US-20260125170-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. A packaging machine may include a conveyance system that provides continuous blank transport through multiple processing stages. 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.

Inventors

• Carlos Molina Pena
• Ryan Dye
• Nicholas Evans
• JUAN MENA
• 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 manipulating a blank into a construct, the system comprising: a conveyor configured to propagate a blank through the system, the blank having a main panel region connected to a trailing-edge tab at a fold line; and a trailing-edge tab pre-break stage having: a cam coupled to a rotatable shaft, the system configured to rotate the cam at a first rotational velocity during which the cam contacts the trailing-edge tab and bends the trailing-edge tab along the fold line to an initial position that is at an obtuse angle with respect to the main panel, the system configured to subsequently rotate the cam at a second rotational velocity during which the cam bends the trailing-edge tab from the initial position to a final position where the trailing-edge tab is at least partially overlapped with the main panel, wherein the second rotational velocity is greater than the first rotational velocity.
2. 2 . The system of claim 1 , wherein the cam bends the trailing-edge tab to the initial position and to the final position while the blank continuously propagates through the system at a constant velocity.
3. 3 . The system of claim 1 , wherein the trailing-edge tab is a first trailing-edge tab and wherein the fold line is a first fold line, the blank including a second trailing-edge tab connected to the main panel at a second fold line, and wherein the cam is a first cam, the trailing-edge tab pre-break stage further having: a second cam coupled to the rotatable shaft, the system configured to simultaneously rotate the first and second cams at the first rotational velocity to simultaneously bend the first and second trailing-edge tabs along respective first and second fold lines to the initial position, the system configured to rotate the first and second cams at the second rotational velocity to simultaneously bend the first and second trailing-edge tabs to the final position.
4. 4 . The system of claim 1 , wherein the rotatable shaft is controlled by a servomotor.
5. 5 . The system of claim 1 , wherein the cam includes a base coupled to the shaft, the cam further including an arcuate engagement finger extending from the base to a distal end.
6. 6 . The system of claim 1 , wherein the blank includes a leading edge tab connected to the main panel at a leading edge tab fold line, the system further comprising a leading edge tab pre-break stage having a breaker arm arranged to engage the leading edge tab as the blank continuously propagates through the system, the breaker arm further arranged to maintain engagement with the leading edge tab until the leading edge tab is at least partially folded over the main panel then to disengage with the leading edge tab.
7. 7 . The system of claim 6 , further comprising a tamper wheel positioned after the trailing-edge tab pre-break stage, the tamper wheel including an outer rolling surface arranged to roll across the blank as the blank propagates through the system, wherein the rolling surface is interrupted by a recess, and wherein the system is configured to align the recess with the trailing-edge tab.
8. 8 . The system of claim 7 , wherein the system is arranged to match a rotational velocity of the tamper wheel to a horizontal velocity of the blank as the tamper wheel rolls across the main panel, the system further arranged to increase the rotational velocity of the tamper wheel when the trailing-edge tab is at least partially aligned with the recess to further bend the trailing-edge tab about the fold line.
9. 9 . The system of claim 1 , wherein the breaker arm further comprises an elongated arm culminating in a finder-like protrusion facing an engaged blank.
10. 10 . A packaging system for assembling containers with a construct, the system comprising: a conveyor configured to propagate a blank through a packager, the blank having a central panel region connected to a trailing-edge tab at a fold line; a trailing-edge tab pre-break stage having: a cam coupled to a rotatable shaft, the system configured to rotate the cam at a first rotational velocity during which the cam contacts the trailing-edge tab and bends the trailing-edge tab along the fold line to an initial position that is at an obtuse angle with respect to the main panel, the system configured to subsequently rotate the cam at a second rotational velocity during which the cam bends the trailing-edge tab from the initial position to a final position where the trailing-edge tab is at least partially overlapped with the main panel, wherein the second rotational velocity is greater than the first rotational velocity; a container feed stage configured to insert a plurality of containers into orifices disposed in the central panel; and a clipping stage configured to clip cap-enclosing panels over one or more containers.
11. 11 . The packaging system of claim 10 , wherein the cam bends the trailing-edge tab to the initial position and to the final position while the blank continuously propagates through the system at a constant velocity.
12. 12 . The packaging system of claim 10 , wherein the trailing-edge tab is a first trailing-edge tab and wherein the fold line is a first fold line, the blank including a second trailing-edge tab connected to the main panel at a second fold line, and wherein the cam is a first cam, the trailing-edge tab pre-break stage further having: a second cam coupled to the rotatable shaft, the system configured to simultaneously rotate the first and second cams at the first rotational velocity to simultaneously bend the first and second trailing-edge tabs along respective first and second fold lines to the initial position, the system configured to rotate the first and second cams at the second rotational velocity to simultaneously bend the first and second trailing-edge tabs to the final position.
13. 13 . The system of claim 10 , wherein the blank includes a leading edge tab connected to the main panel at a leading edge tab fold line, the system further comprising a leading edge tab pre-break stage having a breaker arm arranged to engage the leading edge tab as the blank continuously propagates through the system, the breaker arm further arranged to maintain engagement with the leading edge tab until the leading edge tab is at least partially folded over the main panel then to disengage with the leading edge tab.
14. 14 . The system of claim 13 , further comprising a tamper wheel positioned after the trailing-edge tab pre-break stage, the tamper wheel including an outer rolling surface arranged to roll across the blank as the blank propagates through the system, wherein the rolling surface is interrupted by a recess, and wherein the system is configured to align the recess with the trailing-edge tab.
15. 15 . The system of claim 14 , wherein the system is arranged to match a rotational velocity of the tamper wheel to a horizontal velocity of the blank as the tamper wheel rolls across the main panel, the system further arranged to increase the rotational velocity of the tamper wheel when the trailing-edge tab is at least partially aligned with the recess to further bend the trailing-edge tab about the fold line.
16. 16 . The system of claim 10 , wherein the at least one blank further comprises a central panel with eight orifices for engaging eight containers.
17. 17 . The system of claim 10 , wherein the at least one blank further comprises a central panel with six orifices for engaging six containers.
18. 18 . A method of forming a package comprising: receiving a blank having a central panel with a plurality of orifices and cap enclosing panels connected to the central panel along fold lines; propagating the blank through a conveyance system at a constant velocity; inserting a plurality of containers through the orifices such that caps of the containers extend through the central panel; and performing a pre-break procedure on trailing-edge tabs of the blank by rotating a cam at a first rotational velocity to bend the trailing-edge tabs to an initial position at an obtuse angle with respect to the central panel, then rotating the cam at a second rotational velocity different from the first rotational velocity to bend the trailing-edge tabs to a final position where the trailing-edge tabs are at least partially overlapped with the central panel.
19. 19 . The method of claim 18 , further comprising performing a leading-edge pre-break procedure by engaging leading-edge tabs of the blank with breaker arms that maintain contact with the leading-edge tabs until the leading-edge tabs are at least partially folded over the central panel.
20. 20 . The method of claim 19 , further comprising tamping the trailing-edge tabs using a tamper wheel having an outer rolling surface with a recess, wherein the tamper wheel rotates at a velocity matched to the propagation velocity of the blank and increases rotational velocity when the recess aligns with the trailing-edge tabs.

Description

CROSS-REFERENCE TO RELATED APPLICATION The present application claims priority to U.S. Provisional Patent Application No. 63/714,935 entitled “METHOD AND SYSTEM FOR FORMING A PACKAGE” filed Nov. 1, 2024 and to U.S. Provisional Patent Application 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 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 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 include eccentric motion a