Patent Description:
This invention relates generally to a carrier such as used to unitize a plurality of containers such as cans or bottles, for example.

It is known to use container carriers to unitize a plurality of containers. Typical containers include bottles, cans and other containers having a sidewall and a chime or raised rib around an upper portion of the container. Much of the prior art in this area, specifically container carriers constructed from polymeric materials, comprises devices that engage the chime or rib around the upper portion of the container. Another style of container carrier is the sidewall-applied carrier wherein the carrier engages the sidewall of the container.

Regardless of the style of container carrier, one challenge in the art is to provide a container carrier that can be used with a variety of containers, including different container diameters and containers having sidewalls with different qualities. Specifically, some containers may include sidewalls that utilize different paints or varnished finishes that may change the coefficient of friction between the container and container engaging portions of the multi-packaging device. Because the container engaging portions of the container carrier are generally elastic, which is governed by the modulus of elasticity or "modulus" of the container carrier, the container carrier relies upon the engagement of a stretched container engaging portion with the container sidewall or chime. Container diameters outside of a narrow range of diameters will either stretch the container engaging portion too much thereby permanently losing elasticity, called "neck-down," or not stretch the container engaging portion at all, both scenarios resulting in package failure.

In addition, container engaging portions may slide too easily or not enough relative to the sidewall of a container depending upon a coefficient of friction of the sidewall thus resulting in package failure. For example, if too much friction occurs between the container engaging portions of the carrier and the container sidewall, application of the carrier will destroy the integrity of the carrier or result in a misapplied carrier relative to the sidewall. Typically, in the past, moisture was added to the container or the carrier to permit free sliding of the carrier relative to the container, however, recent industry trends disfavor use of moisture or water in the packaging process.

Prior art container carriers have typically been constructed from a plastic sheet having a single, homogeneous surface having a single coefficient of friction. Prior art container carriers generally require several different versions or configurations to accommodate different container diameters or a certain sidewall smoothness. For example, a matte finish may be applied to an entire carrier to permit application of the carrier to containers having sidewalls with a high coefficient of friction. A disadvantage of the matte finish is that a matte finish results in a generally cloudy or opaque carrier that obscures or shrouds graphics on the containers and/or package. This clarity disruption has led to the implementation of striped matte chrome rolls which allow imparting a matte finish selectively only to those areas which contact a respective container during application, e.g., just down the center of carriers. Such processing, however, has proven to be very labor intensive as, for example, it requires changing of the extruder chrome rolls when going between matte and non-matte product requirements. Also, different carrier styles typically require the striped matte finish in different areas, requiring additional changeovers for carriers with a different configuration or manufacturing lanes.

<CIT> relates to a carrier and method of manufacture for a carrier according to the preambles of claim <NUM> and <NUM>, respectively, that results in a package of containers includes a plastic sheet having an array of container apertures and a portion having a matte finish where the matte finish includes a lower coefficient of friction relative to a container than a remaining surface of the plastic sheet. <CIT> relates to a decorative cover positionable about a flower pot or floral grouping is formed of a polymeric material or a laminated polymeric material.

In view of the above, it is desirable to provide a container carrier that can accommodate an increased range of containers without adversely affecting package aesthetics.

A carrier according to one preferred embodiment is constructed from a generally flexible plastic sheet that is preferably generally transparent and includes a generally smooth surface. A matte finish is printed via flexography onto at least a selected portion of the plastic sheet.

The printed matte finish is preferably imparted to the plastic sheet via UV-curable flexography. For example, through the use of one or more rolls or rollers that impart or meter sufficient amount of ink, a printed matte finish is desirably applied or provided to or at a predetermined width and location on or along the plastic sheet. As will be appreciated, a wide variety of printed matte finishes such as including or involving sections, rings, bands or stripes, for example, are possible and are herein contemplated and encompassed.

Following application of the printed matte finish to the plastic sheet, portions of the plastic sheet include a smooth surface with a generally transparent appearance and portions include the printed matte finish that typically includes a generally cloudy appearance.

Thus, according to a preferred method of manufacturing carrier, the plastic sheet with the printed matte finish arranged in a desired location or locations is formed into individual carriers. According to a preferred embodiment of this invention, each carrier is formed so that the printed matte finish is longitudinally arranged and positioned between outer bands of the carrier and, more particularly, between outer edges of apertures in the carrier.

This configuration permits the printed matte finish to slide along container sidewalls during application to containers in the areas between apertures and avoid the tendency of the plastic sheet in that area to engage, drag and/or overstretch relative to the sidewall, particularly a sidewall having a high coefficient of friction or unfavorable surface finish relative to the carrier. Therefore, in a preferred embodiment of the invention, when individual containers are inserted into the carrier to create an assembled package, the containers are positioned within respective container apertures so that the printed matte finish contacts at least a portion of each container and thus permits the sidewall of the respective container to slide freely enough within container aperture to permit application of carrier to containers without destroying the carrier.

