WO2008011415A1

WO2008011415A1 - Method and apparatus for manufacturing a multi-piece packaging carton

Info

Publication number: WO2008011415A1
Application number: PCT/US2007/073695
Authority: WO
Inventors: Pascal Martini
Original assignee: Meadwestvaco Packaging Systems Llc
Priority date: 2006-07-17
Filing date: 2007-07-17
Publication date: 2008-01-24
Also published as: GB0614140D0

Abstract

A device for manipulating a group (G1) of carton blanks forms a sub-assembly of a packaging machine which comprises a transfer element for picking up a plurality of carton blanks in a group. The transfer element is also structured and arranged for moving the group of carton blanks onto a processing line (322) of a packaging machine. The device also comprises a spacing element (362, 364) for adjusting the relative lateral spacing of the carton blanks of said group and a folding element having means for folding primary panels of each of the carton blanks. The transfer element, folding element and said spacing element being operative simultaneously such that manipulation of the primary panels and lateral spacing of said plurality of carton blanks is effected during transfer such that a group of spaced, folded carton blanks simultaneously are delivered to the processing line for processing by the packaging machine.

Description

PACKAGING METHOD FOR MULTI-PIECE CARTON FORMATION AND APPARATUS FOR CARRYING OUT THE SAME

Background of the Invention

The present invention relates to a packaging method for formation of cartons constructed to accommodate a plurality of articles such as beverage bottles and to apparatus for carrying out such a method.

In particular, the invention relates to a carton formed from a plurality of blank integers which are each to be aligned and secured to one another in a finished package. An example of such a carton is found in International Patent Application Number PCT/US2005/012198 incorporated herein by reference and is further shown loaded and assembled as a package in the final figure of the accompanying drawings of the present specification.

Cartons comprised of multiple integers, for example two-part cartons present many advantages to the user. For example, such a construction often imparts extra strength to the carton whilst providing large areas to be printed with advertising graphics if desired. A two- part construction may also, for example, present advantages with respect to the ease of access to the articles contained in such a carton.

It is an object of the present invention to provide such a method for loading and formation of a multi-part carton.

International Patent Application No WO/2006/036730, to LeBras teaches an apparatus for the continuous set-up and loading of such cartons. In the apparatus disclosed therein the bottom part of the carton is set-up, and bottles are continuously side loaded into the partially erect bottom part. Thereafter the construction of the bottom part is completed and a partially formed top part is formed and secured onto the loaded base to complete the carton construction. The construction method and apparatus therefore provides a continuous loading and construction system in which cartons are sequentially loaded and constructed. The arrangement taught by LeBras in WO '730 is advantageous in that the bottom part; top part and bottles are all in continuous motion throughout the loading and construction process. In this way a high-throughput of completed packages is achieved.

The disadvantage of this arrangement however that is the apparatus is limited in its application to a particular size of carton, number and configuration of bottles. To adapt the machine so that an alternative carton size or arrangement can be processed requires considerable down time of the machine which is expensive and likely to result in the shutting down of the entire bottling line and not just the packaging line. Additionally the machine takes up a considerable length of processing line which can be difficult to install in many plants where space is limited.

It is therefore required to provide a method and apparatus for the assembly of two part cartons which provides a considerable though-put of packages and at the same time offers flexibility in the size of carton and articles packaged without a significant changeover period and without incurring excessive downtime of the processing plant and or which requires a compact processing line.

The present application discloses a packaging method and apparatus which offer these benefits and which seek to overcome - or at least to mitigate - the problems presented by the prior art.

Summary of the Invention

To this end, a first aspect of the present invention provides a device for manipulating a group of carton blanks, the device comprising a transfer element for picking up a plurality of carton blanks in a group and for moving said group of carton blanks on to a processing line of a packaging machine, a spacing element for adjusting the relative lateral spacing of the carton blanks of said group and a folding element having means for folding primary panels of each of the carton blanks, said transfer element, folding element and said spacing element being operable simultaneously such that manipulation of the primary panels and lateral spacing of said plurality of carton blanks is effected during transfer such that a group of spaced, folded carton blanks are deliverable to the processing line for processing by the packaging machine.

