TECHNICAL FIELD

The present invention relates to a packaging system, to an apparatus and to a method for constructing packages or article carriers from article carrier blanks. More specifically, but not exclusively, the invention relates to a jig or forming device for creating a package comprising an article carrier of the top-gripping type and a group of articles.

BACKGROUND

In the field of packaging, it is known to provide cartons for carrying multiple articles. Cartons are well known in the art and are useful for enabling consumers to transport, store and access a group of articles for consumption. For cost and environmental considerations, such cartons or carriers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Further considerations are the strength of the carton and its suitability for holding and transporting large weights of articles. It is desirable that the contents of the carton are secure within the carton.

It is well known to provide top gripping article carriers in which an aperture is formed in a panel of the carrier, wherein tabs are struck from said panel and are arranged about the aperture. The tabs are displaced out of the plane of said panel when an article is received in the aperture, wherein said tabs engage the article generally about a flange or lip of the article.

It is desirable to provide method and apparatus for constructing packages from article carrier blanks that is simple, reliable, and efficient.

The present invention seeks to provide an improvement in the field of packaging, of cartons, typically formed from paperboard or the like, and apparatus for assembly of said cartons.

SUMMARY

A first aspect of the invention provides an apparatus for forming an article carrier from a carrier blank. The apparatus comprises a body having top wall, opposed side walls and a first end wall. The opposed side walls and a first end wall depend from the top wall. The top wall comprises at least one article-receiving opening in an inner surface thereof. The apparatus further comprises a blank alignment device for aligning a blank with respect to the at least one article-receiving opening. The blank alignment device comprises a blank receiving recess defined in each of the opposed side walls and in the first end wall. The blank receiving recess provides a support ledge for a carrier blank. The blank receiving recess extends from a second open end of the body to the first end wall such that a carrier blank is slidably receivable therein. Optionally, the apparatus further comprises an article engaging device in the form of a guide provided by the opposed side walls and a first end wall, wherein the guide provides a plurality of surfaces facing inwardly of the body for engaging at least one article to align the at least one article with respect to the at least one article-receiving opening.

Optionally, the body is unitary.

Optionally, the apparatus is configured to apply the carrier blank to at least one article, and wherein the article engaging device groups the at least one article together into a group and aligns the group with respect to the at least one article receiving opening.

Optionally, the apparatus is configured to apply the carrier blank to at least one article, and wherein the article engaging device maintains the at least one article in a group, and align the group with respect to the at least one article receiving opening.

Optionally, the apparatus further comprises a stabilisation device, wherein the stabilisation device comprises at least one stabilisation peg extending inwardly from the inner surface of the top wall.

Optionally, the apparatus further comprises at least one folding break extending into the interior of the body from the inner surface of the top wall, wherein the stabilisation device extends further from the inner surface of the top wall than the at least one folding break.

Optionally, the apparatus further comprises at least one folding break extending into an interior of the body from the inner surface of the top wall, wherein the stabilisation device extends further from the inner surface of the top wall than the at least one folding break so as to engage a carrier blank prior to the at least one folding break such that the position and orientation of the carrier blank is maintained when the at least one folding break engages a carrier blank.

Optionally, the at least one article receiving opening comprises a tab-receiving recess struck from a portion of the top wall defining the at least one article-receiving opening.

Optionally, the apparatus further comprises at least one folding break extending into an interior of the body from the inner surface of the top wall, wherein the tab-receiving recess is disposed adjacent to the at least one folding break.

Optionally, the at least one folding break is disposed linearly along a boundary between the inner surface of the top wall and an inner surface of at least one of the side walls, the tab-receiving recess is colinearly arranged with respect to the at least one folding break.

Optionally, the at least one article-receiving opening is at least partially blind to provide an article end stop.

Optionally, the at least one article-receiving opening is at least partially blind to provide an end stop for inhibiting movement of the body with respect to articles being packaged by the article carrier.

Optionally, the body comprises a panel receiving recess, the panel receiving recess being disposed between the blank alignment device and the article engaging device.

Optionally, the panel receiving recess is configured to accommodate at least one folded panel hinged to an article engaging panel of the article carrier.

Optionally, the apparatus is configured to form a top-engaging article carrier. A second aspect of the invention provides an applicator device for applying a carrier blank to a group of articles. The applicator device comprises: a top wall having a blank-pressing ceiling; a pair of opposed side walls; an end wall; an end opening through which to insert a carrier blank; a blank-receiving channel in at least each side wall; and a registration peg for inserting into a registration opening in the carrier blank. The top wall, the side walls and the end wall together define an interior of the device. The registration peg extends from a blank-pressing ceiling into the interior of the device. A first distance defined between the blank-pressing ceiling and the floor of the channel, providing a blanksupporting ledge, is greater than an operative length of the registration peg.

Optionally, the operative length of the registration peg is the dimension measured between the blank-pressing ceiling and the distal or lowermost end of the registration peg.

Optionally, the device further comprises blank edge folding breaks or ribs extending into the interior of the device from the blank-pressing ceiling, and wherein the operative length of the registration peg is greater than a second distance defined between the blank-pressing ceiling and the leading edge of the blank panel-folding breaks or ribs.

Optionally, the blank-receiving channel is provided also in the end wall.

A third aspect of the invention provides a method of packaging articles comprising: sliding a carrier blank though an open end into a blank receiving recess in a body of a forming jig and aligning the carrier blank with respect to the body; placing the forming jig over at least one article; lowering the forming jig with respect to at least one article; engaging the at least one article with an article engaging device provided by the body to align the at least one article with respect to the carrier blank; pressing the carrier blank onto the at least one article; receiving the at least one article in an opening in a top wall of the body; receiving the at least one article in an opening of an article retention device provided in an engagement panel of the carrier blank; folding at least one engaging tab of the article retention device into engagement with the at least one article; folding at least one panel hinged to the engagement panel with respect to the engagement panel; raising the forming jig with respect to the carrier blank and the at least one article such that the at least one article clears the top wall of the body; sliding the forming jig with respect to the carrier blank and the at least one article such that they pass through an open end of the body adjacent to the top wall.

