Patent Abstract:
A substantially tubular end-loadable carton ( 200 ) comprising a top wall ( 212 ), an inwardly-extending structure (X 2 ) foldably adjoining said top wall ( 212 ) stowable in a substantially flat-face position with an underside of said top wall ( 212 ), and a top end flap (X 1 ) connected to said inwardly-extending structure is translated in a direction (F) and a flap deflector ( 310 ) is disposed to engage and deflect the end flap (X 1   a ) downwardly and thereby cause the inwardly-extending structure (X 2   a ) to pivot upwardly inside the carton ( 200 ) into substantially flat-face position with the underside of the top wall ( 212 ) of the carton ( 200 ).

Full Description:
RELATED APPLICATIONS 
   This application claims priority to U.S. Provisional Application No. 60/870,830, filed Dec. 19, 2006; and is a continuation-in-part of U.S. application Ser. No. 11/868,253, filed Oct. 5, 2007, which are hereby incorporated by reference in their entirety. 

   TECHNICAL FIELD 
   This invention relates generally to machines and systems for loading cartons. More specifically, the invention relates to apparatuses and methods for preparing end-loadable cartons for loading. 
   BACKGROUND OF THE INVENTION 
   Certain cartons include flaps or other elements that are stowed beneath the top wall of the carton. For instance, some cartons are expandable or can otherwise be arranged to include an expanded open-top portion, which is sometimes referred to as a chimney. The expanded portion of the carton increases the volume or capacity of the carton and allows a consumer to, for example, pour ice into the expanded portion and on top of the contents of the carton. Thus, these cartons are sometimes referred to as ice-pack cartons. It is also desirable for such cartons to retain liquid that may accumulate in the bottom of the carton. In certain ice-pack carton configurations, extension panels and gusset panels, or other panels, are elements that are stowed beneath the top wall of the carton and form at least a portion of an expandable structure that allows for the expansion of the carton. 
   Stowed elements of an ice-pack type carton in particular can undesirably inhibit machine loading of articles into the carton. This is because the placement of the extension panels and gusset panels beneath the top wall of the carton can at least partially obstruct sliding movement of articles that are introduced into the carton via an open end thereof when the carton is arranged as a tubular structure for loading. The stowed elements prevent smooth mechanical loading and may cause the articles to tip. One method of preventing the articles from tipping is to hand load the cartons. However, hand-loading is an inefficient method of loading large quantities of cartons. 
   Another approach to prevent the articles from tipping or being obstructed as they are loaded is to arrange the extension panels and gusset panels such that they are secured to and stowed against the outside of the top wall or end walls, so that the interior of the carton is free from obstructions. However, stowing the extension and gusset panels against the outside of the carton is a less aesthetically appealing design since the walls of the carton are then not clean or continuous. 
   Thus, a heretofore unaddressed need exists in the industry to provide an apparatus and method for loading cartons having an inwardly-extending feature such as a chimney-forming expansion element that is stowed inside the carton. 
   SUMMARY OF THE INVENTION 
   The shortcomings of the prior art are overcome by a system, method and apparatus for loading a carton having an inwardly-extending element that is stowed underneath a top wall of the carton such that loading of the carton is not hindered. 
   The present invention provides a method of preparing a carton for loading and further provides an apparatus for facilitating the method. 
   The invention provides a carton formable from a blank into a tubular structure, which structure has elements that are stowed beneath the top wall of the carton when the carton is loaded with articles such as cans. The elements that extend inwardly into the tubular structure/carton and that are stowed beneath the top wall thereof hingedly adjoin the top wall and adjoin respective end flaps. In an aspect of the invention, the stowable elements and the respective end flaps adjoined thereto are foldable with respect to one another. 
   The method taught by the invention comprises engaging the end flaps such that the respective adjoining elements are pivoted upwardly into face-contacting position with the underside of the top wall. 
   The apparatus taught by the invention engages the end flaps of cartons as those tubular structures are moved along a path so as to cause the respective adjoining, inwardly-extending elements to pivot upwardly. In one aspect, the apparatus comprises a guide that downwardly deflects an end flap thereby causing the respective adjoining, inwardly-extending element to pivot upwardly. In another aspect, the apparatus further provides a means for both deforming and deflecting an end flap so as to inhibit undesired folding of an end flap and element with respect to one another and thereby promote pivoting. 