Preferably wherein the carton blanks of the group are blanks for forming either a top part or bottom part of a two-part composite carton.

Preferably wherein the pick up means comprises a plurality of suction heads, each suction head for picking up a carton blank of the group and preferably each of said suction heads is slidably coupled to a common bar, the common bar forming part of said transfer element. Optionally, the common bar may be coupled to an articulated arm which facilitates movement of the common bar.

A second aspect of the present invention provides a method for manipulating a group of carton blanks, which method comprises picking up a plurality of carton blanks in a group and moving said group of carton blanks on to a processing line of a packaging machine, adjusting the relative lateral spacing of the carton blanks of said group, and folding primary panels of each of the carton blanks, each of which moving, spacing, and folding being carried out simultaneously such that manipulation of said primary panels and lateral spacing of said plurality of carton blanks is effected whilst there are being moved, such that a group of spaced, folded carton blanks are delivered to said processing line.

Preferably, the method further comprises simultaneously manipulating groups of differing carton blanks.

Brief Description of the Drawings

An exemplary, non-limiting embodiment of the present invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1A. Illustrates a first part of a blank for forming a crate style carton to be erected by the method and apparatus of the first embodiment; Figure IB. Illustrates a second part of a blank for forming the crate style carton;

Figure 1C. Illustrates a step in the process to erect the crate style carton from the blanks of Figs. 1A and 1B;

Figure 1D. shows the crate style carton formed from form the blanks of Figs. 1A and 1B;

Figure 2A. shows a schematic representation of an apparatus for constructing the carton of figures 1 A-1D, broadly showing four areas of construction;

Figure 2B shows a schematic representation of the apparatus of Figure 2A, illustrated from the opposite side;

Figures 3-5 illustrate three progressive steps which take place in the first area of construction in the apparatus shown in Figures 2 A and 2B;

Figures 6-8 illustrate three progressive steps which take place in the second area of construction in the apparatus shown in Figures 2 A and 2B;

Figures 9-11 illustrate three progressive steps which take place in the third area of construction in the apparatus shown in Figures 2A and 2B and

Figures 12-15 illustrate four progressive steps which take place in the fourth area of construction in the apparatus shown in Figures 2 A and 2B.

Detailed Description of the Preferred Embodiment

The invention provides a method and a packaging machine for carrying out the method for constructing and loading a two part carton containing articles such as bottles. An exemplary embodiment will be described with reference to a carton depicted in figures 1A-1D, which is of a known construction and provided to aid understanding of the invention. Figs. 1A and 1B show a first 210 and a second part 220 respectively, of a two-part blank for forming a crate style carton 230 (shown in Figure 1D), made from paperboard or similar foldable sheet material. The two blanks 210 and 220 of Figs. 1A & 1B are formed into a tray (T) and a cover (C) respectively. Together the tray (T) and cover (C) form a crate style carton 230 which is shown in Fig. 1D. The carton 230 is designed to receive similar articles, such as bottles (B), but it is envisaged that in other embodiments, articles other than bottles 2 would be contained in the carton 230 and the apparatus and method of the present invention would be used to load such articles 2 into a carton 230, without departing from the scope of the invention.

Turning to Figure 1A, the tray blank 210 comprises a first end wall 216, a bottom panel 224 and a second end wall 218, hinged one to the next in series, along fold lines 244 and 248 respectively. Handle apertures 254 are struck from the first and second end walls 216, 218, respectively to facilitate carrying of the completed and loaded carton 230.

