CA2153308C - Stacked article packaging method - Google Patents

Abstract

A method for continuously forming stacked article groups, comprising the steps o f supplying at least two steams of articles, each at a predetermined vertically distinct level; forming and longitudinally transporti ng a steam of first article groups having at least one article, at a first level; placing a support base on a top surface of each first article group; and forming a second article group, having at least one article, at a second level on top of the support base of each longitudinally mov ing first article group, whereby stacked article groups are formed. The stacked article groups are subsequently processed for packaging.

Description

~Wo 94Q0369 PCT/US94/02176 STACKED ARTICLE PACKAGING METHOD

SPECIFICATION

BACKGROUND OF THE INVENTION

This invention relates to p~rl~gin~ mPthofls and apyalalus. Particularly, this invention relates to a continuous method of follllillg stacked or multiple layer article groups. The p2cl~in~ m~otht~d of the present invention is 10 useable to package dirr~.ll types, styles and sizes of articles, in a wide range of stacked article group ~ , and into a variety of p~rL-~gin~
media, into cartons in a fast and reliable lllallllC~.
In the past, various ...~hi.lF~ and ~ cesses have been proposed and utilized to package selPctecl article groups into p~r~e~. Each prior art rl~ ? and plocess, ho~ ,el, acc~,llll.lishes the p~eL-~gin~ of the article groups in a distinct lllallll~,~ and utilizes particular .~rhi~-f ~,. Moreover, prior art c~lun~l~ have limited ~djt-ct~hility, limited output capability, and have been ~liffirlllt to Col~lluCL and ~.,~;..1;~;" due to their ~ designs.
And finally, no method or d~)pàLaluS, insofar as is known provides 20 continuous motion par~in~ of stacked or layered ploduc~ groups.
Prior art pacl~ging assemblies include U.S. Patent 4,802,324 to applicants' a~si~n~oe for a Vertical C~LO lg Assembly and Metho~l which SU~3STITUTE Sl~EET (RULE 26~

Wo 94/20369 / PCTIUS94/02176 ~3~ 2 discloses the pl~remPnt and assembly of cartons over preselected article groups being moved on a conveyor. U.S. Patent 5,036,644, also to applicants' ~csignpe7 discloses a p~rk~gjng Sleever Assembly which ~lal~rt:l~ flat pack~ging sleeves directly onto preselpctr~l article groups and 5 sl~bseqllently wraps and closes the cartons. Various end loading par~ging m~rhinPs have also been proposed in the art. For example, U.S. Patent 3,778,959 to Langen et al. discloses an end loader which utilizes a plurality of tlal~ ely rX~ g spaced apart fences or flights mounted on a conveyor to Mke or capture a prede~ ed lluln~l of containers from infeed Co.. ~ l slips. U.S. Patent 4,237,673 to Calvert et al. discloses a m~rhinP also for loading cont~inpr sleeves through their open ends. U.S.
Patent 4,936,077 to T ~ngen et al. discloses a carton loading ...~rh;..f which utilizes pusher ...~ch~ with spring loaded pusher heads to stagger cent product group rows during tlal~r._. into the carton.
In view of the limit~tions and sholLcol "l~ of prior art mPtho-l~ and a~alalus, it is an object of this invention to provide a method of contiml~lsly and reliably follllillg stacked ~lo-lu.;L groups at high speed.
Another object of this invention is to provide a parl!~ging mPth-xl which is useable with a variety of p~r~ge types, articles and stacked article group 20 types and sizes. A particular object of the invention is to ~luvide a mPtho which forms stacked or multiple layer article groups via a base mell.be ,lisl,osed b~l~.,en a lower article sub-group and an upper article sub-group.

