138 ,  140  and a sidewall  142 . A central recess  144  is provided adjacent either the upper or lower surface or at the center to receive a weight unit  144 , which may be molded into the bumper. The bumper  118  also includes a plurality of spaced apertures  148  for receiving connecting structure therethrough. The apertures  148  are positioned for alignment with the corresponding apertures  136  in the base. The bumper is sized to have a diameter greater than that of the base  116  as well as the housing module  120 , so that it is outstanding from the carrier  100 . The bumper is constructed of a resilient material such as rubber or a synthetic resin, so that it will cushion the impact of a collision with another object such as the bumper of another container carrier, the guide rails  194  or other portion of the conveyor system  188 , or any other equipment or materials encountered along the production line. By cushioning such impacts, the noise usually associated with impact is damped, resulting in a quieter production line. 
         [0042]    The housing module  120  may be variously configured, but generally includes a platform  152  supporting a container holder, which may be in the form of a support sleeve  154 . The platform  152  includes an upper surface  156 , lower surface  158  and sidewall  160 . A plurality of support structures, legs or lugs  162  depend from the platform lower surface  158 . The lugs  162  are sized and positioned for alignment with the bumper apertures  148 . Each lug terminates in a stud or pin  164 . The pins  164  are undersized to enable a slip fit in the base apertures  136 . The arrangement of the supports  162  may be reversed, so that the apertures  136  are positioned in the platform  152 , rather than the base  116  and the legs  162  extend upwardly from the base  116  for registry with apertures  136  in the platform  152 . 
         [0043]    In one aspect, the container support sleeve  154  of the upper housing module  120  is substantially as previously described, including an external sidewall  166  and a coaxial internal sidewall  168  circumscribing a recess or bore having an opening  172  at its upper end for receiving the container  112 . The internal sidewall  168  includes a series of abutment surfaces  172  and a series of bevels or chamfers  174  adjacent the opening  172 . A similarly configured bushing may be used. The lower end of the recess  170  terminates at a generally planar container support surface  176  positioned between the platform upper and lower surfaces  156  and  158 . The surface  176  may also be positioned on a level with either of the platform upper or lower surfaces  156  and  158 . The sleeve internal sidewall includes a plurality of container abutment surfaces  178  as previously described. 
         [0044]    An exemplary container  112  is shown in  FIG. 8  with a cap  180  installed. The container is substantially as previously described, and includes a body  182  having a flanged or threaded neck (not shown) and three walls  184  that meet at angles to form corners  186 . 
         [0045]    When the container  112  is filled with a heavy product, the carrier unit  100  with filled container  112  may become top-heavy and likelihood of tipping the container and spilling the product may be increased. Such likelihood is substantially increased in the case of taller narrow containers such as shampoo bottles. Advantageously, the weight distribution of the container carrier  100  may be adjusted to raise or lower the center of gravity of the carrier to accommodate a particular type of product. This may be accomplished by raising or lowering the positions of one or more of the weights  132  and  146  and/or the weighted bumper  118  in the carrier until the center of gravity is positioned for maximum efficiency. The bumper  118  and base  116  may also be constructed to have taller sidewalls  118  and  126 , allowing greater flexibility in vertically positioning the respective weights  146  and  132 . In another aspect, a weight unit may be constructed to include a central aperture sized for installation over the sleeve  154 , to rest on the upper surface  156  of the platform  152 . Such a weight unit may be an additional weight (not shown), or one or both of weight units  132  and  146  may be constructed to include a central aperture and repositioned in this manner. 
         [0046]    In a method of manufacture of the container carrier  100 , the base  116 , bumper  118  and housing  120  are constructed separately. In the exemplary embodiment shown, the platform  152  and sleeve  154  are depicted as being of unitary construction. However, it is foreseen that they may also be constructed separately. A data element  130  and weight  132  are molded in or otherwise installed in respective recesses  128 ,  123  in the base  116 . A weight  146  is molded in or otherwise installed in puck recess  144 . The parts of the container carrier  100  are assembled and fastened together using thermoplastic or heat staking. The base  116 , bumper  118  and housing module  120  are aligned and assembled so that the lugs  162  project through the bumper apertures  148  and the pins  164  project through the base apertures  136 . In the reversed configuration previously described, the lugs  162  project from the base  116 , through the bumper apertures  148  and the pins  164  project through the platform  152 . Heat and pressure are then applied to deform the pins  164  to form a rivet-type head on the lower surface  124  of the base, or alternately, on the upper surface  156  of the platform. Heat staking is particularly well-suited to fasten the parts together in close relation; however conventional fasteners may also be employed. 
