Systems and methods for packaging articles within a carton

Abstract

A packaging system includes a conveyor configured to convey a group of articles and a blank along a packaging path. The packaging system includes a folding machine configured to fold a first end panel of the blank relative to a main panel of the blank and to fold a second end panel of the blank relative to the main panel, after the first end panel is folded, as the group of articles and the blank travel along the packaging path. The packaging system includes an alignment machine configured to position a first side panel and a second side panel of the blank at a predetermined angle relative to the main panel as the group of articles and the blank travel along the packaging path.

What is claimed is: 
     
         1 . A system ( 100 ) for forming a carton ( 104 ) about articles ( 102 ), the system ( 100 ) comprising:
 a conveyor ( 236 ) configured to convey a group of articles ( 102 ) and a blank ( 106 ), applied to an upper end ( 246 ) of the articles ( 102 ), along a packaging path;   a folding machine ( 228 ) configured to:
 fold a first end panel ( 142 ) of the blank ( 106 ) relative to a main panel ( 108 ) of the blank ( 106 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; 
 fold a second end panel ( 144 ) of the blank ( 106 ) relative to the main panel ( 108 ) of the blank ( 106 ), after the first end panel ( 142 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; 
 fold a first end flap ( 150 ) of the blank ( 106 ) relative to the first end panel ( 142 ), after the first end panel ( 142 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; 
 fold a second end flap ( 152 ) of the blank ( 106 ) relative to the second end panel ( 144 ), after the second end panel ( 144 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; 
 fold a first side panel ( 110 ) of the blank ( 106 ) relative to the main panel ( 108 ), after the first end flap ( 150 ) and the second end flap ( 152 ) are folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; 
 fold a second side panel ( 112 ) of the blank ( 106 ) relative to the main panel ( 108 ), after the first end flap ( 150 ) and the second end flap ( 152 ) are folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; 
 fold a first cover panel ( 118 ) of the blank ( 106 ) relative to the first side panel ( 110 ), after the first side panel ( 110 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; and 
 fold a second cover panel ( 120 ) of the blank ( 106 ) relative to the second side panel ( 112 ), after the second side panel ( 112 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; and 
   an alignment machine ( 230 ) configured to position the first side panel ( 110 ) and the second side panel ( 112 ) at a predetermined angle ( 282 ) relative to the main panel ( 108 ) while the first cover panel ( 118 ) and the second cover panel ( 120 ) are folded.   
     
     
         2 . A packaging system ( 100 ) comprising:
 a conveyor ( 236 ) configured to convey a group of articles ( 102 ) and a blank ( 106 ), applied to an upper end ( 246 ) of the articles ( 102 ), along a packaging path; and   a folding machine ( 228 ) configured to:
 fold a first end panel ( 142 ) of the blank ( 106 ) relative to a main panel ( 108 ) of the blank ( 106 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; and 
 fold a second end panel ( 144 ) of the blank ( 106 ) relative to the main panel ( 108 ) of the blank ( 106 ), after the first end panel ( 142 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path. 
   
     
     
         3 . The packaging system ( 100 ) of  claim 2 , wherein the folding machine ( 228 ) is further configured to:
 fold a first end flap ( 150 ) of the blank ( 106 ) relative to the first end panel ( 142 ), after the first end panel ( 142 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; and   fold a second end flap ( 152 ) of the blank ( 106 ) relative to the second end panel ( 144 ), after the second end panel ( 144 ) is folded, as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path.   
     
     
         4 . The packaging system ( 100 ) of  claim 3 , wherein:
 the folding machine ( 228 ) comprises:
 a lower folding wheel ( 242 ) configured to rotate about a lower rotational axis ( 244 ); 
 a first lower folding arm ( 250 ) projecting radially from the lower folding wheel ( 242 ); 
 a second lower folding arm ( 252 ) projecting radially from the lower folding wheel ( 242 ); and 
 a lower rotary drive ( 254 ) configured to rotate the lower folding wheel ( 242 ) about the lower rotational axis ( 244 ), 
   wherein:
 the first lower folding arm ( 250 ) is configured to fold the first end panel ( 142 ) upward to an orientation that is approximately perpendicular to the main panel ( 108 ) of the blank ( 106 ) as the lower folding wheel ( 242 ) rotates and the group of articles ( 102 ) and the blank ( 106 ) pass over the lower folding wheel ( 242 ); 
 the second lower folding arm ( 252 ) is configured to:
 fold the second end panel ( 144 ) upward to an orientation that is approximately perpendicular to the main panel ( 108 ) as the lower folding wheel ( 242 ) rotates and the group of articles ( 102 ) and the blank ( 106 ) pass over the lower folding wheel ( 242 ); and 
 fold the second end flap ( 152 ) in a direction of travel of the group of articles ( 102 ) and the blank ( 106 ) to an orientation that is approximately perpendicular to the second end panel ( 144 ) as the lower folding wheel ( 242 ) rotates and the group of articles ( 102 ) and the blank ( 106 ) pass over the lower folding wheel ( 242 ). 
 