   The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exemplary embodiment of a blank for forming an exemplary expandable carton. 
       FIGS. 2-9  are perspective views of the blank of  FIG. 1  showing the set up of a carton formed from the blank of  FIG. 1 . 
       FIG. 10  is a perspective view of the carton formed from the blank of  FIG. 1 . 
       FIG. 11  is a perspective view of an exemplary embodiment of an apparatus for loading a carton. 
       FIG. 12  is a side elevation view of a carton illustrating a step of an exemplary embodiment of a method of loading the carton. 
   

   DETAILED DESCRIPTION 
   As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. 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 present invention. 
   Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of an apparatus and method for folding and loading a carton that includes an inwardly-extending structure. Specifically, the apparatus and method are focused towards folding expansion feature elements that are stowed inside the cartons such that the expansion elements do not impede end loading of the carton. 
   The apparatus and methods described herein are described with respect to an exemplary embodiment ice-pack carton  200  that is formed from a blank  100 . The carton  200  and blank  100  forming the carton are also described in co-pending U.S. application Ser. No. 11/868,253, filed Oct. 5, 2007, which application is hereby incorporated by reference in its entirety. The apparatus and the methods of the invention are not only applicable to the exemplary embodiment of the carton shown, but are also applicable to alternative types of cartons having inwardly-extending features that are stowed against the interior surface of a carton wall. 
   Referring to  FIG. 1 , the blank  100  is preferably a single sheet of suitable substrate. It is to be understood that, as used herein the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, and the like. The carton may include a water-resilient coating on at least one surface and may be equipped with features that prevent liquid from leaking from the bottom of the carton. In the exemplary embodiment, the blank is designed for packaging beverage cans. It is envisaged that other articles and/or different arrangements of articles may be contained within the carton and that the blank may therefore be sized accordingly. 
   As used herein, the terms “fold line” and “severance line” refer to all manner of means for indicating optimal fold or cut locations, respectively, including frangible or otherwise weakened lines, perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, scored lines, slits, printed lines, any combination thereof, and the like. To aid in distinguishing the features of the blank  100  and tubular structure T, fold lines are shown as dashed lines in  FIG. 1-9 . 
   The blank  100  includes a series of primary panels which define the walls of a tubular structure T (shown in  FIGS. 8 and 9 ) that defines the body of the expandable carton  200  that is shown in  FIG. 10 . The blank  100  includes first side panels  110 ,  118  that are partial side panels, a top panel  112 , a second side panel  114  that is a full side panel, and a bottom panel  116 . The primary panels are hingedly connected one to the next along fold lines. First side panel  110  is hingedly connected to the top panel  112  along fold line  120 , the top panel  112  is hingedly connected to the second side panel  114  along fold line  122 , the second side panel  114  is hingedly connected to the bottom panel  116  along fold line  124 , and the bottom panel  116  is hingedly connected to first side panel  118  along fold line  126 . 
   End flaps are hingedly connected to opposite ends of each primary panel along fold lines. Certain of the end flaps form end closure structures at respective open ends of the tubular structure T and thereby define the end walls of the expandable carton  200 . The blank  100  is substantially symmetric such that the end flaps that are hingedly connected to opposite ends of each primary panel are substantially identical. Accordingly, the end closure structures of the carton  200  are substantially identical and like references have been used with a suffix “a” or “b” affixed to distinguish one end of the carton from the other. Thus, the description of an element or group of elements having a suffix “a” is generally applicable to a like-numbered element or group of elements having a suffix “b.” In several instances herein, for clarity, only one of the like elements may be described unless a description of the other or both of the like elements is useful for understanding the invention. 