Further features and advantages of the present invention will be apparent from the specific embodiments illustrated in the drawings and discussed below. Within the scope of this application, it is envisaged or intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be considered or taken independently or in any combination thereof.

Features or elements described in connection with, or relation to, one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into, or combined with, any of the other embodiments disclosed herein, said features or elements extracted from said one embodiment may be included in addition to, or in replacement of one or more features or elements of said other embodiment.

A feature, or combination of features, of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment. Alternatively, a feature, or combination of features, of an embodiment may be omitted from that embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

Figure 1 is a perspective view from above of a jig for forming a top-engaging carrier according to a first embodiment of the present disclosure;

Figure 1A is a plan view from above of the jig of Figure 1;

Figure 1 B is a sectional view of the jig of Figure 1 ;

Figure 1C is alternative perspective of the jig of Figure 1 comprising hidden (dashed) lines to show hidden features;

Figure 2A is a plan view from below of the jig of Figure 1 ;

Figure 2B is a first end view of the jig of Figure 1 ;

Figure 2C is a second end view of the jig of Figure 1 ;

Figure 2D is a side view of the jig of Figure 1 ;

Figure 3A is a second end view of the jig of Figure 1 comprising hidden (dashed) lines to show hidden features;

Figure 3B is a side view of the jig of Figure 1 comprising hidden (dashed) lines to show hidden features;

Figure 4 is a plan view from above of blank for forming a top-engaging carrier according to an embodiment of the present disclosure;

Figure 5 is a perspective view from above of a package formed from the carrier blank of Figure 4;

Figures 6 to 9 are perspective views of stages of construction of the package of Figure 5 employing the jig of Figure 1;

Figure 10 is a perspective view from above of a stage of construction of an alternative package employing a forming jig according to an alternative embodiment of the disclosure; Figure 11 is a perspective view from above of an alternative package formed from a carrier blank according to an alternative embodiment of the disclosure;

Figure 12 is a sectional view of the jig of Figure 1 in which a blank according to Figure 4 has been overlaid, indicated by dashed lines; and

Figure 13A and 13B show first end views of the jig of Figure 1 relative to an article carrier and articles during stages of construction of a package.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the packaging system, apparatus, jigs, methods, blanks, and carriers are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packaging system, apparatus, jigs, methods, blanks, and carriers described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale, and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any 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 invention.

Referring to Figure 4, there is shown a plan view of a blank 2010 which is capable of forming a top-engaging carton or carrier 2090, as shown in Figure 5, for containing and carrying a group of primary products such as, but not limited to, bottles or cans, hereinafter referred to as articles B, as shown in Figure 5. The articles B may be generally cylindrical; the articles B may comprise a circular cross-sectional shape, at least about a region of engagement with the carrier 2090. The blank 2010 forms a secondary package for packaging at least one primary product container or package. An alternative carton or carries 2190 is shown in Figure 11. The carrier 2190 is formed from an alternative blank 2110 which is partially shown in Figure 10.

In the embodiments detailed herein, the terms “carton” and “carrier” refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging and carrying articles, such as primary product containers. It is contemplated that the teachings of the invention can be applied to various product containers, which may or may not be tapered and/or cylindrical. Exemplary containers include bottles (for example metallic, glass or plastics bottles), cans (for example aluminium cans), tins, pouches, packets, and the like.

The cartons or carriers in the drawings are shown in the form of top engaging carriers as options only. The top engaging carriers, as illustrated throughout the disclosure, each has a main or primary engaging panel provided with a plurality of article retention structures. Each structure typically comprises an aperture for receiving an upper portion of an article and one or more engaging teeth or tabs joined along the perimeter of the aperture. The blanks 2010; 2110 are formed from a 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, combinations thereof, and the like. It should be recognised that one or other numbers of blanks may be employed, where suitable, for example, to provide the carrier structure described in more detail below.

The packaging structures or cartons described herein may be formed from a sheet material such as paperboard, which may be made of or coated with materials to increase its strength. An example of such a sheet material is tear resistant NATRALOCK® paperboard made by WestRock® Company. It should be noted that the tear resistant materials may be provided by more than one layer, to help improve the tear-resistance of the package. Typically, one surface of the sheet material may have different characteristics to the other surface. For example, the surface of the sheet material that faces outwardly from a finished package may be particularly smooth and may have a coating such as a clay coating or other surface treatment to provide good printability. The surface of the sheet material that faces inwardly may, on the other hand, be provided with a coating, a layer, a treatment or be otherwise prepared to provide properties such as one or more of tear-resistance, good glue-ability, heat sealability, or other desired functional properties.

In the illustrated embodiments, the blanks 2010; 2110 are configured to form a carton or carrier 2090; 2190 for packaging an exemplary arrangement of exemplary articles B. In the embodiment illustrated in Figure 4, the blank 2010 is designed for six articles B (see Figure 5) arranged in a 2 x 3 matrix or array — two rows of three articles B — and the articles B are 350ml cans beverage cans. In the embodiment illustrated in Figure 11, the articles are arranged in a 1 x 4 matrix or array — one row of four articles B — and the articles B are 350ml cans beverage cans. Alternatively, the blanks 2010; 2110 can be configured to form a carrier for packaging other types (e.g. , bottles), number (e.g., two, three, four, five or eight), and size (e.g., 330 ml cans or 500ml cans) of articles and/or for packaging articles in a different arrangement or configuration (e.g., 1 x 2, 1 x 3, 1 x 5, 2 x 2, 2 x 4).