The tray blank 210 further comprises corner flaps 266a/266b and 268a/268b hinged to the first and second end walls 216 and 218 respectively. The corner flaps 266a/266b and 268a/268b provide additional protection to the bottles contained within the carton 230 at those corners. The corner flaps 266a/266b and 268a/268b are hinged to side flaps 276a/276b and 278a/278b along fold lines 286a/286b and 288a/288b respectively, as shown in Fig. 1A The side flaps 276a/276b and 278a/278b provide a means for securing the tray (T) formed from blank 210 to the cover (C) formed from blank 220 when the carton 230 is constructed.

The tray blank 210 further comprises bottom end flaps 274a and 274b hinged to the bottom panel 224, along fold lines 294a and 294b. The bottom end flaps 274a, 274b provide an additional means for securing the tray and cover together.

The tray blank 210 also comprises inner reinforcement panels 226 foldably connected to the first and second end walls 216, 218 about fold lines 240 and 242. The inner reinforcement panels 226 are shaped such that upon folding the inner reinforcement panels 226, 180° about the fold lines 240 and 242, a 2 ply reinforced edge of the end walls 216, 218, proximate the uppermost edge of the handle apertures 254 of the set up carton 230, is created. The cover blank 220 is shown in Figure 1 B. The cover blank 20 is used to form a cover (C) for the tray (T) formed from the blank 210 of Figure 1A. Blank 220 comprises a top panel 222 which is hinged to first and second side walls 212, 214 along fold lines 234a, 234b. The first and second side walls 212, 214 comprise fold lines 232a and 232b which although not essential assist in the construction process of the carton 230 as will be described later.

A series of apertures 256 are struck from the top panel 222 and are structured to receive an upper portion of the articles 2 which are to be contained within the crate style carton 230. The apertures 256 are designed to receive the necks of the bottles 2, and therefore they are circular and comprise radial tabs 260 which protrude toward the centre of each of the apertures 256 and serve to hold a bottle securely within each aperture 256.

The top panel 222 further comprises a series of weakened lines or nicks 237 which connect each aperture 256 to at least one other aperture 256. These frangible connections 237 are provided to assist in providing access to the bottles when a consumer removes the bottles 2 from the carton 230.

Turning to the construction of the crate style carton 230 from the tray blank 210 and cover blank 220, a series of sequential folding and gluing operations are required which are to be performed by the apparatus provided by the present invention. The sequence of operative steps required to construct the carton 230 will now be described, thereafter the features of the apparatus and method for constructing the carton will be described.

The first stage is to secure, if provided, the inner reinforcing panels 226 to the inside faces of the end wall panels 216, 218. The end wall panels 216, 218 are then folded about fold lines 244 and 248, out of the plane of the bottom panel 224 to produce a tray (T).

The tray (T) is then loaded with bottles 2, as shown in Fig. 1 C and the bottom end flaps 274a, 274b are folded upwardly of the base panel 224 of the tray (T). The corner panels 266a/266b and 268a/268b and side flaps 276a/276b and 278a/278b are then folded about fold lines 296a/296b, 298a/298b, 286a/286b and 288a/288b into an erected position as shown in Figure 1C.

In preparation of the final folding and gluing operations to complete the erection of the crate style carton 230, the cover blank 220 is folded about fold lines 234a and 234b. The side walls 212, 214 are folded 90° about fold lines 234a and 234b, out of the plane of top panel 222.

Cover blank 220 is then brought into registry with the bottles 2 which have been loaded into the tray (T). Top portions of the first and second side walls 212, 214 are placed in flat face contact with the inner faces of the side flaps 276a/276b and 278a/278b respectively, and may be secured together by adhesive of other means known in the art.

The first and second side walls 212, 214 are then folded about fold lines 232a and 232b to bring bottom portions of the first and second side walls 212, 214 back into the plane of the top panel 222. Glue can then be applied to the bottom flaps 274a/274b and side flaps 276a/276b and 278a/278b before the bottom portions of the side walls 212, 214 are returned to a position in line with the remainder of the side walls 212, 214 and thereby fastened to the glued portions of the bottom flaps 274a/274b and side flaps 276a/276b and 278a/278b. This completes the construction of the carton 230.