   First side end flaps  130   a ,  138   a  are hingedly connected to first side panels  110 ,  118  along fold lines  140   a ,  148   a , respectively. A top end flap  132   a  is hingedly connected to top panel  112  along fold line  142   a . A second side end flap  134   a  is hingedly connected to second side panel  114  along fold line  144   a . Lastly, a bottom end flap  136   a  is hingedly connected to bottom panel  116  along fold line  146   a . The bottom end flap  136   a  is preferably long enough to cover an entire open end of the tubular structure T and can include a fold line F to facilitate folding and loading the carton  200 . The top end flap  132   a  includes first extension panels  170   a ,  172   a  which are separated by a tear strip  190 , which is defined by severance lines  164   a ,  164   b  and will be described in further detail below. 
   The first extension panels  170   a ,  172   a  are hingedly connected to second extension panels  174   a ,  176   a  along fold lines  178   a ,  180   a , respectively. Each of the fold lines  178   a ,  180   a  extends convergingly from fold line  142   a  to a cutout (which may also be considered a notch or a void) V that separates the second extension panels  174   a ,  176   a  and defines a distal end of the top end flap  132   a . The second extension panels  174   a ,  176   a  are further hingedly connected to tabs  182   a ,  184   a  along fold lines  186   a ,  188   a , respectively. It should be noted that the side end flaps  130   a ,  134   a  are separated from the tabs  182   a ,  184   a , respectively, along cut lines C. 
   Certain of the end flaps are connected to adjacent end flaps by respective intervening gusset panels. The bottom end flap  136   a  is connected to the side end flaps  134   a ,  138   a  by gusset panels  171   a ,  173   a , respectively. The side end flaps  134   a ,  138   a  are hingedly connected to gusset panels  171   a ,  173   a  along a fold line  175   a ,  177   a , respectively. The gusset panels  171   a ,  173   a  are further hingedly connected to the bottom end flap  136   a  along fold lines  154   a ,  156   a , respectively. 
   The second extension panels  174   a ,  176   a  include distal edges E 1 , E 2 . The width of the cutout V is defined by the edges E 3 , E 4  of the second extension panels  174   a ,  176   a , respectively, and the cutout V is further defined by an edge E 5  of the top end flap  132   a.    
   The tear strip  190  extends across the top panel  112  to define side expansion panel portions  192 ,  194  of the top panel  112 . The tear strip  190  further extends across the top end flaps  132   a ,  132   b  to define the first extension panels  170   a ,  172   a . The opposing distal ends of the severance lines  164   a ,  164   b  extend to the cutouts V, terminating at the convex distal edges E 5 , respectively. The first extension panels  170   a ,  172   a  are hingedly connected to respective portions  192 ,  194  of the top panel  112  along fold line  142   a  so as to remain connected thereto after removal of the tear strip  190 . 
   Erecting the carton  200  from the blank  100  may be accomplished with the folding operations as described herein. The operations can be performed entirely or in part by automatic erecting machinery or manually. The method of performing the erecting process is not limited to the exemplary method described. Particularly, the order of the steps can be altered according to manufacturing requirements, steps may be added or omitted, and the means for securing components to one another may vary. The surfaces of sheet material may be secured together by suitable means for securing, such suitable securing means including tape, staples, interlocking folds, VELCRO®, glue or other adhesives, combinations thereof, and the like. 
   A first phase of setup can be performed on what is typically referred to as Inplant Equipment (IPE). Specifically, the blank  100  can be folded and secured into a collapsed tubular structure that can thereafter be erected into a loadable condition without additional gluing. The loadable condition is achieved when an open-ended tubular structure T can be loaded through one or both ends and then sealed, as described in further detail below. 
   Referring to  FIGS. 2 and 3 , the inside surface of the blank  100  is folded along fold line  142   a  such that inside surfaces of the top end flaps  132   a , the second extension panels  174   a ,  176   a , and the tabs  182   a ,  184   a  are in a face-contacting arrangement with the inside surfaces of the first side panel  110 , the top panel  112 , and the second side panel  114 , respectively. 
