US-20260125169-A1 - METHOD AND SYSTEM FOR FORMING A PACKAGE

Abstract

A method and system for forming a package that addresses operational challenges in container packaging systems. The system may include a conveyor to propagate the blank and the plurality of containers at a first velocity through the system, the blank includes a main panel having a plurality of apertures, a left clip enclosing panel foldably coupled to a first side of the main panel and a right clip enclosing panel foldably coupled to a second side of the main panel. The system further includes a latching tool including a blade member configured to travel in an eccentric path such that the blade member is arranged to move vertically to secure a portion of the clip enclosing panel to a first set of containers while simultaneously moving horizontally at the first velocity.

Inventors

• Carlos Molina Pena
• Nicholas Evans
• John Pate
• Miguel Lopez
• Ainsworth Wright
• Clifton R. Howell

Assignees

• GRAPHIC PACKAGING INTERNATIONAL, LLC

Dates

Publication Date

20260507

Application Date

20251031

Claims (20)

1. 1 . A system for securing a blank to a plurality of containers, the system comprising: a conveyor arranged to propagate the blank and the plurality of containers at a first velocity horizontally through the system, wherein the blank includes a main panel having a plurality of apertures, a left clip enclosing panel foldably coupled to a first side of the main panel and a right clip enclosing panel foldably coupled to a second side of the main panel, wherein each of the plurality of containers are at least partially received within a respective aperture of the plurality of apertures; a left latching tool including a left blade member traveling in an eccentric path, the blade member arranged to move vertically to secure a portion of the left clip enclosing panel to a first group of the plurality of containers while simultaneously moving horizontally at the first velocity.
2. 2 . The system of claim 1 , wherein the left latching tool includes: a first arm extending from a first base region to a first distal region; and a second arm extending from a second base region to a second distal region; wherein the left blade member is pivotably coupled between the first distal region and the second distal region.
3. 3 . The system of claim 2 , wherein each of the first and the second arms are arranged to synchronously rotate about the respective first base region and second base region.
4. 4 . The system of claim 2 , wherein the first arm is coupled to a drive motor and wherein the second arm is coupled to the second arm via a belt.
5. 5 . The system of claim 1 , further comprising a left dynamic guide including a belt moving at the first velocity and arranged to move the left clip enclosing panel into partial alignment with the first group of containers and to hold the left clip enclosing panel in position while the blank and the plurality of containers propagate at the first velocity.
6. 6 . The system of claim 5 , wherein the left dynamic guide holds the left clip enclosing panel in position while the left blade member simultaneously secures the portion of the left clip enclosing panel to the first group of the plurality of containers.
7. 7 . The system of claim 1 , further comprising a right static guide arranged to hold the right clip enclosing panel in place while the blade member secures the portion of the left clip enclosing panel to the first group of the plurality of containers.
8. 8 . The system of claim 1 , further comprising a right latching tool including a right blade member traveling in an eccentric path, the right blade member arranged to move vertically to secure a portion of the right clip enclosing panel to a second group of the plurality of containers while simultaneously moving horizontally at the first velocity.
9. 9 . A packaging system for securing a blank to a plurality of containers, the system comprising: a conveyor arranged to propagate the blank and the plurality of containers at a first velocity horizontally through the system, wherein the blank includes a main panel having a plurality of apertures, a left clip enclosing panel foldably coupled to a first side of the main panel and a right clip enclosing panel foldably coupled to a second side of the main panel, wherein each of the plurality of containers are at least partially received within a respective aperture of the plurality of apertures; a container feeding station configured to insert respective containers into respective apertures; a left latching tool including a left blade member traveling in an eccentric path, the blade member arranged to move vertically to secure a portion of the left clip enclosing panel to a first group of the plurality of containers while simultaneously moving horizontally at the first velocity.
10. 10 . The packaging system of claim 9 , wherein the left latching tool includes: a first arm extending from a first base region to a first distal region; and a second arm extending from a second base region to a second distal region; wherein the left blade member is pivotably coupled between the first distal region and the second distal region.
11. 11 . The packaging system of claim 10 , wherein each of the first and the second arms are arranged to synchronously rotate about the respective first base region and second base region.
12. 12 . The packaging system of claim 10 , wherein the first arm is coupled to a drive motor and wherein the second arm is coupled to the second arm via a belt.
13. 13 . The packaging system of claim 9 , further comprising a left dynamic guide including a belt moving at the first velocity and arranged to move the left clip enclosing panel into partial alignment with the first group of containers and to hold the left clip enclosing panel in position while the blank and the plurality of containers propagate at the first velocity.
14. 14 . The packaging system of claim 13 , wherein the left dynamic guide holds the left clip enclosing panel in position while the left blade member simultaneously secures the portion of the left clip enclosing panel to the first group of the plurality of containers.
15. 15 . The packaging system of claim 9 , further comprising a right static guide arranged to hold the right clip enclosing panel in place while the blade member secures the portion of the left clip enclosing panel to the first group of the plurality of containers.
16. 16 . The packaging system of claim 9 , further comprising a right latching tool including a right blade member traveling in an eccentric path, the right blade member arranged to move vertically to secure a portion of the right clip enclosing panel to a second group of the plurality of containers while simultaneously moving horizontally at the first velocity.
17. 17 . A method of forming a package comprising: providing a blank comprising a main panel having a plurality of apertures, a left clip enclosing panel foldably coupled to a first side of the main panel and a right clip enclosing panel foldably coupled to a second side of the main panel; inserting a plurality of containers into respective apertures of the plurality of apertures such that each container is at least partially received within a respective aperture; propagating the blank and the plurality of containers at a first velocity horizontally through a packaging system; securing a portion of the left clip enclosing panel to a first group of the plurality of containers using a left blade member that travels in an eccentric path while moving vertically and simultaneously moving horizontally at the first velocity.
18. 18 . The method of claim 17 , wherein securing the portion of the left clip enclosing panel comprises: rotating a first arm about a first base region; rotating a second arm about a second base region synchronously with the first arm; wherein the left blade member is pivotably coupled between a first distal region of the first arm and a second distal region of the second arm.
19. 19 . The method of claim 18 , wherein rotating the first arm comprises driving the first arm with a drive motor and wherein rotating the second arm comprises transmitting rotational motion from the first arm to the second arm via a belt.
20. 20 . The method of claim 17 , further comprising moving the left clip enclosing panel into partial alignment with the first group of containers using a left dynamic guide comprising a belt moving at the first velocity.