Accordingly, the portion of the carrier that includes the printed matte finish is preferably positioned along an inner portion of package. The outer bands of the carrier are thus generally transparent and free of the printed matte finish so as not to block graphics on containers or otherwise disrupt the aesthetics of the package. In addition, the outer bands are engaged with jaws for applying the carrier to the containers thereby permitting free application of the carrier without contact between each container and the outer bands of the carrier until the jaws disengage, at which time container to carrier friction is desired.

According to the invention, also a method for manufacturing a container carrier having an array of apertures each for receiving a container is provided.

In accordance with the invention, such a method involves feeding a flexible plastic sheet across a roller. The method further involves printing a matte finish onto at least a portion of the plastic sheet and forming the plastic sheet into the container carrier into the plastic sheet so that the matte finish is positioned in a desired location.

The above-mentioned and other features and objects of the subject development will be better understood from the following detailed description taken in conjunction with the drawings wherein:.

<FIG> show a representative method of manufacture, a carrier for carrying an array of containers and a package according to various preferred embodiments of this invention. The physical configurations of the carrier <NUM> and the package <NUM> are merely illustrative and, as will be appreciated by those skilled in the art and guided by the teaching herein provided, may be varied without departing from the principles of this invention.

In a manner similar to the types of multi-package carriers described above, carrier <NUM> according to one preferred embodiment of this invention is constructed from a thermoplastic material, preferably an extruded low- to medium-density polyethylene sheet material, or plastic sheet <NUM> having a generally smooth surface. Plastic sheet <NUM> is preferably generally transparent. As is common in plastic extrusion, plastic sheet <NUM> is extruded such that a longitudinal direction of plastic sheet <NUM> is in a machine direction, by definition the direction of the extrusion that is perpendicular to the face of an extrusion die, and the lateral dimension of plastic sheet <NUM> is in a transverse direction, the direction of the extrusion that is parallel with the extrusion die.

According to a preferred embodiment of this invention, matte finish is integrated, along a generally single plane, with plastic sheet <NUM> in carrier <NUM> so as to create discrete segments of printed matte finish <NUM> integrated with respect to plastic sheet <NUM>. The plastic sheet <NUM> shown in <FIG> has or includes printed matte in a four-stripe pattern such as may be desired for certain carriers. It is to be understood and appreciated that the broader practice of the subject development is not necessarily so limited as plastic sheets with printed matte patterns having a greater or lesser number of stipes as well as non-stripe patterns are contemplated and herein encompassed.

Matte finish <NUM> is imparted to plastic sheet <NUM> by flexography printing such as via UV-curable flexography. For example, standard <NUM> to <NUM> BCM (billions of cubic microns) anilox rolls can be used to meter sufficient amount of ink to the printing plates and then print a continuous stripe such as match the carrier lane centers.

In accordance with a preferred aspect of the development, printed matte areas desirably provide or result in a roughness value Ra of at least <NUM> microinches and, in accordance with one preferred embodiment, preferably in a range of <NUM> to <NUM> microinches. For comparison purposes, typical or commonly used standard chrome rolls are much smoother, such as having Ra values in a range of about <NUM> to <NUM> microinches.

In accordance with one preferred aspect of the development, extruded sheets can be desirably prepared for printing by undergoing corona pretreatment. For example, in accordance with one preferred embodiment, such corona treatment can or may involve standard electron discharge corona treatment of areas or selected areas to be printed, with such treatment typically involving application of a minimum of <NUM> dynes/cm<NUM>.

Following application of printed matte finish <NUM> to plastic sheet <NUM>, plastic sheet <NUM> may include portions having a smooth surface and generally transparent appearance and portions having a printed matte finish <NUM> that typically includes a generally cloudy appearance. In addition, printed matte finish <NUM> includes a lower coefficient of friction against container <NUM>, specifically relative to a sidewall of container <NUM>, than the smooth surface of the plastic sheet.

Thus, according to a preferred method of manufacturing carrier <NUM> according to this invention, plastic sheet <NUM> is fed across a roller following extrusion of plastic sheet <NUM>. The roller then applies printed matte finish <NUM> to a desired portion of plastic sheet <NUM> and carrier <NUM> is subsequently formed from plastic sheet <NUM> so that printed matte finish <NUM> is positioned in a desired location.

As such, after printed matte finish <NUM> is integrated with, or otherwise applied to, plastic sheet <NUM>, the resulting plastic sheet <NUM> is preferably stamped or die-cut to create individual carriers <NUM>. As described, plastic sheet <NUM> is preferably die-cut after the integration of plastic sheet <NUM> and printed matte finish <NUM> for the preferred embodiment of this invention shown in <FIG> and <FIG> and described above. Plastic sheet <NUM> is preferably formed using a punch press to die cut and extract material and create the features of carrier <NUM> described below and generally shown in <FIG>.