SUBSl ITUTE SHEET (RULE 26~

~wo 94/20369 215 3 3 O ~ PCTIUS94/02176 SUMMAP~Y OF THE INVENTION

The present invention provides a method for continuously forming stacked article groups, co~ isil-g the steps of: supplying at least two S streams of articles, each at a predeLcllllilled vertically distinct level; forming and long~ in~lly t~ SpOl~ g a stream of first article groups having at least one article, at a first level; placing a support base on a top surface of each the first article group; ~lll~ing a second article group, having at least one article, at a second level at or above the Su~Gl~ base of each lon~ in~lly 10 moving first article group, wh.,l~y stacked article groups are formed. The S~U1I base is preferably col~Llu~;Led of ~a~e,l,Gald and has a thin, ~b~l;...l;~lly flat, rectilinP~r configuration with a surface area subst~nti~lly co~lr~ e with that of the top surface of the first article group. The ~u~pGlL base may have a flap l,lember disposed along one base edge and 15 defined by a scoreline, the flap lll~ e~ being foldable over one edge of the top surface of the first article group.
In a prer~llcd embo~ the invention provides a continuous C~LùU~llg m~thorl for loading stacked article groups into p~c~g~s or cartons of a type having an outer ~Llu~;lurc and an inner divider ~l~ul;Lul~"
20 culll~ ing the steps of: supplying at least one stream of articles at a first precl~ location and a first vertical level along a lt~nF~it~l-lin~lly oriented axis; f~lllPillg and longi~ in~lly Llal~ulLing a stream of lower SUBSTITUTE SHEET (RULE ~6) Wo 94/20369 PCTtUS94/02176 ~33~ 4 article sub-groups at the first location; depositing the inner divider structure at a second predt;lc~ ed location along the axis, dow,LsL,.,a,l- from the first location; supplying at least one stream of articles at a third location dow"s~" ~,l from the second location, and at a second vertical level higher 5 than the first vertical level; slidably follllill~, at the third location, an upper article group on each the divider structure of each the lower article sub-group, wl~ eby stacked article groups are formed; Lldl~ )lLill~, the stacked article groups along the lonpihl<lin~l axis; providing a lon~ihl~1in~1 stream of cartons, with open ends facing and syl~ul~ed with the stacked article 10 groups, ~ rent to and parallel with the article groups; and laterally moving the stacked article groups into the ~y~chl~l~ed cartons.
These and other ~e.l~rl-~. of this invention will becullle clear from the following description by ~ÇeL-,llce to the dldwillgs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the p~clf~ging or C~Lul~i~lg assembly of the present hlvc;lllioll;
~ IG. 2 is a top plan view of the cdllollel assembly;
20 FIG. 3 is a pels~c~;live view of a carton assembled by the callol~r assembly;

SUBSTITUTE SHEET (RULE ~6) ~WO 94/20369 ~ 31~ 8 PCT/US94/02176 FIG. 4 is a crossectiQnal view of the carton taken along line 4~ of FIG.

FIG. S is a ~çt~ilP~l side view of the ca"oner assembly;
FIG. 6 is a detailed top plan view of the cal.ollel assembly;
FIG. 7 is a top plan view of a portion of the ca,Lo~lel assembly;
FIG. 8 is a side view of selected portions of the article group selection and Llal~pO" l"P~ ni!~...;
FIG. 9 is a top view of a portion of the carton supply and lldllSpCJlL
~Prh5llli~lll;
10 PIG. 10 is a side view of a portion of the carton supply and Lldl~l,ol~

~ ~ ~PC.~
PIG. 11 is a top view of the dischal~;~ end of the carton supply and L~ spG~ ",;
FIG. 12 is a side view of the dischdlge end of the carton supply and 15 transport ~ ..Pçh~";~.";
FIG. 13 is a side view of the infeed guides of the article supply " ,P.çh~
~ :IG. 14 is a side view of the carton ~upyGlL assembly of the carton supply and Lldl~ JUlL ~ rh;~
20 FIG. 15 is a top view of the carton support assembly of FIG. 14;
FIG. 16 is a left end view of the carton ~up~olL assembly of FIG. 14;
FIG. 17 is a right end view of the carton ~u~po~L assembly of FIG. 14;