Figure 4 shows a blank 2010 comprising an engaging panel 2012 forming part of a carrier 2090 shown in Figure 5.

The blank 2010 includes a first end panel 2014 hingedly connected to a first end of the main panel 2012 by a hinged connection in the form of a fold line 2013. The fold line 2013 is linear. The blank 2010 includes a second end panel 2016 hingedly connected to a second end of the main panel 2012 by a hinged connection in the form of a fold line 2015. The fold line 2015 is linear.

The blank 2010 includes a first side panel 2018 hingedly connected to a first side of the main panel 2012 by a hinged connection in the form of a fold line 2017. The fold line 2017 is linear. The blank 2010 includes a second side panel 2020 hingedly connected to a second side of the main panel 2012 by a hinged connection in the form of a fold line 2019. The fold line 2019 is linear.

The main panel 2012 comprises four corner regions 2012A each substantially the same in construction. The corner regions 2012A will be described in further detail with reference to a first corner region 2012A. The first corner region 2012A is defined, at least in part, by a divergently arranged pairof fold lines 2013A, 2017A. The pair of fold lines 2013A, 2017A comprises a first fold line 2013A oriented substantially perpendicularly to a second fold line 2017A.

Each of the pair of fold lines 2013A, 2017A is substantially colinear with a respective one of the fold lines 2013, 2017 hinging the first side panel and first end panel 2014, 2016 to the main panel 2012.

The first corner region 2012A may comprise a bevel, chamfered or filleted corner defining a free edge of the main panel 2012 -that is to say, the free edge is not hinged to any other panel.

The main panel 2012 of the blank 2010 includes at least one article retention structure RT1, RT2. The main panel 2012 comprises a plurality of article retention structures RT1, RT2, specifically six article retention structures RT1, RT2 arranged in a 2 x 3 matrix or array. Each of the article retention structures RT1 , RT2 comprises an opening or aperture A3, A4.

The blank 2010 comprises four first article retention structures RT 1. The first article retention structures RT 1 are located adjacent to ends of the main panel 2012. The blank 2010 comprises two second article retention structures RT2. The second article retention structures RT2 are located between a first pair of first article retention structures RT1 disposed proximate a first end of the main panel 2012 and a second pair of first article retention structures RT 1 disposed proximate a second end of the main panel 2012. The second article retention structures RT2 are also referred to herein as intermediate article retention structures RT2. The first article retention structures RT 1 are also referred to herein as end article retention structures RT 1.

The first article retention structure RT 1 comprises an article receiving opening defined in part by an aperture A3.

The first article retention structure RT1 comprises a plurality of engaging teeth or tabs 2050A, 2050B, 2052A, 2052C disposed about the aperture A3.

The plurality of teeth 2050A, 2050B, 2052A, 2052C are hinged to the main panel 2012 by a fold line.

A first tab 2050A may be hinged to the main panel 2012 via one of the side panels 2018, 2020. The first tab 2050A extends from and is integral with said side panel 2018, 2020. The first tab 2050A comprises a pair of side edges, the side edges are defined by cut lines 2051 extending outward from the aperture A3. The cut lines 2051 may be linear. The cut lines 2051 may be divergently arranged with respect to each other.

A second tab 2050B may be hinged to the main panel 2012 via one of the end panels 2014, 2016. The second tab 2050B comprises a pair of side edges, the side edges are defined by cut lines 2051 extending outward from the aperture A3. The cut lines 2051 may be linear. The cut lines 2051 may be divergently arranged with respect to each other.

Each of the pair of radial cutlines 2051 of the first and second tabs 2050A, 2050B extends to a fold line 2013, 2015, 2017, 2019 hinging a side or end panel 2018, 2020, 2014, 2016 to the engaging panel 2012.

The first and second tab 2050A, 2050B interrupt the respective one of the fold lines 2013, 2015, 2017, 2019 hinging the engaging panel 2012 to the side or end panel 2018, 2020, 2014, 2016 to, or from, which it extends, that is to say, the first and second tabs 2050A, 2050B are integral with one of the side or end panels 2018, 2020, 2014, 2016. The plurality of teeth 2050A, 2050B, 2052A, 2052C includes third and fourth teeth 2052A, 2052C hingedly connected to the main panel 2012 by a fold line. The fold line may be defined by a plurality of cut lines 2055, 2057. The plurality of cut lines 2055, 2057 may define or approximate a circle.

The plurality of teeth 2050A, 2050B, 2052A, 2052C includes third teeth 2052A disposed about a portion of the aperture A3. Each of the plurality of third teeth 2052A comprises an engaging edge E1 opposing a hinged edge. The engaging edges E1 are defined by a linear portion of a cut line defining the aperture A3. Each engaging edge E1 defines a part of a polygon. The illustrated embodiment comprises seven third teeth 2052A. Each third tooth 2052A comprises a pair of side edges, the side edges are defined by cut lines 2053 extending radially outward from respective vertices of the polygon. From a respective vertex between a pair of adjacent linear portions of the cut line defining the aperture A3. The cut lines 2053 are divergently arranged with respect to each other and define an angle therebetween, the angle may be about 22.5°.

The plurality of teeth 2050A, 2050B, 2052A, 2052C includes fourth teeth 2052C, also referred to herein as partial tabs or teeth 2050C, disposed about a portion of the aperture A3. The illustrated embodiment comprises four fourth teeth 2052C. The fourth teeth 2052C are provided on opposing sides of one of the first or second tabs 2050A, 2050B, in this way a partial tooth 2050C is provided on each side of each of the first and second tabs 2050A, 2050B. The first and second tabs 2050A, 2050B and the associated pair of partial teeth 2050C occupy an angular width equivalent to three full teeth 2052A, 2050B, said angular width may be 67.5°. The first and second tabs 2050A, 2050B may occupy approximately 39.5°, each partial tooth 2050C may occupy approximately 14°.