The crate style carton 230 formed from the blanks 210 and 220 is shown in Figure 1D. It can be seen that the bottles 2 are secured within the carton 230, once the cover (C) made from blank 220 has been secured to the tray (T), erected from blank 210. Access to the bottles is gained by separating the frangible connections 237; this may be achieved simply by pulling a bottle 2 from the crate style carton 30.

It can be appreciated that various changes may be made to the carton 230, for example the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape and the description of the carton 230 is provided only to facilitate the following description of an exemplary way of implementing the apparatus and method of the present invention. It is envisaged that the carton base and top part blanks 10, 40 can vary depending upon the shape and/or quantity of articles to be packaged and consequently, a machine in accordance with one or more aspects of the present invention is adjustable in numerous respects, so that it can process a wide variety of such blanks and is not limited to the specific example above. Indeed, a machine of the present invention may be used to package cartons containing articles other than bottles, and the top part may not necessarily comprise apertures for accommodating bottle necks. It is therefore envisaged that the method employed by the present invention may also be adjustable in order to accommodate a variety of carton arrangements.

Turning to the method and apparatus for constructing the carton 230, there is provided a packaging line 300 comprising four primary sections, a first blank feeding section (A), a product metering and loading section (B), a formation and transfer section (C) and a second blank feeding and forming section (D). These primary sections (A, B, C and D) are illustrated from one side in Figure 2 A and from the opposite side in Figure 2B.

Referring firstly to the blank feeding section (A), a series of four hoppers 310 are provided for housing and supplying blanks 210 for forming the tray (T) of the carton 230. Two feeding mechanisms 320 are provided and these can be best viewed from the illustration of Figure 2B. Each feeding mechanism 320 is provided to pick-up two tray blanks 210 from an adjacent hopper 310 and place them, side-by-side, on a main processing line 322. The two feeding mechanisms 320 operate substantially simultaneously such that four blanks 210 are provided, side-by-side, on the processing line 322. The group of four blanks 210 are then conveyed using conventional conveyer means such as an endless belt or lug-chains, to the second primary section, the product metering and loading section (B).

At the product metering and loading section (B), an incoming array of articles, in this embodiment bottles 2, (it being understood that in other embodiments articles other than bottles would be processed) are metered into groups and placed onto the carton base blanks 210. In this embodiment a metering device, having four articulated arms 324, selectively picks up four groups of bottles 2 and moves the selected groups onto the bottom panels 224 of the four carton blanks 210 which are present on the processing line. The metering device and each articulated arm 324 are moveable such between each articulated arm 324 picking up twelve bottles 2 and placing them on the carton base panel 224, the bottles 2 are clustered into the desired configuration of 3x4 close packed bottles 2. In this way the array of incoming bottles 2 are picked up, assembled into the desired configuration and placed on a carton blank base panel 224.

Optionally, in the product metering and loading section, a folding tool 326 is provided to fold the inner reinforcing panels 226 of each blank 210, 180° into face contacting relationship with the first or second end walls 216, 218. In an embodiment where this feature is provided a glue gun 328 or other means for adhering the inner reinforcing panels 226 to the first or second side walls 216, 218 is also provided, either within the product metering and loading section (B) or, as in the present embodiment, disposed at the exit of the blank feeding section (A), (see Figure 2A).