SUBSTITUTE SltEET ~RULE 2~) 2 / 5 3 3 0 ~ PCT/US94/02176 FIG. 18 is ~ t~p ~ ~ of the crossloading ~-.tsch~ m;
FIG. 19 is a crossectional view of the cs, Lonel apparatus taken appro~im~t~ly along line 19-i9 of FIG. 5;
FIG. 20 is a crossectional view of the cartoner apparatus taken S approximately along line 20-20 of FIG. 5;
~IG. 21 is a ~;losse.;lional view of the cs,lonel all~alaLus showing details of the article group selection and Llàl~Ol~ rh~.,i.~i.n;
FIG. 22 is a ~;lossec-~ional view of the csllulle~ appaldLus taken along line 22-22 of FIG. 7;
FIG. 23 is a c,ossecLio~l view of the ca,Lunel a~palalus taken appro~tim~t~ly along line 23-23 of FIG. 5;
FIG. 24 is a ,_,~,s~eclion~l view of the CalLol~l ap~aldLu~ taken approxirnately along line 24-24 of FIG. 5;
FIG. 25 is a c,os~P~Iion~l view of the cartoner appsalaLus taken approxirnately along line 25-25 of FIG. 5;
FIG. 26 is a top view of a loader arm assembly;
FIG. 27 is a colllbined side and end view of a pushing face;
FIG. 28 is an end view of the loader arm assembly taken along line 28-28 of E:IG. 26;
nG. 29 is an end view of a loader arm guide;
FIG. 30 is a clossecli-~nal view of a loader arm assembly ol)ela~ively e~t~n~od across the article group selection and transport ~ ch~n;.~",;

SUBSTITUTE SHEET (RULE 26) ~o 94/20369 2 I 5~ 3 3 ~ 8 PCT/US94/02176 FIG. 31 is a detailed side view of the flight bar structures of the article group selection and transport mPch~l-;x,,, FIG. 32 is a top view of the loading zone of an ~lt~Prn~tive embodiment of the present invention; and S FIG. 33 is a side view of the embodiment shown in ~IG. 32 DESCRIPTION OF THE PREFEPRED EMBODIMENT

The methods and ~dlaLus of the present invention are for forming 10 stacked article groups in a continuous, high speed process. As shown in the drawings, the method of this invention is impl~"~ od via a co~timlollc motion, high-speed p~rl~ging ap~alaluS 10. The al)p~lus 10 is adjustable to provide reliable, contimloll~ and high speed p~rL-~gir~ of articles or products of V~llj~ types, sizes and qn~ntitips into packages of varying 15 types and sizes. For example, the ap~alaLus 10 is useable to load ~ dard twelve ounce beverage cans into 24(12tl2), 30(15/15) and 36(18118) pack st~r~P~1 combinations. Moreover, the process of loading beverage cor,L~ine into paperboard cartons, for example, is accolll~lished quickly and reliably, under typical hl~u~Lly tole.dllces for both coll~ill.,l and carton construction.
20 The reslllt~nt filled cartons output by the ~pal~lus 10 are of high quality and COl~i~L~ ;y, having m~x;...;~fl s~lu~,~less and ~ ..Pss for ull~ro~d storage qualities and llallspcllL~bility. ~lthl llph the embo~ rlose-SUBSr~T~iTE SHEET ~RULE ~;) WO 94/20369 S~,~S 33~ PCT/US94102176 load stacked article groups into paperboard cartons, its within the purview of this invention to process the stacked article groups in a variety of ways s~-bseql~ent their formation, including side loading, shrink wrapping, b~n~ing or having paperboard or other material formed around them.
Refe,~ g to FIGS. 1 and 2, the continuous motion calLollel assembly 10 generally co~ lises a carton supply and llal~spoll mPrh~ni.cm or stream 11, an article group selection and Lldl~ol~ ,.,t~ch~ i", or stream 12, a pair of article supply ~ eh-~ c or streams 13 and 14, a divider pl~rc.~.. "I
rl~ ", 15, and an article group Llal~r.,~ or cross loading mech~ 16.
10 These mPch~ ...c are shown to be ~ulJpullcd by a unitary frame ~uclul~c 17, although if aligned ~rùyelly~ s~ lc :iU~)pOll structures may be utilized col~ with the ~a~k;"~ of this invention.
The carton supply "~rhAi~;~", 11 is shown to be disposed pro~im~te an input end 18 of the assembly 10. Carton sleeves or blanks 25 are 15 subse.lu~ ly lla~pGllcd in a linear fashion to an output end 21 of the app~dlus 10. The article supply ~"Prh~"i~"~c 13 and 14 are also shown to be disposed at the input end 20 of the appdldlu~ 10. A f~rst portion of each article supply mf-rh~ 13 and 14 is disposed spacially parallel to the article group selection and lldl~iJJUll ~ och~ 12, and a second portion 20 merges, at a pre~ ed angle, wi~ the article group selection lldll~i~J
,.,erh~ ;lll 12 to supply ~ ,dlllS of product or articles 20 to two sep~ le positions along the article group selection and tldll~pOll IIIPChA~;CIII 12.