Each of the pair of radial outlines 2051 of the abutment tabs 2050A, 2050B extends to a fold line 2013, 2015, 2017, 2019 hinging a side or end panel 2018, 2020, 2014, 2016 to the engaging panel 2012.

The first and second tabs 2050A, 2050B interrupt a respective one of the fold lines 2013, 2015, 2017, 2019 hinging the engaging panel 2012 to the side or end panel 2018, 2020, 2014, 2016 to, or from, which it extends, that is to say, the first and second tabs 2050A, 2050B are integral with one of the side or end panels 2018, 2020, 2014, 2016.

The first and second tabs 2050A, 2050B are defined by a pair of radial cutlines 2051, the radial outlines 2051 of the first and second tabs 2050A, 2050B are longer in length than at least one of the radial cutlines 2053 defining the first teeth 2052A. The pair of radial outlines 2051 extend beyond a perimeter of the third and fourth engaging teeth 2052A, 2052C, that is to say, beyond the circumferential fold defining outer edges of the plurality of third and fourth engaging teeth 2052A, 2052C, the circumferential fold being defined by the plurality of cut lines 2055, 2057.

The first article retention structure RT 1 may comprise a plurality of first circumferential cut lines 2057. Each of the plurality of first circumferential cut lines 2057 is aligned with one of the radial cut lines 2053 such that said one of the radial cut lines 2053 or a notional extension thereof bisects a respective one of the plurality of first circumferential cut lines 2057. Each of the plurality of first circumferential cut lines 2057 is spaced apart from said one of the radial cut lines 2053 bisecting it so as to define a connecting nick or bridge portion between a pair of adjacently disposed teeth 2050A, 2050B, 2052A, 2052C.

Each of the plurality of first circumferential cut lines 2057 may be linear in shape.

The first article retention structure RT 1 may comprise a plurality of second circumferential cut lines 2055. Each of the plurality of second circumferential cut lines 2055 is disposed between a pair of the plurality of first circumferential cut lines 2057 and is spaced apart therefrom so as to define a pair of connecting nick or bridge portions between each third and fourth tooth 2052A, 2052C and the main panel 2012. The pair of connecting nick or bridge portions provide a hinged or foldable connection between each third and fourth tooth 2052A, 2052C and the main panel 2012.

Each of the plurality of second circumferential cut lines 2055 may be linear in shape. In alternative embodiments, each of the plurality of first circumferential cut lines 2057 may be arcuate or curved. In alternative embodiments, each of the plurality of second circumferential cut lines 2055 may be arcuate or curved.

Each of the second article retention structures RT2 is substantially similar in construction and will therefore be described in detail with reference to a first one of the second article retention structures RT2 located adjacent to the first one of the first article retention structures RT 1 as shown in Figure 1.

The second article retention structure RT2 comprises an article receiving opening defined in part by an aperture A4. The second article retention structure RT2 comprises a plurality of engaging teeth or tabs 2050A, 2052A, 2052C disposed about the aperture A4.

The plurality of teeth 2050A, 2052A, 2052C are hinged to the main panel 2012 by a fold line. Each of the second article retention structures RT2 is substantially similar in construction to the first article retention structure RT1, albeit the second tab 2050B has been omitted, along with its associated pair of fourth teeth 2052C, and replaced with three third teeth 2052A. The second article retention structure RT2 of the illustrated embodiment comprises thirteen third teeth 2052A.

The fold lines 2013, 2015, 2017, 2019 hinging the side or end panel 2018, 2020, 2014, 2016 to the engaging panel 2012 may comprise a plurality of spaced apart cutlines arranged collinearly with each other. The plurality of spaced apart cutlines may comprise two, three or more discrete cutlines. The plurality of spaced apart cutlines may comprise two, three or more discrete cutlines each having a different length.

The blank 2010 forms an article carrier 2090 for packaging a group of articles B, as shown in Figure 5.

The first and second tabs 2050A, 2050B fold out of the plane of the main panel 2012 when an article B is received in the article retention structures RT1, RT2, the first and second tabs 2050A, 2050B being integral with one of the side or end panels 2018, 2020, 2014, 2016 may encourage or initiate folding of the side or end panels 2018, 2020, 2014, 2016 with respect to the main panel 2012. In some embodiments, the first and second tabs 2050A, 2050B may form abutment tabs 2050A, 2050B, an inner surface of the abutment tabs 2050A, 2050B may contact an exterior surface of the articles B, such as a chime or end seam. The abutment tabs 2050A, 2050B, when provided, do not support or suspend the article B.

The third and fourth teeth 2052A, 2052C form engaging teeth 2052A, 2052C in which an edge E1 engages below a protrusion or flange provide by the article B, the protrusion or flange may be provided a chime or end seam if the article B. The engaging teeth 2052A, 2052C support or suspend the article B when carried or when the articles B are unsupported at their bases.

The main panel 2012 comprises a handle structure. The handle structure may comprise at least one handle opening. In the illustrated embodiment, the blank 2010 comprises two handle openings. Each handle opening is defined in, or struck from, a region of the main panel 2012 disposed centrally between four apertures A3, A4 arranged as two adjacent pairs of apertures A3, A4. The handle openings are defined by a pair of handle tabs 2064 hingedly connected to the main panel 2012 by a respective hinged connection in the form of a fold line 20 63. The fold lines may be disposed adjacent to each other and may be orthogonal to each other. The pair of handle tabs 2064 are separated from each other by a cut line or severance line.