         [0047]    Removable fasteners such as screws (not shown) or any other suitable fastener element may be used to enable substitution of alternate housing modules  120  and bases  116  to accommodate a variety container types. Where conventional fasteners are used, the pins  164  may be omitted and the fasteners project upwardly through the base apertures  136  for reception into the lugs  162  from below. Alternately, the fasteners project downwardly through the platform apertures for reception into the lugs  162  from above. In another aspect, the pins and the lugs may both be omitted and the fasteners project upwardly through the base apertures  136  and into the platform  156  or downwardly through the platform apertures into the base  116 . While three fasteners are shown in the drawing figures, any suitable number may be employed, including a single fastener. It is also foreseen that an adhesive substance, either alone or in combination with other fasteners, may be employed to fasten the parts together. 
         [0048]      FIG. 12  illustrates an exemplary container carrier  200  having a housing module  202  designed to receive and transport a generally cylindrical container  204  having a circumscribing sidewall  206 . While the housing module  202  is designed to support any generally cylindrical or other container having a generally circular cross section, the illustrated exemplary container also includes a concentric upstanding neck  208  including threads  210 . The housing module  202  includes a platform  212  as previously described supporting a container support sleeve  214 . The sleeve includes an external sidewall  216  and a coaxial internal sidewall  218  circumscribing a recess or bore  220  having an opening  222  at its upper end for receiving the container  204 . The external sidewall  216  may include a plurality of abutment surfaces as previously described or a similarly configured bushing may be employed. The recess  220  may also include a smaller opening or drainage hole at its lower end. As shown in  FIG. 12 , the sleeve  214  may be designed so that the sidewalls  216  and  218  are shortened to allow a greater portion of the container  204  to project above the sidewalls for engagement with container handling structure such as a side belt. 
         [0049]    The internal sidewall  218  includes a plurality of spaced abutment members  224 , in the form of ribs, ridges, or other vertically oriented structures for engaging the container sidewall  206 . The ribs  224 , the sleeve internal sidewall  218 , and the container sidewall  206  cooperate to form a series of circumferential spaces or vents  226  between the sidewall of the container  204  and the sleeve. The relief vents  226  enable air to escape as the container  204  is introduced into the recess  220 , reducing back pressure on the container  204  as it is loaded and thus speeding the carrier loading process. The method of manufacture of the container carrier  200  is as previously described. 
         [0050]      FIG. 11  illustrates an exemplary container carrier  300  having a housing module  302  configured to receive and transport a container  304  having a sidewall  306 . While the housing module  302  is designed to support a container having virtually any shape, the illustrated exemplary container is a cylindrical vial having a plurality of spaced apart lugs  308  adjacent an upper opening  310 . The housing module  302  includes a platform  312 , having an upper surface  314 . The platform  312  supports a container holder  316 . The holder includes a base  318  supporting a pair of upright support members or posts  320 . The posts are positioned in spaced relation equidistant from the central vertical axis of the carrier, with the distance between them selected to accommodate the diameter or width of the container  304 . The posts  320  each include an exterior sidewall  322  and an interior sidewall  324 . The interior sidewalls  124  of the posts cooperatively form a container receiving area  326  having a pair of opposed side openings  328  extending from a lower container support surface  330  to the tops of the posts  320 . It is foreseen that the base  318  may be omitted, and the posts  320  connected directly to the platform  312 , which in this aspect also serves as the container support surface  330 . One or more of the posts  320  may also include structure providing lateral adjustability so that the posts may be adjusted to receive larger or smaller containers. In one aspect, the interior sidewalls  324  or a portion thereof may include a resilient compressible collar adjacent the opening or bushings on the interior sidewalls  324 . The bushings are compressed by the container sidewalls  306  when the container is introduced into the carrier  300 . The compressed bushings push against the container sidewalls  306 , providing lateral support to containers  304  that are too small to engage the interior sidewalls  324 . 
         [0051]    As shown in  FIG. 11 , the container holder  316  is designed so that opposed portions of the generally cylindrical container sidewall  306  will extend radially outwardly beyond the uprights  320  for engagement with container handling structure such as a side belt or star wheel. In addition, the full length of the opposed portions that extend radially outwardly will be exposed, for example, for optical reading of a label, bar code, or the like. 
         [0052]    A modular container carrier system includes a base  116 , bumper  118 , weights  132  and  146 , data element  130  and housing modules  14 ,  120 ,  202  and  302 . Bases  116  and bumpers  118  are provided having the weight  147  positioned in the middle or adjacent the upper or lower surface,  138  or  148 . A carrier is assembled by selecting a base and bumper  118  having a weight distribution selected to provide sufficient ballast for the filled container. A housing module is selected based on the type of container to be filled. The base, weight  132 , bumper with weight  147  and lugs  162  of the housing module  14 ,  120 ,  202  or  302  are aligned and assembled as previously described. The parts may be fastened together using heat staking or a removable fastener. An additional weight may be installed by aligning a central aperture over the holder element  154 ,  214 , or  316  and sliding the weight downwardly until it contacts the upper surface of the platform or base  318 . The resultant carrier may be subsequently disassembled and reassembled using a different base, housing module or vertical positioning of the weights to enable use of the carrier with a different type of container as well as distribution of the weight of the carrier in accordance with the shape of the container and weight of the filled product. 