Once a configured group of bottles 2 has been placed onto each blank 210 the four loaded blanks 330 are conveyed along the processing line to the formation and transfer section (C). Here, the loaded blanks 330 are more completely formed into loaded base trays 332, by the upward folding of the first and second end walls 216, 218. Conventional folding and moving tools such as star wheels and guides are provided to facilitate the folding steps. Similarly the corner panels 266a/266b and 268a/268b and side flaps 276a/276b and 278a/278b are then folded about fold lines 296a/296b, 298a/298b, 286a/286b and 288a/288b into an erected position. In some embodiments the side flaps 276a/276b and 278a/278b are adhered by means of glue to the bottom flaps 274a/274b. In other embodiments, no adhesion of the side panels 212, 241 to the bottom flaps 274a/274b takes place and when the top cover is secured to the base tray (T) the side flaps 276a/276b and 278a/278b, the side walls being secured to each of the bottom flaps 274a/274b and side flaps 276a/276b is sufficient to secure the carton 230 in its constructed form.

The loaded and assembled trays 332 are then conveyed along the processing line 322, in a group of four, to the final section; the second blank feeding and forming section (D). Viewing the second blank feeding and forming section (D) from Figure 2B, it can be seen that four farther suction heads 334 are provided each being slidably moveable along a common bar 336. Each of the further suction heads 334 is structured and arranged such that it can pick-up a cover blank 220 from a hopper 311 and, as the cover blank 220 is moved toward the assembled group of four loaded trays 332, fold the cover blank 220 about fold lines 234a/234b such that a substantially "U-shaped" cover portion (C) is formed. Each further suction head 334 is further moveable such that it can place the cover portion (C) on top of a loaded tray 332, as illustrated at section D of Figure 2B.

To secure the top cover (C) to the loaded tray 332, a folding wheel or other panel manipulating means is utilitsed to raise a skirt 253 of each of the first and second side walls 212, 214 of each carton top cover (C), such as glue (or other adhesive means) can be placed along the bottom flaps 274a/274b of each loaded and covered trays 340. The skirts 253 are then folded (again by a known star wheel) and secured to the bottom flaps 274a/274b, thus adhering the top cover (C) to the loaded tray and thus completing the construction of the carton 230.

Following from the overview of the apparatus 300, each of the sections will now be taken in turn and described in further detail.

Referring to Figures 3-5, the articulated arms 320 can be seen. Each Articulated arm 320 is founded on a base 360 and adjoins a moveable bar 362. Connected by mechanical couplings to the moveable bar 362 are four suction plates 364. Each suction plate 364 is simultaneously moveable by virtue of each suction plate 364 being connected to the moveable bar 362. The suction plate 364 is provided with a plurality of suction cups (not shown) which together provide sufficient suction to retrieve a tray blank 210 from an associated hopper 310. Each suction plate 364 is brought up to one of four blanks 210 by movement of the adjoining moveable bar which in turn is controlled by the articulated arms 320. Together four blanks

210 are retrieved from the hoppers 310 and lowered and rotated toward the processing line

322 as can best be seen in Figure 4. As the four blanks 210 are lowered and rotated the relative spacing between adjacent blanks is adjusted so that the spacing of the blanks 210 as they are placed onto the processing line 322 matches the pitch of the processing line. This is achieved by virtue of the connection of the suction plate 364 being moveable relative to the moveable bar 362, which movement is, in some embodiments controlled by a computerised control unit which automatically adjusts the spacing of the carton blanks to match the pitch of the processing line 322.

The pitch of the processing line is determined by a number of factors but primarily the speed of delivery of the incoming bottles. The pitch is maintained by the conveyor means, which in the preferred embodiment takes the form of carrier 366. The carriers 366 are attached to a moveable chain (not shown), which convey the base blanks 210 at the required pitch. The base blanks are conveyed by the carriers 366 being disposed either side of the base panel 224 of the base blank 210. The base 365 of the carrier 366 is sized to be smaller than the overall width of the base panel 224 plus the two bottom flaps 374a/374b. Preferably the base 365 of the carrier 366 is only just larger than the width of the base panel 224 such that upon placing the base blank 210 into the carrier 366, the bottom flaps 274a/374b are forced to be folded upwardly as the blanks 210 are placed onto the carriers 366. The folded base blank 210 is shown in Figure 6, though the carriers 366 themselves are not illustrated.).