The handle opening may be substantially square or diamond shaped. The handle opening may provide a receiver element for receiving a retention or stabilising pin or lug 28 of a forming jig 10.

The blank 10 may comprise at least one stabilisation device. In the illustrated embodiment, the blank 10 comprises two stabilisation devices each provided by one of the handle openings. Each stabilization device comprises an opening in the main panel 2012. Each stabilisation device is configured to receive an abutment peg or dog 28 of a packaging machine.

An opening forming at least part of the stabilisation device may be non-circular in shape and may be substantially square or diamond shaped. The opening or openings in the main panel 2012 providing the stabilisation device may be defined by at least one tab struck from the panel in which it is formed and hingedly connected thereto.

Turning to the construction of the carrier 2090 from the blank 2010, the blank 2010 may be formed into an assembled carrier 2090, as shown in Figure 5. Figures 1 to 3B show an apparatus or jig 10 for forming the blank 2010 into an article carrier 2090 about a group of articles B.

The jig 10 comprises a top wall 12, a pair of opposed side walls 14, 16 depend from the top wall 12. A first end wall 18 depends from the top wall 12 and extends between the pair of opposed side walls 14, 16. A second end 8 of the jig 10 is open. The top wall 12 comprises orifices or openings A1 , A2 in an inner surface thereof. The orifice A1 , A2 may extend through the top wall 12 to an outer surface thereof to define an aperture through the top wall 12. The orifices A1, A2 may be at least partially blind. In the illustrated embodiment, the top wall 12 comprises six openings A1, A2, arranged in a 2 x 3 matrix or array. The openings A1, A2 include four endmost openings A1 and a pair of intermediate openings A2 disposed therebetween. The endmost opening A1 are partially blind and define end stops 24 preventing or inhibiting articles B from passing through the top walH 2. The intermediate openings A2 may define apertures A2 passing through the top wall 12.

Each of the pair of opposed side walls 14, 16 comprises a blank receiving recess in the form of a channel CH extending from the open end 8 to a closed end defined by end wall 18. The channel CH in the first side wall 14 opposes the channel CH in the second side wall 16. The channels CH are disposed proximate the top wall 12. The first end wall 18 comprises a blank receiving recess in the form of a channel CH extending thereacross between the channel CH in the first side wall 14 and the channel CH in the second side wall 16. The channels CH define a ledge 30, see Figure 2C, upon which the blank 2010 may rest when received in the blank receiving recess. The blank receiving recess aligns the blank 2010 with respect to the jig10.

The jig 10 comprises at least one stabilisation peg 28 extending from the top wall 12 into the interior of the jig 10. The illustrated embodiment comprises a pair of stabilisation pegs 28 extending from the top wall 12 into the interior of the jig 10. Each of the stabilisation peg 28 comprises a generally pyramidal shape. The stabilisation pegs 28 maintain or hold the blank in position when applying the blank 2010 to the articles B, in particular when the side and end panels 2018, 2020, 2014, 2016 fold with respect to the main panel 2012; when folded the side and end panels 2018, 2020, 2014, 2016 disengage from the blank receiving recess, the stabilisation pegs 28 prevent or mitigate against shifting of the blank 2010 with respect to the jig 10 and/or articles B.

The orifice A1, A2 comprise, or define an internal wall. That is to say a portion of the top wall 12 provides a bore wall. The bore wall is interrupted, or comprises a recess 26, the recess 26 is shaped to accommodate one of the first and second tabs 2050A, 2050B when folded out of the plane of the main panel 2012. The recess 26 may define a trapezoidal prism shape. The first and second tabs 2050A, 2050B can be folded into the recesses 26 outside the bore wall of the orifices A1, A2

The end stops 24 may be arranged to prevent or inhibit insertion of the articles B beyond, or past, the recesses 26 such that free end edges of the first and second tabs 2050A, 2050B (the free end edges are defined by a portion of the aperture A1, A2) are prevented or inhibited from engaging with the articles B below a protrusion of flange.

The jig 10 comprises at least one folding guide, die or break, 16b, 18b, 14b, 8b extending from the top wall 12. The folding guide 16b, 18b, 14b contacts one of the side or end panels 2018, 2020, 2014, 2016 to fold said panel 2018, 2020, 2014, 2016, with respect to the main panel 2012, about the side or end of the group of articles B.

The jig 10 comprises an article grouping device in the form of a plurality of surfaces 20, 22 partially surrounding the articles B. The plurality of surfaces 20, 22 comprises a pair of opposed surfaces 20 provided by portions of the pair of opposed side wall 14, 16 and an end surface 22 provided by the first end wall 18. In the illustrated embodiment, the end surface 22 comprises a non-linear shape and may be contoured or undulating so as to be complementary to the cylindrical walls of the articles B. In other embodiments the first end wall 18 may be linear or planar in shape.

The first end wall 18 comprises an opening H, the opening H may provide a viewing window to allow an operator to monitor the interior of the jig 10 in use, to ensure correct alignment of the blank 2010, and/or inspect positioning of the blank 2010 and jig relative to the articles B. The opening H may also allow the operator to inspect the engagement of the blank 2010 with the articles B prior to removal of the jig 10. In some embodiments, the opening H may be employed by the operator as a handle to facilitate handling of the jig 10.

Referring to Figure 1B, the stabilisation pegs 28 extend from a lower or internal surface Ls of the top wall 12 of the jig 10 by a first distance L1.

The channel CH comprises a ledge 30 defining an upward facing surface, or a surface facing towards the lower or internal surface Ls of the top wall 12. The surface of the ledge 30 is spaced from the lower or internal surface Ls of the top wall 12 by a second distance L2. The second distance L2 is greater than the first distance L1.