SUBSTITUTE SHEET (RULE 26) ~WO 94/Z0369 21~ 3 3 0 8 PCT/US94/02176 These merging ,.,~c~ni~ 12-14 are further constructed and arranged to meter individual articles 20, via a fixed flight bar arrangement, into predçtçrminrd stacked article groups 21 and 22 on the m,och~ni~m 12.
The st~rking function of the device 10 is accomplished by forming a first 5 group 21 at a low level, placing a sepa~ator or divider sheet 24 on the lower group 21 via the divider sheet pl~re~ lPçllAl~ 5, and then sim~ r~ ly forming a second group 22 dowl~L~ at a higher level and allowing the upper group 22 to slide across the divider sheet 24 by the action of the flight bars of the article group selecting Ill~Cl-A~ lll 12. In an 10 all~ . ,.~.l ;~re embo~limPnt, the second group is formed on an upper dead plate and dr~ped or otherwise deposited onto the divider sheet.
The article group selection and L~ Oll ~ rl~ 12 is di~osed adj~rent and parallel to the carton supply and transport ",PçhA~ ", 11 and extonrlc do~ . all" in a linear oliell~lion. Merged or colllbilled article 15 groups 23 are Lldl~y~ ed dOwl~l~,alll thereon in a spaced and metered fashion, each group 23 being aligned with a carton 25 traveling on the carton supply and ~ Ull ~"f~rll~i"i~"~ 11. The crossloading l--Pç1lA~ -- 16 is disposed ~ rçnt to and parallel with the second portion of the article group selection and transport ...Pch~ -.. 12, e~l. n~ and traveling lon~it~ in~lly 20 with respect to the ~lus 10. The crossloading ",P~ "i~", 16 has a plurality of loading arms which extend ~ v~lsely or pc~l,e~ rly with respect to the ~ SpOll ",Pr~ 11, 13 and 14, to move product groups SUBSTITUTE SHEET ~RULE 26) wo 94120369 PCT/US94/02176 33~8 lo 23 on the article group selection transport mPch~nicm 12 into aligned cartons 25 traveling on the carton transport mPrh,lnicm 11, thereby loading the cartos 25 with product groups 23. Preferably, each of the aforementioned mPch~nicmc 11-14 and 16 has a conveyor type structure with an endless 5 chain or belt confi~lred about roltatable drive and idler end means and ll,ovi,lg longi~ in~lly with respect to the input (I~Llcdlll) and output dow~lsLI~d"~) ends 18 and 19 of the appdld~lls 10. The mo~ ,lcllL of each ...Pch~ ... is further ~yllc~ol~cd with one another, for example by a common drive and/or gearing means.
10 Rcr~,~ling to ~IGS. 3 and 4, the method of this invention is useable to construct C~l;~ or cartons 26 co,.~ cans 20 or other articles which are disposed on top of one an~,Lh.,l or St~rl~P~. The pdp~,l,oard carrier blank or sleeve 26 is co,l~ised of leading and trailing side panels 40 and 41 foldably CO~ .;le(1 to top panel 42 and to a bottom panel 43. End panels 44 connect the top, bottom and side panels 40-43. As shown, the carrier 26 co"L~h~s a bottom layer or sub-group 21 of articles, shown for purpose of illustration as beverage cans 20, and an upper layer or sub-group 22 of cans in stacked relationship. The lower ends of the upper cans 22 are ~uppoll~d on a thin, paperboard divider sheet 24 (also l~Ç~ d to as a base or ~u~l)OlL
20 sheet) with the bottom cans 21 resting on the bottom panel 43. An eYt~n~ic)n tab located on the medial edge of the sheet 24, and which folds down via a ,c.Çul~Lion or scoreline is preferably provided to help stabilize the divider SUBSTITUTE SHEET (RULE 28) ~wO 94/20369 21 ~ 3 3 0 8 PCT/US94102176 sheet 24. The extension tab provides a means for holding the sheet 24 stable while the upper layer of cans 22 are pushed onto the separator sheet 24.
Once the cans 23 have been all ~lopPlly positioned the sheet 24 is held in place by guides on the appaldLus 10. The top panel 42 is disposed closely S adj~rent, and preferably is in contact with, the top chimes 43 of the upper level 22 of cans to provide for a tight fit beL~ the cans 20 and the carrier 25. ~lthnllgh the a~l)dldLus 10 shown in the drawings is utilized in a beverage can calLonillg operation with ~ape.lloald carrier sleeves, mt~ rir~t;ol~ co~ with the te~rhin~c of this invention may be made to 10 p~r~e various other stacked conLail~ls or articles. In various carrier CO~l~ulahOllS or to p~rk~e the article groups via shrink ~vla~ g, bA.-~
or the like.
R~Llling also to FIGS. 5, 6, 20 and 22, the carton supply and lldlL~l~Oll"~rrhA~ 11 is preferably a rotary type carton placer 49, such as that ~ rlose~l in U.S. Patent 4,530,686 owned by Applir~ntc' acsi~nPe. The carton e l~ illg app~d~us 49 is ~u~polled above the input end of the carton lldl~OlL ~--~ochA-~i~--- 11 by a vertically adjustable frame ~LIUCIU~ 50, and b~cir~lly lldl~Ç~lS flat carton blanks or sleeves 25 from a power m~7inP
51 to the collvt;yallce surface of the ...~-rhA.~;~..- 11, sim~ ..P~usly O~l ~lillg 20 the blank 25 so that it ACi~lllll~S a four-sided configuration with opposi~g open ends bounded by at least one flap 44 each. Illl~ul~llly, the partially erected carton 25 is placed in a llal~ e or lateral o~ )ll so that its SUBSTITUTE SHEET ~RULE 26) Wo 94l2030 PCT/US94/02176 g3Q~ 12 ends are open to the sides of the carton ~ransport mPch~ni~m 11 for loading purposes.
The carton transport conveyor 52 receives cartons or other carriers 25 from the carton supply placer 49 and transports them linearly downstream 5 with respect to the overall appald~us 10. The dowl~Ll~alll LldllS~Oll of cartons 25 is synchronized with the article group selection and Llal~Oll mPch~ ... 12 and with the cross~ ing m~.h~ 16, as described further below, to effectuate carton 25 loading. ImpolL~nLly, the carton conveyor 52 is adjustable to ~rc~l...-.o~l~te cartons 25 of varying types and sizes. Rer~.lillg also to FIGS. 9, 10 and 22-25 in particular, the carton Llal~OlL conveyol 52 basically colll~lises a plurality of flight lugs 56 which are co..l~f~-lrrl to a pair of flight chains 181 and 182, the flight chains 181 and 182 being CQIIllf'e~ to and revolving about drive and idler ends 53 and 54. ~Ithough a pair of lugs 56 is shown, the llulllbC. of lugs 56 per carton 15 25 may be varied for all~ live carton configurations. The lugs 56 are shown to serve a dual purpose in t_at they are disposed anterior with respect to a particular carton 25 for control and stabilization ~ oses, while the pair 56 which is disposed posterior to the carton urges the carton 25 rul~vdld on the cGllvey~l ...Pch~ ... 52. The lugs 56 are preferably col~ll~~;led of nylon 20 or a similar material. The lugs 56 are ~tt~rh~ to the flight chains 181 and 182 via lug bases. The flight chains 181 and 182 are ~u~pol~d at the top or rul~v~d run of the collv~yol 52 by chain guides 183. The chain guides 183 SUBSTITUTE SHEET (RULE 2~) _Wo 94/20369 PCT/US94/02176 ~ 13 21S~3~