Plastic sheet <NUM> having integrated printed matte finish <NUM> is die-cut to form a plurality of apertures <NUM>, each aperture <NUM> capable of receiving container <NUM>. A plurality of outer bands <NUM> are preferably positioned along outer portions of carrier <NUM> and partially define apertures <NUM>. Outer bands <NUM> preferably do not include printed matte finish <NUM>.

Apertures <NUM> are preferably arranged in an array of lateral rows and longitudinal ranks. As shown in <FIG>, an additional preferable array is an arrangement of two lateral rows and three longitudinal ranks to form carrier <NUM> for holding six containers <NUM>. Accordingly, rows of apertures <NUM>, although extending lengthwise across plastic sheet <NUM>, are counted laterally across a width of plastic sheet <NUM> and ranks of apertures <NUM>, although extending widthwise across plastic sheet <NUM>, are counted longitudinally along a length of plastic sheet <NUM>. It should be noted, however, that although <FIG> and <FIG> show carrier <NUM> for holding six containers <NUM>, the invention is not intended to be so limited and carrier <NUM> may contain any feasible array of apertures <NUM>.

In one preferred embodiment of this invention, shown in <FIG>, apertures <NUM> are formed so that printed matte finish <NUM> is longitudinally arranged and positioned between outer bands <NUM> and, more particularly, between outer edges of apertures <NUM> in the lateral rows of apertures <NUM>. This configuration permits printed matte finish <NUM> to slide along container sidewalls in the areas between apertures <NUM> and avoids the tendency of plastic sheet <NUM> in that area to drag and overstretch relative to the sidewall of container <NUM>.

Apertures <NUM> may comprise any suitable opening, preferably, though not necessarily, an elongated opening having an elongation in the longitudinal direction. As shown in <FIG>, apertures <NUM> are narrower in the lateral direction than in the longitudinal direction.

When the preceding embodiment of carrier <NUM> is assembled into a package <NUM> such as shown in <FIG>, the plurality of interconnected bands formed by plastic sheet <NUM> are positioned along the sidewalls of respective containers <NUM>, for instance, approximately <NUM>" from a top of each container <NUM>. Package <NUM> preferably provides a reduced surface finish resistance along the portions of the plastic sheet <NUM> that include printed matte finish <NUM>, specifically along a middle portion of plastic sheet <NUM> extending between outer bands <NUM> and more specifically between outer edges of apertures <NUM>. A surface finish resistance of container <NUM> as used in this specification and claims is defined as the amount of resistance a sidewall of container <NUM> provides as carrier <NUM> is slid down its surface.

In a preferred embodiment of the invention shown in <FIG>, when containers <NUM> are inserted into carrier <NUM> to create an assembled package <NUM>, containers <NUM> are positioned within respective container apertures <NUM> so that printed matte finish <NUM> contacts at least a portion of each container <NUM>. This arrangement permits the sidewall of container <NUM> to slide freely enough within container aperture <NUM> to permit application of carrier <NUM> to containers <NUM> without destroying carrier <NUM>.

Accordingly, the portion of plastic sheet <NUM> that includes printed matte finish <NUM> is preferably positioned along an inner portion of package <NUM>. Outer bands <NUM> of carrier <NUM> are thus generally transparent and free of printed matte finish <NUM> so as not to block graphics on containers <NUM> or otherwise disrupt the aesthetics of package <NUM>.

Carrier <NUM> will therefore unitize groups of containers having a range of diameters and a range of sidewall characteristics, including container sidewalls having high coefficients of friction. Carrier <NUM> according to this invention will permit a single carrier <NUM> to engage a relatively broad range of existing and conceivable containers.

In addition, according to another preferred embodiment of this invention, carrier <NUM> is engaged and applied to containers <NUM> by sets of moveable jaws (not shown). These moveable jaws typically engage carrier <NUM> along outer bands <NUM> and then stretch carrier <NUM> for application onto containers <NUM>. As a result of the described embodiment, portions of carrier <NUM> that include printed matte finish <NUM> maintain exclusive contact with the sidewalls, and are slideable relative to the sidewalls, of the respective containers <NUM> until carrier <NUM> is applied to containers <NUM> and jaws are released from outer bands <NUM>. Outer bands <NUM> are then released into engagement with containers <NUM> thereby providing a higher coefficient of friction relative to the sidewalls than printed matte finish <NUM> of carrier <NUM>. This results in a package having containers <NUM> tightly and firmly maintained within carrier <NUM>.

The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) "means for" or "step for," respectively.

The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.

Claim 1:
A carrier (<NUM>) for carrying an array of containers comprising:
a plastic sheet (<NUM>) having a generally smooth surface and a plurality of container apertures (<NUM>) formed therein, wherein the plastic sheet is generally transparent,
wherein the plastic sheet (<NUM>) includes a matte finish (<NUM>) on at least one desired portion of the plastic sheet (<NUM>)
characterized in that the matte finish is printed via flexography.