   Referring to  FIGS. 3-5 , the blank  100  is folded along the fold lines  178   a ,  180   a  such that the outside surfaces of the second extension panels  174   a ,  176   a  are in a face-contacting arrangement with the outside surfaces of the top end flap  132   a  generally and its constituent elements first extension panels  170   a ,  172   a , respectively. Thereby, the portions of the second extension panels  174   a ,  176   a  and the tabs  182   a ,  184   a  that are adjacent to the edges E 1 , E 2  overlap one another and are secured to one another. Tabs  182   a ,  184   a  are secured to one another to form a composite top end flap X 1  that at least partially forms an end closure structure of the carton, as described in further detail below. The second extension panels  174   a ,  176   a  are secured to one another and, along with the first extension panels  170   a ,  172   a , define a two-ply expandable structure (also considered to be an expansion feature) X 2 . As the portions of the second extension panels  174   a ,  176   a  and the tabs  182   a ,  184   a  are secured to one another, the fold lines  186   a ,  188   a  substantially align to define a fold line  186   a / 188   a  along which the end flap X 1  is hingably connected to the expansion feature X 2 . More specifically, the composite end flap X 1  and the pair of second extension panels  174   a ,  176   a  are joined to one another along the fold line  186   a / 188   a . Further, the end flap X 1  and the pair of second extension panels  174   a ,  176   a  are at least initially coplanar with respect to one another across the line  186   a / 188   a . The line  186   a / 188   a  does not serve as a fold line until the end flap X 1  is folded downwardly to close the end of the tubular structure T. The fold line  186   a / 188   a  is aligned with or is otherwise substantially adjacent to fold line  142   a  along which the expansion feature X 2  is hingedly connected to the top panel  112 . 
   Referring to  FIGS. 6 and 7 , glue or other adhesive is applied to at least one of the inside surface of the first side panel  118  and the outside surface of the first side panel  110  so that the portion of the first side panel  118  adjacent to the edge  119  overlaps and is secured to the first side panel  110 . Similarly, the first end flaps  130   a ,  138   a  overlap and are secured to one another. Referring to  FIG. 7 , the collapsed tubular structure T of the carton  200  is formed as the first side panels  110 ,  118  are secured to one another to form a composite first side panel  110 / 118  and the first side end flaps  130   a ,  138   a  are secured to one another to form a composite first side end flap  130   a / 138   a.    
   The carton is now in a collapsed tubular condition which is ready for the second phase of setup, including automatic erecting, loading and sealing using outplant equipment (OPE). OPE, including the apparatus of the invention that is described in further detail below, is typically located in a bottling or packaging facility that is distinct from the location where the tubular structures T and the collapsed cartons  200  are formed. Those skilled in the art will be familiar with the equipment and methods for erecting, loading, and sealing a tubular carton. Therefore, only operations specific to the embodiments described herein will be detailed. 
   As shown in  FIGS. 8 and 9 , the cartons are erected as tubular structures T. The primary panels that define the tubular structure T and the end closure structures define the walls of the carton  200 . The top panel  112  defines a top wall  212 , the side panels  110 / 118 ,  114  define side walls  210 ,  214 , and the bottom panel  116  defines a bottom wall  216 . The side  130   a / 138   a ,  134   a  and bottom  136   a  end flaps can be arranged to align with a respective wall of the carton  200  or can otherwise be folded outwardly to facilitate loading. Accordingly, articles, such as cans, can be easily loaded into the carton  200 . 
   Referring to  FIG. 10 , an end wall  218  which can be seen and an opposing end wall  22  that cannot be seen in this view are formed from the various flaps that are overlapped and adjoined to form end closures for the tubular structure. 
   Referring to  FIG. 11 , an apparatus  300  is illustrated that includes means for deflecting the end flap X 1  according to the exemplary method. The apparatus  300 , or a packaging machine of which the apparatus  300  is a part, includes a conveyor N on which tubular structures T are supported and transported in a flow direction F. In the exemplary embodiment, means for deflecting the end flap X 1  includes a guide  310  that extends substantially parallel to the flow direction F. The guide  310  is dimensioned and positioned such that, as a carton  200  is transported by the carton conveyor N within contacting proximity of the guide  310 , the angled upstream end of the guide  310  contacts the end flap X 1  to pivot the expansion feature X 2  about the fold line  142   a . The end flap X 1  continues to deflect or pivot until it comes in contact with the bottom edge of the guide  310 , where the end flap X 1  is held at a maximum deflected position until reaching the end of the guide  310 . It should be understood that the end flap X 1  is deflected or pivoted by a certain amount such that the extension feature X 2  is deflected a certain amount and such that the end flap X 1  and the extension feature X 2  remain substantially coplanar. Thereafter, the articles can be loaded through the first open end of the tubular structure T. It should be understood that the guide  310  is disposed adjacent to the second open end of the tubular structure T. 