   
     
     
         5 . The packaging system ( 100 ) of  claim 4 , wherein:
 the folding machine ( 228 ) further comprises an end-flap fold guide ( 262 ) located above the lower folding wheel ( 242 ); and   the end-flap fold guide ( 262 ) is configured to fold the first end flap ( 150 ) opposite to the direction of travel of the group of articles ( 102 ) and the blank ( 106 ) to an orientation that is approximately perpendicular to the first end panel ( 142 ) as the blank ( 106 ) travels under the end-flap fold guide ( 262 ).   
     
     
         6 . The packaging system ( 100 ) of  claim 5 , wherein:
 the folding machine ( 228 ) further comprises an anchor-flap fold guide ( 264 ) located below the end-flap fold guide ( 262 ); and   the anchor-flap fold guide ( 264 ) is configured to:
 fold a first anchor flap ( 158 ) and a second anchor flap ( 160 ) of the blank ( 106 ) opposite to the direction of travel of the group of articles ( 102 ) and the blank ( 106 ) to an orientation that is approximately parallel to the main panel ( 108 ) as the blank ( 106 ) travels under the anchor-flap fold guide ( 264 ); and 
 fold a third anchor flap ( 162 ) and a fourth anchor flap ( 164 ) of the blank ( 106 ) in the direction of travel of the group of articles ( 102 ) and the blank ( 106 ) to an orientation that is approximately parallel to the main panel ( 108 ) as the blank ( 106 ) travels under the anchor-flap fold guide ( 264 ). 
   
     
     
         7 . The packaging system ( 100 ) of  claim 4 , wherein the first lower folding arm ( 250 ) and the second lower folding arm ( 252 ) are angularly displaced from each other. 
     
     
         8 . The packaging system ( 100 ) of  claim 4 , wherein:
 the first lower folding arm ( 250 ) is fixed to the lower folding wheel ( 242 ); and   the second lower folding arm ( 252 ) is configured to pivot about a pivot axis ( 328 ) relative to the lower folding wheel ( 242 ).   
     
     
         9 . The packaging system ( 100 ) of  claim 8 , wherein the second lower folding arm ( 252 ) is radially movable relative to the lower folding wheel ( 242 ). 
     
     
         10 . The packaging system ( 100 ) of  claim 9 , wherein:
 the folding machine ( 228 ) further comprises:
 a cam track ( 256 ) located adjacent to the lower folding wheel ( 242 ); and 
 a cam follower ( 258 ) coupled to the second lower folding arm ( 252 ) and engaged with the cam track ( 256 ); and 
   the second lower folding arm ( 252 ) is configured to pivot about the pivot axis ( 328 ) and radially move relative to the lower folding wheel ( 242 ) as the cam follower ( 258 ) moves along the cam track ( 256 ).   
     
     
         11 . The packaging system ( 100 ) of  claim 4 , wherein:
 the folding machine ( 228 ) further comprises:
 an upper folding wheel ( 266 ) configured to rotate about an upper rotational axis ( 268 ); 
 an upper folding arm ( 270 ) projecting radially from the upper folding wheel ( 266 ); and 
 an upper rotary drive ( 330 ) configured to rotate the upper folding wheel ( 266 ) about the upper rotational axis ( 268 ), 
   wherein the upper folding arm ( 270 ) is configured to:
 fold the second end panel ( 144 ) upward to the orientation that is approximately perpendicular to the main panel ( 108 ) as the upper folding wheel ( 266 ) rotates and the group of articles ( 102 ) and the blank ( 106 ) pass under the upper folding wheel ( 266 ); and 
 fold the second end flap ( 152 ) in the direction of travel of the group of articles ( 102 ) and the blank ( 106 ) to the orientation that is approximately perpendicular to the second end panel ( 144 ) as the upper folding wheel ( 266 ) rotates and the group of articles ( 102 ) and the blank ( 106 ) pass under the upper folding wheel ( 266 ). 
   
     
     
         12 . The packaging system ( 100 ) of  claim 2 , further comprising:
 a lug ( 272 ) configured to engage the upper end ( 246 ) of the articles ( 102 ); and   a post ( 274 ) projecting downwardly from the lug ( 272 ) and configured to be at least partially inserted through a handle aperture ( 132 ) formed in the main panel ( 108 ).   
     
     
         13 . A packaging system ( 100 ) comprising:
 a conveyor ( 236 ) configured to convey a group of articles ( 102 ) and a blank ( 106 ), folded about the articles ( 102 ), along a packaging path; and   an alignment machine ( 230 ) configured to position a first side panel ( 110 ) and a second side panel ( 112 ) of the blank ( 106 ) at a predetermined angle ( 282 ) relative to a main panel ( 108 ) of the blank ( 106 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path.   
     
     
         14 . The packaging system ( 100 ) of  claim 13 , wherein the alignment machine ( 230 ) comprises:
 a first alignment block ( 276 ) configured to engage the first side panel ( 110 ) after the first side panel ( 110 ) is folded upward to an orientation that is approximately perpendicular to the main panel ( 108 ); and   a second alignment block ( 278 ) configured to engage the second side panel ( 112 ) after the second side panel ( 112 ) is folded upward to an orientation that is approximately perpendicular to the main panel ( 108 ).   
     