A lowermost or leading edge or surface of the folding breaks 8b, 16b, 18b is spaced a third distance L3 from the lower or internal surface Ls of the top wall 12. The third distance L3 is less than the first distance L1.

The stabilisation pegs 28 extend a fourth distance L4 beyond or below the lowermost or leading edge or surface of the folding breaks 8b, 16b, 18b.

The upward facing surface of the ledge 30 provided by the channel CH is spaced apart from the lowermost, innermost, end of the stabilisation pegs 28 by a fifth distance L5. Fifth distance L5 defines a gap for insertion of the blank 2010 without interference from the stabilisation pegs 28.

The article grouping device takes the form of a projection or rib extending from the side and end walls 14, 16, 18 into the interior of the jig 10. The projection or rib is spaced apart from the ledge 30 of the channel CH by a sixth distance L6. The side walls 14, 16 have thickness L7, as shown in Figure 3A. The projection or rib has thickness L8, thickness L8 is greater than thickness L7. A gap, void or recess G is defined by an internal surface of the side walls 14, 16 and the respective internal surface 20 of the projection or rib; the internal surface 20 of the projection or rib is offset, inset, by a ninth distance L9 from the internal surface of the side wall 14, 16 from which it extends.

The internal surfaces of the pair of opposed side wall 14, 16 are spaced apart by a tenth distance L10. The internal surfaces 20 of the opposed projections or ribs are spaced part by an eleventh distance L11. The tenth distance L10 is greater than the eleventh distance L11. In this way a region or gap G is provided inside the jig 10 to accommodate the side walls 2018, 2020 of the article carrier 2090 when folded about the sides of the article group, best shown in Figure 13A and 13B.

Figures 6 to 9 illustrate use of the jig 10 to form the article carrier 2090 from the blank 2010. Figure 6 shows a stage of construction in which a blank 2010 is inserted into the jig 10, the blank 2010 in its flat form is slide, as indicated by direction arrow D1, into the channel CH through the second, open, end 8 of the jig 10. The side panel 2018, 2020 rest upon the ledges 30 of the channels CH in each of the opposed side walls 14, 16 of the jig 10. When fully inserted one of the end panels 2014, 2016 of the blank 2010 rests upon the ledge 30 of the channel CH in the first end wall 18 of the jig 10. Figure 12 illustrates the blank 2010 (the blank 2010 position is indicated by dashed lines) in a fully inserted position with respect to the jig 10, sections of the side wall 14, 16 and end walls 18 have been removed for illustrative purposes. Figure 12 illustrates how the folding breaks 8b, 14b, 16b, 18b align with the side and end panels 2018, 2020, 2014, 2016 and their respective hinged connections 2017, 2019, 2013, 2015. Figure 12 also shows how the abutment tabs 2050A, 2050B align with the recesses 26 in the orifices A1, A2.

A group of articles B is received in the interiorof the jig 10, in some embodiments the group of articles B is received by sliding the jig 10 with respect to the article group, as indicated by direction arrow D2 in Figure 7; the articles B passing through the open end 8 of the jig 10. In other embodiments, the articles B may be received by lowering the jig 10 with respect to the articles B, the articles B passing through an opening defined in part by the side and end walls 14,16, 18. In still other embodiments, the articles B may be received by a combination of lowering and sliding the jig with respect to the articles B. Once the articles B are received the blank 2010 rests upon upper ends of the articles B and the jig 10 rests upon the blank 2010, end portion of the stabilisation pegs 28 may pass through opening in the main panel 2012. The folding breaks 8b, 14b, 16b, 18b may rest upon the side and end panels 2018, 2020, 2014, 2016.

An operator may press downwardly upon the jig 10, as indicated in Figure 8 by direction arrow D3, to effect folding of the side and end panels 2018, 2020, 2014, 2016 with respect to the main panel 2012. In doing so the articles B are received in a respective one of the article retention structures RT 1 , RT2, the teeth or tabs 2050A, 2050B, 2052A, 2052C fold outwardly of the main panel 2012. The engaging teeth 2052A, 2052C engage the articles B below a flange or protrusion. The abutment tabs 2050A, 2050B fold with the side or end panel 2018, 2020, 2014, 2016 from which they extend and abut a side wall of the article B. The abutment tabs 2050A, 2050B may abut a side wall or edge of the flange or protrusion of the articles B. Figure 13A illustrates the jig 10 pressed down over the articles B, upper ends of the articles B are received in the opening or orifices A1, A2 in the top wall 12. The upper ends of the articles B may abut the end stops 24.

In order to withdraw the article carrier 2090 and articles B from the jig 10, the jig 10 is raised or lifted with respect to the package formed from the article carrier 2090 and articles B, as indicated in Figure 13B by direction arrow D4. The stabilisation pegs 28 clear the main panel 2012 such that the jig 10 can be slid with respect to the package, as indicated in Figure 9 by direction arrow D5. The package slides out through the open end 8 of the jig 10. The gap G between the article grouping device and the channel CH provides a space for receiving the side walls 2018, 2020 of the article carrier 2090 and provides a tolerance for separating the package from the jig 10 when sliding the package through the open end 8.

Referring now to Figure 10 there is shown an alternative forming jig for use with an alternative blank for forming a top-engaging carton or carrier according to another embodiment of the present disclosure. In the illustrated embodiment, like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefixes “100”; “2100” to indicate that these features belong to the jig and article carrier or secondary package of Figure 10. The embodiment of Figure 10 shares many common features with the embodiments of Figure 1 to 9 and 12 to 13B, therefore only the differences from that embodiment will be described in any greater detail.