Once delivered to the processing line, the carton blank group Gl is conveyed (by the carrier 366) to the next section. The entire packaging line is moved simultaneously such that preceding carton groups that have been processed in the subsequent primary sections (B. C & D) are conveyed by the conveying means 322 at the same time as the carton blank group Gl is transferred to the product metering and loading section (B). When the carton group Gl is completely conveyed to the succeeding section, the product metering and loading section (B), the conveyer means or processing line 322 is stopped. The operation performed in the blank feeding section (A) will then be repeated with a subsequent group of four blanks. Meanwhile the first group of four carton base blanks Gl is processed by the product metering and loading section (B).

The product metering and loading section (B) is illustrated in Figures 6-8 wherein the incoming array of bottles 2 are assembled into groups. In a preferred arrangement, the incoming array 376 of bottles 2 is ordered by the conveyor means for the bottles 2, which are conveyed in channels matching the end dimension of the cartons, in this case in channels of 3 bottles wide. Each articulated suction arm 324 of the metering and formation device 370 is connected by a second moveable bar 372 along which each articulated suction arm 324 is slidably moveable. Each articulated suction arm 324 comprises 12 suction heads 374, each sized and designed to grip, for lifting, an upper portion of a bottle. It is envisaged that in other embodiments the suction heads 374 are adaptable in diameter so that when the packaging line is needed to process a different sized product, the suction heads are adaptable to increase/decrease in diameter so that such products may be accommodated. In other embodiments wherein greater or fewer than twelve bottles are to be packaged, the number of suction heads matches the number and configuration of bottles to be packaged.

By providing a plurality of articulated suction arms 324, each connected to a common movable bar 372, the transfer of four groups of configured articles is conducted simultaneously thus providing an easy mechanism for co-ordinating the placing of the four groups onto the processing line 322 from the article income supply 376. Because the four articulated suction arms 324 are each independently moveable along the moveable bar 372, the relative lateral spacing between adjacent groups is adjustable.

It is envisaged that sensing means will be provided in some embodiments which detect the position of the bottles to be picked up and detects their axial centre line. The suction heads 324 would additionally be provided with means for adjusting either the position of the suction head or for preventing the suction arm 324 from attempting to pick up bottles if one or more bottles are considerably out of alignment or of the incorrect configuration.

Spacing of the picked-up groups of bottles is illustrated between figures 7 and 8 wherein the closely packed incoming bottles are grouped, spaced and placed onto one of the four carton base blanks. The selection and arrangement of a 4x3 group of bottles being lifted and placed onto a carton base panel 224 is further illustrated in Figures 9 - 11.

Primarily Figures 9 - 11 illustrate the processing which takes place in the formation and transfer section (C). As the group of loaded base blanks G2, illustrated in Figure 8, are transferred to the formation and transfer section (C) glue guns 380 disposed adjacent the processing line apply glue/adhesive to lower portions of the inner faces of the side flaps 276a/276b. The first and second side walls 216, 218 are raised and the side flaps 276a/276b adhered to the bottom flaps 274a/274b, to form a group of four loaded and partially constructed cartons G3. In one embodiment the side flaps 276a/276b are secured by pressure plates which move above the processing line, between the carriers 366 to apply pressure to the both sides of the loaded tray simultaneously and then descend below the processing line so that the progression of the carriers and loaded trays is not interrupted.

Again, synchronised in time with the forward movement of the groups Gl and G2 from the preceding processing sections, the group of four part- assembled and loaded trays G3 are moved into the second blank feeding and forming section (D). This may be achieved simply by means of a pushing plate (not shown), which slides the group G3 proximate the cover blank hoppers 311. In some embodiments, the location of the group G3 relative to the hoppers 311 does not have to be exact since the common bar 336 can move to meet the group G3, once the cover blanks 220 have been picked up and folded.