     
         15 . The packaging system ( 100 ) of  claim 14 , wherein:
 each one of the first alignment block ( 276 ) and the second alignment block ( 278 ) comprises an alignment surface ( 280 ) that is oriented at an alignment angle ( 284 ) relative to a vertical plane; and   the alignment angle ( 284 ) is complementary to the predetermined angle ( 282 ) of the first side panel ( 110 ) and the second side panel ( 112 ).   
     
     
         16 . The packaging system ( 100 ) of  claim 14 , wherein the first alignment block ( 276 ) and the second alignment block ( 278 ) are configured to travel with the blank ( 106 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path. 
     
     
         17 . The packaging system ( 100 ) of  claim 16 , wherein the alignment machine ( 230 ) further comprises a drive mechanism ( 286 ) configured to:
 move the first alignment block ( 276 ) into engagement with the first side panel ( 110 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; and   move the second alignment block ( 278 ) into engagement with the second side panel ( 112 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path.   
     
     
         18 . The packaging system ( 100 ) of  claim 17 , wherein the drive mechanism ( 286 ) is further configured to move the first alignment block ( 276 ) and the second alignment block ( 278 ) with the blank ( 106 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path. 
     
     
         19 . The packaging system ( 100 ) of  claim 16 , wherein:
 the first alignment block ( 276 ) is configured to maintain the first side panel ( 110 ) at the predetermined angle ( 282 ) relative to the main panel ( 108 ) while a first cover panel ( 118 ) of the blank ( 106 ) is folded relative to the first side panel ( 110 ); and   the second alignment block ( 278 ) is configured to maintain the second side panel ( 112 ) at the predetermined angle ( 282 ) relative to the main panel ( 108 ) while a second cover panel ( 120 ) of the blank ( 106 ) is folded relative to the second side panel ( 112 ).   
     
     
         20 . The packaging system ( 100 ) of  claim 19 , further comprising a forming machine ( 284 ) configured to couple the first cover panel ( 118 ) and the second cover panel ( 120 ) to each other,
 wherein the first alignment block ( 276 ) is configured to maintain the first side panel ( 110 ) at the predetermined angle ( 282 ) relative to the main panel ( 108 ) and the second alignment block ( 278 ) is configured to maintain the second side panel ( 112 ) at the predetermined angle ( 282 ) relative to the main panel ( 108 ) while the first cover panel ( 118 ) and the second cover panel ( 120 ) are coupled to each other.   
     
     
         21 . The packaging system ( 100 ) of  claim 13 , wherein the alignment machine ( 230 ) comprises:
 a series of first alignment blocks ( 276 ) configured to engage the first side panel ( 110 ) after the first side panel ( 110 ) is folded upward to an orientation that is approximately perpendicular to the main panel ( 108 ); and   a series of second alignment blocks ( 278 ) configured to engage the second side panel ( 112 ) after the second side panel ( 112 ) is folded upward to an orientation that is approximately perpendicular to the main panel ( 108 ).   
     
     
         22 . A packaging method comprising steps of:
 conveying a group of articles ( 102 ) and a blank ( 106 ), applied to an upper end ( 246 ) of the articles ( 102 ), along a packaging path;   folding a first end panel ( 142 ) of the blank ( 106 ) relative to a main panel ( 108 ) of the blank ( 106 ) as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path;   folding a second end panel ( 144 ) of the blank ( 106 ) relative to the main panel ( 108 ) of the blank ( 106 ), after folding the first end panel ( 142 ), as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path;   folding a first end flap ( 150 ) of the blank ( 106 ) relative to the first end panel ( 142 ), after folding the first end panel ( 142 ), as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path;   folding a second end flap ( 152 ) of the blank ( 106 ) relative to the second end panel ( 144 ), after folding the second end panel ( 144 ), as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path;   folding a first side panel ( 110 ) of the blank ( 106 ) relative to the main panel ( 108 ), after folding the first end flap ( 150 ) and the second end flap ( 152 ), as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path;   folding a second side panel ( 112 ) of the blank ( 106 ) relative to the main panel ( 108 ), after folding the first end flap ( 150 ) and the second end flap ( 152 , as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path;   positioning the first side panel ( 110 ) and the second side panel ( 112 ) at a predetermined angle ( 282 ) relative to the main panel ( 108 ), after folding the first side panel ( 110 ) and the second side panel ( 112 );   folding a first cover panel ( 118 ) of the blank ( 106 ) relative to the first side panel ( 110 ), while maintaining the first side panel ( 110 ) at the predetermined angle ( 282 ), as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path; and   folding a second cover panel ( 120 ) of the blank ( 106 ) relative to the second side panel ( 112 ), while maintaining the second side panel ( 112 ) at the predetermined angle ( 282 ), as the group of articles ( 102 ) and the blank ( 106 ) travel along the packaging path.