         [0053]      FIG. 7  illustrates a plurality of exemplary container carriers  100  loaded onto a portion of a packaging system conveyor  188 . The conveyor includes a frame  190  having an endless conveyor or bottom belt  192 , which serves as a load-supporting surface. The belt  192  transports the carriers along a predetermined path through an assembly or production line to be filled, capped and labeled. The frame  190  includes a pair of opposed guide rails  194 , which are adjusted to a selected spaced distance to accommodate the width of the carriers  100  and maintain them in centered relation on the belt  192  as it travels over the frame  190 . Such conveyor systems also generally include one or more pairs of bottle gripper or side belts (not shown) for use with tall or unstable containers or tall container carriers  100 . 
         [0054]    In use, a quantity of container carriers  100  is loaded onto a conveyor belt  192  with their container holders in an upward-facing orientation for transport along the production line. The carriers may be accumulated on an accumulating table, so-called “puck pond” or similar area awaiting production line demand, and shunted onto another conveyor for transport to the next station. The carriers may be pushed by mechanical means to urge them into position and jostle each other during transport. Advantageously, the outstanding bumpers  118  prevent the platform sidewalls  160  and bases  116  of the carriers  100  from making noise-generating contact with the hard sidewalls and bases of adjacent carriers. Instead, when the carriers  100  collide, the resilient bumpers  118  contact each other, absorbing the force of the collision and damping any noise. 
         [0055]    A container  112  is typically dropped by a loading component of the packaging system into the sleeve portion  154  of the housing module  120  of each carrier  100 . The bevels  174  serve to introduce the container  112  into the container carrier  100  and guide it into contact with the container abutment surfaces  178 , which cooperate to center the container  112  in the carrier with the mouth or opening centered along the central vertical axis of the carrier  100 . While the container  112  is illustrated in  FIGS. 1 and 8  as a generally triangular shaped bottle, it may have any suitable three dimensional shape and need not be symmetrical along any axis. 
         [0056]    For example, the container may present multiple planar surfaces such as a solid rectangular, square, star-shaped or irregular container. It may also present single or multiple curved surfaces, such as a cylinder, oval, heart shape or irregularly curved container. It may also present a combination of planar and curved surfaces. 
         [0057]    The carrier  100  and container  112  proceed along the conveyor to at least a station where the container is filled with one or more preselected products. Preferably, the package handling system also includes a series of scanning and verifying stations where the data unit in the carrier is read and compared with a bar code on the container  112 . The filled container  112  is then transported in its carrier  100  to a capping station where a cap  180  is positioned on the container to engage a fastening member such as a flange  50  ( FIG. 1 ). While the fastening member is illustrated in  FIG. 1  to include a plurality of radially expanded flanges  50 , it may include threading, a continuous circumferential rib or any other suitable fastening means. 
         [0058]    Typically, the capping station employs side belts or a rotary assembly such as a star wheel, or other structure to engage the housing module  120  or the container. Side belts capture the carrier  100  against rotation and position it so that the container opening is centered under the cap. Where the sleeve  18  is configured to include abutment surfaces  36  as shown in  FIG. 1 , they provide additional areas of belt-to-carrier or wheel-to-carrier contact that assist in securing the carrier against rotation. Where the housing module  202  is configured to allow the container  204  to project above the sleeve  214  as shown in  FIG. 12 , the side belts or star wheel engage the free surface of the container sidewall  206  rather than the carrier. Where the housing module  302  is configured to allow the container  304  to project outwardly from the container holder  316 , the belts or wheels engage the free sides of the container  304  rather than the carrier  300 . 
         [0059]    The internal abutment surfaces  178  of the sleeve  154  ( FIG. 9 ) provide a series of seating surfaces for the container  112  that grasp or grip the container corners  186  ( FIG. 8 ) and hold the container in place. Where the container is shaped other than as depicted, the abutment surfaces  178  grip the edges, protrusions, or any other suitable grippable portions of the container. Thus securely seated within the carrier  100 , rotation or spinning of the container  112  is prevented during the capping operation. The container  112  remains stationary and coaxial with a central vertical axis of the carrier  100  while capping structure positions the cap  180  over the flanges  50 , rotates the cap into mating engagement with flanges and snugs the cap in place on the container  112  to a preselected torque. Once filled and capped the conveyor belt  192  transports the container  112  past any additional scanning and verifying stations onto an order accumulation lane, which brings together multiple orders. In the case of a single component order, the container is then transported to a packing station for final packaging and/or delivery. In the case of a multi-component order, the container is deposited into a tote for further processing. 
         [0060]    It is to be understood that while certain forms of the product container carrier have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.

Technology Classification (CPC): 1