The suction heads 334 comprise a plurality of removable, moveable vacuum suction cups each of which is disposed between an aperture 256 of the blank cover panel 220 when the articulated arms 338 raise the common bar 336 and hence the four suction heads 334 towards the cover panels 220, located in the hoppers 311. A formation element (not shown), provided

The suction heads 334 are moveable along the common bar 336 by means of a motor coupled to a control unit. In other embodiments the suction heads may be moveable by other mechanical means such as a pneumatic piston, a cam track or a moveable belt for example. Preferably location sensors are provided on the suction heads 334 and/or common bar 336 which can be used to determine the relative spacing between the picked up blanks and a control means coupled to the location sensors will determine the lateral adjustment of the relative location of the picked up blanks which is needed to provided four correctly oriented carton covers (C). In the present embodiment however, the relative adjustment of the cover blanks 220 is already calculated by the pitch of the carton bases and the spacing of the hoppers 311. In other embodiments location sensors may be provided to determine the position of the loaded bases of group G3 to ensure correct alignment of the covers (C) with the loaded trays (T). The present invention utilises the velocity of the conveyer and the known pitch of the groups to ensure vertical alignment between the centre of the hoppers 311 and the centre point of the group G3 after it has been transferred to the formation and transfer section (C).

This is illustrated in Figure 13 wherein the group G3 is disposed substantially centrally of the hoppers such that the relative lateral sliding movement required by each of the suction heads (which is different for each head, the outer heads moving further than the middle two heads) is easily calculated and is the same each time a group of loaded bases are delivered from the formation and transfer section (C).

Inward movement of the suction heads 334, each holding a blank 220 can only be commenced after folding of the primary panels 212, 214 of the cover blank 220. Otherwise, adjacent carton blanks would overlap and folding of the blanks would be hampered. To avoid this, in other embodiments the hopper may be oriented at 90° relative to the configuration shown. In such arrangements, the folded blanks or loaded carton bases would need to be rotated in order to facilitate the depositing of the cover (C) onto the base (T). Therefore the present arrangement, as shown in figures 14 and 15 is preferred.

The primary panels 212, 214 of the cover 220 may be folded using conventional tools, for example supporting guides (not shown) coupled to the suction head and aligned with the fold lines 234a/234b of the cover 220 together with a folding wheel (not shown), fold the side walls 212, 214 into a substantially perpendicular arrangement with the top wall 222.

The final section of the packaging line is reached by the assembled group G4 being transferred away from and substantially perpendicular to the direction of the main packaging line 322. This arrangement is preferable as the packaging line is thereby kept as compact as possible, however in other embodiments the packaging line is a straight line and continues linearly such that the securing section is upstream of the second blank feeding and forming section (D).

The skirts 235 of each of the first and second side walls 214, 212 of the group G4 are raised by a static guide (not shown) as the carton group G4 are moved out of the second blank feeding and forming section (D). Glue or other adhesive is applied to the bottom flaps 274a/274b by conventional means, to secure the side walls to the base and thereby complete the construction of the cartons in the group.

It should be understood that various changes may be made within the scope of the present invention, for example, the size and shape of different components being adjusted to accommodate articles or cartons of differing size or shape. The carton may be adapted to accommodate more than one article in a differently configured array, and the method and apparatus of the present invention may be adapted accordingly. For example the group of cartons processed in other embodiments will container fewer or greater than four cartons.

It is also envisaged that the sections of the packaging machine herein described are synchronised such that the groups are transferred from one section to another at the same time thus defining an intermittent packaging line, nevertheless, in other embodiments the timing of the groups being transferred to successive sections may be such that as the processing is completed in one section, the subsequent section is not yet finished but the velocity of transfer or transfer distance between the sections may be such that by the time the group arrives at the successive section, the previous group has started to be transferred away. Ideally all groups are conveyed on a single conveyer which starts and stops intermittently to facilitate the processing and transfer of each group.