The blank 2110 is adapted to accommodate a group or articles B in a 1 x 4 matrix or array arrangement, the jig 100 is similar arranged. The present disclosure provides an apparatus orjig 10; 110 for forming an article carrier 2090; 2190 from a carrier blank 2010; 2110, the apparatus 10; 110 comprising a body having top wall 12; 112, opposed side walls 14, 16; 114, 116 and a first end wall 18, the opposed side walls 14, 16; 114, 116 and a first end wall 18 depending from the top wall 12; 112. The top wall 12; 112 comprises at least one article receiving opening A1, A2 in an inner surface thereof. The apparatus 10; 110 comprises at least one folding break 8b, 14b, 16b, 18b extending into the interior of the apparatus 10; 110. The apparatus 10; 110 comprises a blank alignment device CH for aligning a blank 2010; 2110 with respect to the at least one article receiving opening A1, A2 and the at least one folding break 8b, 14b, 16b, 18b. The blank alignment device CH comprises a blank receiving recess defined in each of the opposed side walls 14, 16; 114, 116 and in the first end wall 18. The blank receiving recess providing a support ledge 30 for a carrier blank 2010; 2110. The blank receiving recess extends from a second open end 8 of the body to the first end wall 18 such that a carrier blank 2010; 2110 is slidably receivable therein.

The apparatus or jig 10; 110 may comprise an article engaging device in the form of a guide provided by the opposed side walls and a first end wall. The guide provides surfaces 20, 22 facing inwardly of the body for engaging at least one article B to align the at least one article B with respect to the at least one article receiving opening A1, A2 and the at least one folding break 8b, 14b, 16b, 18b. In some embodiments, the apparatus 10; 110 may be configured to apply the carrier blank 2010; 2110 to a plurality of articles B, in such embodiments the article engaging device may group the articles B together, or at least maintain grouping of the articles B, and align the group with respect to the at least one article receiving opening A1, A2 and the at least one folding break 8b, 14b, 16b, 18b.

The apparatus orjig 10; 110 may comprise a stabilisation device, which may take the form of stabilisation pegs 28, extending inwardly from the inner surface of the top wall 12; 112. The stabilisation device extends further from the inner surface of the top wall 12; 112 than the at least one folding break 8b, 14b, 16b, 18b so as to engage a carrier blank 2010; 2110 prior to the at least one folding break 8b, 14b, 16b, 18b such that the position and orientation of the carrier blank 2010; 2110 is maintained when the at least one folding break 8b, 14b, 16b, 18b engages a carrier blank 2010; 2110.

The at least one article receiving opening A1 , A2 may comprise a tab receiving recess 26 struck from a portion of the top wall 12; 112 defining at least one article receiving opening A1, A2. The tab receiving recess 26 may be disposed adjacent to at least one folding break 8b, 14b, 16b, 18b. The tab receiving recess 26 may be colinearly arranged with respect to at least one folding break 8b, 14b, 16b, 18b.

The at least one article receiving opening A1, A2 may be at least partially blind to provide an end stop 24 for preventing or inhibiting movement of the body with respect to articles B being packaged by the article carrier 2090; 2190.

The body may comprise a panel receiving recess G, the panel receiving recess G disposed between the blank alignment device and the article engaging device. The panel receiving recess G configured to accommodate at least one folded panel 2014, 2016, 2018, 2020; 2114, 2118 hinged to an article engaging panel 2012 of the article carrier 2090; 2190.

The article carrier 2090; 2190 may be a top-engaging article carrier.

The present disclosure also provides an applicator device or jig 10; 110 comprising: a top wall 12; 112 having blank-pressing ceiling Ls; a pair of opposed side walls 14, 16; an end wall 18; an end opening through which to insert a carrier blank 2010; 2110; a blank-receiving channel CH in at least each side wall 14, 16 and optionally within the end wall 18; and a registration peg 28 for inserting into a registration opening in the carrier blank 2010; 2110. A distance L2 between the blank-pressing ceiling Ls and the channel floor, providing a blank-supporting ledge 30, is greater than the operative length L1 of the registration peg 28. Where the operative length L1 of the registration peg 28 is the dimension measured between the blank-pressing ceiling Ls and the distal or lowermost end or tip of the registration peg 28.

The operative length L1 may be greater than a distance L3 between the blank-pressing ceiling Ls and the lower end or leading edge of blank panel-folding breaks or ribs 8b, 14b, 16b, 18b.

In this way the registration peg 28 is short enough that it does not engage the carrier blank 2010; 2110 when the blank 2010; 2110 is received in the applicator device 10; 110. The registration peg 28 are not inserted into or received in a registration or finger opening of the blank 2010; 2110 (or even in contact with the blank 2010; 2110) when the blank 2010; 2110 is received in the applicator device 10; 110. This avoids or mitigates against displacement, deformation or dislodgement of the blank 2010; 2110 by the registration peg 28 during insertion of the blank 2010; 2110 into the applicator device 10; 110. Thus, the blank 2010; 2110 maintains its correct registered position within the applicator device 10; 110.

The registration peg 28 is inserted into the registration opening of the blank 2010; 2110 in the process of lowering the applicator device 10; 110 over a group of articles B, while the blank 2010; 2110 is supported from below by the tops or upper ends of the articles B. As a result, deformation of the blank 2010; 2110 during the registration peg 28 insertion process may be mitigated. Once the registration peg 28 is inserted, horizontal movement of the blank 2010; 2110, that is to say movement in the plane of the blank 2010; 2110, with respect to the applicator device 10; 110 is inhibited.