are col,llP~-led to the main frame 17 via guide supports 184. An elongated, longil~-~in~lly e~tt?n~ing return guide 185 is disposed along the bottom run of the conveyor 52 and mates with a notch in each lug 56 to stabilize their return during high speed operation. Additionally, a longit~l~in~lly oriented 5 slide rail (not shown) may be disposed between the flight chains 181 and 182, level with the hol~ollLdl plane of the chain guides 183, and with a low-friction top surface to ~u~)l)ûl~ the bottom of each carton 25 on the conveyor 52. The width-wise or Llal~ e spacing b~L-.~ell lugs 56 on the parallel, side-by-side chains is preferably variable via a Lldl~ se lug adjl~stmPIt 10 Ill.~rh~ ", ,Althr.-lgh a single pair of flight lugs 56 is shown, an ~ , IIA~
~LIu~;Lul~, may be col~LlucL~,d with phase a~ ct~hle leading and trailing flight lugs, as is known in the art. This phase adj..~ is desirable to permit the a~alaLu~ 10 to be used with various carton cor1fi~-rations to allow for adj~ .l of carton ~l,ac~ beL~ , for example, 6 and 12 inch, on center ~ gf l.~ x to convert the al,p~aLus 10 from 6 to 36 pack ~loces~i.. g.
R~r~l;u~ to FIGS. 5, 10 and 14-17, the a~aldLus preferably inr.ln(1es a carton stabilization sLluL;Lure 28 which ~u~OlL~ the tops of the relatively tall, bi-level cartons 25 traveling on the carton supply and transport ~ ch~
11, particularly during the loading phase of operation. The carton stabilization structure 28 b~xic~lly co~ lises a pair of ~,.llead rails 191 and 192 COII.If~ to vertical and holi~ul~Ldl ~uppOIL ".~...h.,l~ 193 and 194 which are linked via ~dj!~XI~ ch~;x~ 195 ~u~polLed by posts 196. A