   Referring to  FIG. 12 , when the carton  200  is erected as a tubular structure T, the expansion features X 2  in effect become inwardly-extending structures that tend to extend into the open ends of the tubular structure T or to otherwise obstruct the open ends of the tubular structure T. The end flaps X 1  extend outwardly from the open ends of the tubular structure T. To aid in this portion of the description, the end flaps X 1  and expansion features X 2  will be denoted by the alphabetical suffixes “a” and “b” that have been previously used herein to distinguish features at opposing ends of the carton  200 . As articles are loaded through a first open end of the tubular structure T, the articles contact a first expansion feature X 2   b  and displace the first expansion feature X 2   b  toward the top wall  212  so as to properly position the first expansion feature X 2   b . As the articles continue to move through the tubular structure T toward a second open end of the tubular structure T, the articles would tend to contact a second expansion feature X 2   a  that is hinged at the opposing end of the carton tubular structure T. If this contact were to occur the articles might displace the second expansion feature X 2   a  towards the open end so as to improperly position the second expansion feature X 2   a  or the articles might be made to tip over. 
   The exemplary method and apparatus will facilitate loading the carton  200  such that the second expansion feature X 2   a  is properly positioned and does not cause the articles to tip over. Specifically, the exemplary methods and apparatuses position the second expansion feature X 2   a  such that the second expansion feature X 2   a  is stowed along the inside surface of the top wall  212 . To displace the second expansion feature X 2   a  from the second or non-loading end of the tubular structure T, the corresponding end flap X 1   a  is contacted, deflected, or pivoted such that the second expansion feature X 2   a  deflects or pivots toward the inside surface of the top wall  212  of the tubular structure T. For example, the end flap X 1   a  can be pressed downwardly so as to press the second expansion feature X 2   a  or the distal end of the second expansion feature X 2   a  against the inside surface of the top wall  212 . As those skilled in the art will recognize, at minimum, the deflection of the end flap will at least cause the distal end of the second expansion feature X 2   a  to be raised above the height of the articles such that the articles can slide underneath the second expansion feature X 2   a . In certain embodiments, the distal end is flush with the top wall, while in certain embodiments, the entire expansion feature X 2   a  is flush with the top wall. 
   In alternative embodiments, means for deflecting can include guide structures that travel along a path in the flow direction F and extend downwardly or otherwise transversely with respect to the flow direction F to contact the end flaps X 1  or the top walls of the cartons  200 . For example, means for deflecting can include a plunger apparatus with plungers that extend to deflect the end flaps X 1 . As another example, the plungers can have a substantially flat shape and extend into the open end of the carton to hold the expansion features against the inside surface of the top wall  212 . Thereby, the articles can slide underneath the plunger as they are loaded and the plunger is thereafter removed before forming the end closure. 
   In certain embodiments, the apparatus  300  may also include means for deforming the end flap X 1  to prevent the end flap X 1  and the expansion feature X 2  from folding along the fold line  186   a / 188   a . In certain embodiments, means for deforming includes the guide  310  wherein the guide  310  is disposed to engage the end flap X 1  in such a manner that it deforms sufficiently to inhibit the end flap X 1  and the expansion feature X 2  from folding along the fold line  186   a / 188   a . In alternative embodiments, means for deforming includes the plunger apparatus described above. For example, the plunger apparatus can include plunger elements with pointed ends that contact a central portion of the end flap X 1  and/or a central portion of the top wall  212  such that the end flap X 1  and expansion feature X 2  bow, thereby making it difficult to fold the end flap X 1  and expansion feature X 2  along the fold line  186   a / 188   a . In other embodiments, the material properties of the carton  200  are such that the end flap and expansion feature X 2  do not fold along the fold line  186   a / 188   a  as the end flap X 1  is contacted or deflected and means for deforming is omitted. 
   The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.

Technology Classification (CPC): 1