It will be obvious to one skilled in the art that various changes may be made without departing from the scope of the present invention. For example articles other than bottles may be loaded into the cartons and therefore apertures provided in the top panel may be omitted or sized to accommodate the different articles. In other embodiments the packaging line may be completely linear and in other embodiments the packaging line may be L-shaped, other configurations are also considered as comprised within the scope of the invention.

It should be understood that the articulated arms 320, 338 may each be attached to only one base 360 rather than two arms to each base. In an alternative embodiment more than one articulated arm 320, 338 may be attached to the base 360 and/or each articulated arm may coordinate the movement of fewer or greater than two suction heads. It will be recognised that as used herein directional references such as "top", "base", "end", and "side", do not limit their respective components to such orientation but serve merely to distinguish these panels one from another. Any reference to foldable connection should not necessarily be construed as referring to a single fold line only; indeed, it is envisaged that hinged connection may be formed from one or more of the following: a score line, a frangible line or a fold line. Any of these options may be chosen without departing from the scope of the present invention.

Claims

1. A device for manipulating a group of carton blanks, the device comprising a transfer element for picking up a plurality of carton blanks in a group and for moving said group of carton blanks onto a processing line of a packaging machine, a spacing element for adjusting the relative lateral spacing of the carton blanks of said group and a folding element having means for folding primary panels of each of the carton blanks, said transfer element, folding element and said spacing element being operable simultaneously such that manipulation of the primary panels and lateral spacing of said plurality of carton blanks is effected during transfer such that a group of spaced, folded carton blanks are deliverable to the processing line for processing by the packaging machine.

2. A device according to claim 1 wherein the carton blanks of the group are blanks for forming either a top part or bottom part of a two-part composite carton.

3. A device according to claims 1 or 2 wherein the transfer element comprises a plurality of suction heads, each suction head being able to pick up a carton blank of the group.

4. A device according to claim 3 wherein each of said suction heads is slidably coupled to a common bar, the common bar forming part of said transfer element.

5. A device according to claim 4 wherein the common bar is coupled to an articulated arm to facilitate movement thereof.

6. A packaging machine for assembling and loading a two-part carton, the packaging machine comprising a device for manipulating a group of carton blanks, the device comprising a transfer element for picking up a plurality of carton blanks in a group and for moving said group of carton blanks onto a processing line of the packaging machine, a spacing element for adjusting the relative lateral spacing of the carton blanks of said group and a folding element having means for folding primary panels of each of the carton blanks, said transfer element, folding element and said spacing element being operable simultaneously such that manipulation of the primary panels and lateral spacing of said plurality of carton blanks is effected during transfer such that a group of spaced, folded carton blanks are deliverable to the processing line for processing by the packaging machine.

7. A packaging machine according to claim 6 wherein said transfer element starts and stops intermittently to move said group of carton blanks.

8. A packaging machine according to claim 6 wherein the transfer element comprises a plurality of suction heads, each suction head being able to pick up a carton blank of the group.

9. A packaging machine according to claim 8 wherein each of said suction heads is slidably coupled to a common bar, the common bar forming part of said transfer element.

10. A packaging machine according to claim 9 wherein the common bar is coupled to an articulated arm to facilitate movement thereof.

1 1. A method for manipulating a group of carton blanks, wherein the method comprises picking up a plurality of carton blanks in a group and moving said group of carton blanks onto a processing line of a packaging machine, adjusting the relative lateral spacing of the carton blanks of said group, and folding primary panels of each of the carton blanks, each of which moving, spacing, and folding being carried out simultaneously such that manipulation of said primary panels and lateral spacing of said plurality of carton blanks is effected whilst there are being moved, such that a group of spaced, folded carton blanks are delivered to said processing line.

12. The method of claim 1 1, further comprising simultaneously manipulating groups of differing carton blanks.