The applicators or jigs 10, 110 each may be used with a selected number of articles less than the number of articled for which that jig 10, 110 is designed. For example, the jig 10 may be used to apply a blank having four article retention structures RT 1 , RT2 arranged in a 2 x 2 matrix or array. To do so, the blank having the four article retention structures may be inserted into the jig 10 all the way till the blank abuts on the end wall 18. Then, a group of four articles of a 2 x 2 configuration is introduced into the jig 10 at the position below the blank. After that, the jig 10 is lowered to apply the blank onto the group of the four articles. One of the pins 28 closer to the open end of the jig 10 may be removed from the jig 10 before such a blank application process, depending on the design of the blank. In an analogous way, the jig 110 may be used to apply a blank having two or three article retention structures arranged in a 1 x 2 or 1 x 3 matrix or array.

The present disclosure provides a method of packaging articles comprising: sliding a carrier blank 2010; 2110, through an open end, into a blank receiving recess in a body of a forming jig 10; 110 and aligning the carrier blank 2010; 2110 with respect to the body; placing the forming jig 10; 110 over at least one article B; lowering the forming jig 10; 110 with respect to at least one article B; engaging the at least one article B with an article engaging device 20/22 provided by the body to align the at least one article B with respect to the carrier blank 2010; 2110; pressing the carrier blank 2010; 2110 onto the at least one article B; receiving the at least one article B in an opening A1, A2 in a top wall 12; 112 of the body; receiving the at least one article B in an opening A3, A4 of an article retention device RT1 , RT2 provided in an engagement panel 2012 of the carrier blank 2010; 2110; folding at least one engaging tab 2050A, 2050B of the article retention device RT 1 , RT2 into engagement with the at least one article B; folding at least one panel 2014, 2016, 2018, 2020 hinged to the engagement panel 2012 with respect to the engagement panel 2012; raising the forming jig 10; 110 with respect to the carrier blank 2010; 2110 and the at least one article B such that the at least one article B clears the top wall 12; 112 of the body; sliding the forming jig 10; 110 with respect to the carrier blank 2010; 2110 and the at least one article B such that they pass through an open end 8 of the body adjacent to the top wall 12, 112.

The blanks 2010; 2110 include at least a paperboard substrate. The material of the paperboard substrate may be selected from any conventional paperboard, for example, ranging in weight upwardly from about 10pt., preferably from about 16pt. to about 28pt. (0.0287~0.7mm). An example of such a substrate is a 27-point (pt.) SBS board (solid bleached sulphate paperboard coated on one side, trade name PrintKote®) or CNK® board (Coated Natural Kraft® - an unbleached kraft paperboard having a clay coating on one side, trade name CarrierKote™) manufactured by WestRock® Company. The paperboard substrate may be a bleached or unbleached board. The board may be coated on at least one side, optionally the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and board composition.

The blanks 2010; 2110 may include a tear resistant layer laminated to the paperboard layer. It optionally includes an adhesive layer between the paperboard substrate and the tear resistant layer. The tear resistant layer may be disposed over the uncoated side of the paperboard substrate and may be formed of polymeric material and secured to the substrate. The tear resistant layer imparts toughness to the laminate structure. Suitable tear resistant materials may include, but not be limited to, tear resistant laminated sheet material, e.g., NATRALOCK®, which may include a layer of an n-axially oriented film, e.g., MYLAR®, which is a bi-axially oriented polyester, oriented nylon, crosslaminated polyolefin or high-density polyolefin. The orientation and cross-laminated structure of these materials contribute to the tear resistant characteristic. Also, tear resistance may be attributed to the chemical nature of the tear resistant material such as extruded metallocene-catalysed polyethylene (mPE).

Alternatively, the tear resistant layer may be a layer of linear low-density polyethylene (LLDPE). In embodiments where linear low-density polyethylene (LLDPE) or mPE is used, it is not necessary to incorporate an adhesive layer. Other suitable materials having a high level of tear resistance may also be used.

The adhesive layer may be formed of polyolefin material such as a low-density polyethylene (LDPE). The adhesive layer may be placed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape. In some embodiments a machine tool may be employed to press the jig onto the articles B, the machine tool may simultaneously press two or more jigs onto separate article groups.

It will be recognised that as used herein, directional references such as "top", "bottom", “base”’, "front", "back", "end", "side", "inner", "outer", "upper" and "lower" do not necessarily limit the respective panels to such orientation but may merely serve to distinguish these panels from one another.

As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed, a hinged connection can be formed from two or more fold lines wherein each of the two or more fold lines may be either straight/linear or curved/curvil inear in shape. When linear fold lines form a hinged connection, they may be disposed parallel with each other or be slightly angled with respect to each other. When curvilinear fold lines form a hinged connection, they may intersect each other to define a shaped panel within the area surrounded by the curvilinear fold lines. A typical example of such a hinged connection may comprise a pair of arched or arcuate fold lines intersecting at two points such that they define an elliptical panel therebetween. A hinged connection may be formed from one or more linear fold lines and one or more curvilinear fold lines. A typical example of such a hinged connection may comprise a combination of a linear fold line and an arched or arcuate fold line which intersect at two points such that they define a half moon-shaped panel therebetween.

As used herein, the term “fold line” may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted outline, a line of aligned slits, a line of scores and any combination of the aforesaid options.

It should be understood that hinged connections and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half- cut, a outline, an interrupted outline, slits, scores, embossed lines, debossed lines, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

The phrase "in registry with” as used herein refers to the alignment of two or more elements in an erected carton, such as an aperture formed in a first of two overlapping panels and a second aperture formed in a second of two overlapping panels. Those elements in registry with each other may be aligned with each other in the direction of the thickness of the overlapping panels. For example, when an aperture in a first panel is "in registry with” a second aperture in a second panel that is placed in an overlapping arrangement with the first panel, an edge of the aperture may extend along at least a portion of an edge of the second aperture and may be aligned, in the direction of the thickness of the first and second panels, with the second aperture.