Description

CROSS-REFERENCE TO RELATED APPLICATION The present application claims priority to U.S. Provisional Patent Application Ser. No. 63/714,935 entitled “METHOD AND SYSTEM FOR FORMING A PACKAGE” filed Nov. 1, 2024 and to U.S. Provisional Patent Application Ser. No. 63/715,028 entitled “METHOD AND SYSTEM FOR FORMING A PACKAGE” also filed Nov. 1, 2024. INCORPORATION BY REFERENCE The disclosure of U.S. Provisional Patent Application Ser. No. 63/714,935 entitled “METHOD AND SYSTEM FOR FORMING A PACKAGE” filed Nov. 1, 2024, is hereby incorporated by reference for all purposes as if presented herein in its entirety. Additionally, the disclosure of U.S. Provisional Patent Application Ser. No. 63/715,028 entitled “METHOD AND SYSTEM FOR FORMING A PACKAGE” filed Nov. 1, 2024, is hereby incorporated by reference for all purposes as if presented herein in its entirety. BACKGROUND Container packaging systems may encounter a variety of operational challenges that impact efficiency and reliability in commercial applications. Instability and misalignment of containers during automated transport can create downstream processing problems, while floor space requirements for conventional equipment limit facility layout options and reduce overall manufacturing flexibility. Existing packaging systems may struggle to maintain consistent container positioning, often resulting in separation of individual containers from their groups and disruptions to automated processing sequences. Conventional packaging methods also frequently fail to provide sufficient protection against impact damage during storage and shipping, leading to crushing, surface damage, and the need for manual intervention. High mechanical forces during folding and dynamic assembly operations may further reduce efficiency, accelerate equipment wear, and increase maintenance demands. These operational shortcomings may drive increased labor requirements due to frequent manual adjustments or system stoppages. Inefficiencies in space utilization and transportation often result in higher storage and shipping expenses, expanded facility requirements, and increased supply chain costs. Frequent system downtime and component failures may interrupt production schedules, reduce throughput, and compound operational expenses, while unreliable packaging operations may also lead to product damage-related losses and additional quality assurance challenges. As a result, conventional packaging system limitations may create broader negative impacts throughout the industry. These impacts may include increased environmental waste, inefficient warehouse utilization, production and distribution delays, and difficulties meeting modern supply chain demands for speed, flexibility, and compliance. Emerging requirements for sustainability, regulatory compliance, real-time operational visibility, and package customization continue to widen the performance gap between current market needs and the capabilities of existing packaging machinery. SUMMARY OF THE DISCLOSURE The disclosure relates to a method and system for forming a package that addresses operational challenges in container packaging systems. The system may include a specialized blank design for forming carriers and an automated machine system for assembling these blanks with beverage containers. The automated packaging machine may include a conveyance system that provides continuous blank transport through multiple processing stages. The conveyance system may include motorized belt conveyors with drive wheels and guide rails for blank alignment. Support stanchions and anchors may provide structural stability for the system. Velocity control mechanisms may enable synchronized operation throughout the assembly process. The system may include pre-break stages that prepare fold lines in the blank for subsequent folding operations. Leading edge manipulators may include mechanical elements with finger-like protrusions and biasing mechanisms for controlled pressure application. Trailing edge cam assemblies may include dynamic cams with engagement points mounted on rotatable shafts driven by servo motors. Tamper wheels may provide rolling surfaces with wedge-shaped recesses for secondary fold line reinforcement. Progressive folding stages may transform the flat blank into a three-dimensional carrier structure. First stage plows may provide angled surfaces for initial cap enclosing panel folding. Second stage plows may include advanced folding mechanisms for continued panel shaping. Multi-stage plows may create sequential folding operations that form complex panel geometries. Mounting brackets and fixtures may provide component support throughout the folding process. The clipping stage may secure the final assembly through dynamic engagement mechanisms. A dynamic guide system may include a belt-driven guide that matches blank propagation velocity. Static guides may provide fixed positioning elements for panel stabilization. Latching tools may includ