SUBSTITUTE SHEET (RULE 26) WO 94l20369 2~.~33~ 14 PCT/US94/02176 carton sleeve set up guide assembly 197 is also preferably disposed anterior to the carton stabilizer 28 and immPrli~t~ly do-wl~Ll~alll of the point of initial pl~rernPnt of the sleeve on the conveyor 52 by placer 49.
Referring to FIGS. 5, 6 and 13, the first or low article supply 5 ...Pc~ .., 13 provides a plurality of input individual articles 20 to the ap~alaLus 10 at a first pre~1~tf .,.;.~r~l level or height and at a pre~ete~ ;..P~l point on the article group selection and Llal~oll ...P~h~ 12. The mPch~ ... 13 is shown to colllylise a conveyor 60 disposed about a drive sprocket/shaft assembly 61 and an idler sprocket/shaft assembly 62. The 10 collvcyor 60 preferably Cul~isL~ of a unitary, belt. Articles 20 Llal~ulL~d on the top, Ç~ vald run of the conveyor 60 are s~u~aLcd into a plurality of single file paths by lane sepalatol~ 63. Each lane se~ator 63 is shown to be an u~s~ plate of a height ~urrlciellL to guide the flow of one or more collLah~ls 20 on the col-veyor 60, and which is sllcpen~iPcl above the 15 conveyor 60. The lane se~atfjls 63 form product coL.vt;y~ce lanes which angle towalds the article group selection and coliv~y~lce ~-.~ch~ ... 12. An approach angle of a~r~ Ply 20-25 degrees wi~ respect to the lon~it~iin~l axis of the l~Prh~";~", 12 has been found to provide optimal product group selection results. The conveyor 60 is disposed parallel with 20 and immPfii~trly pro~im~tr to the article group selection and Ll~OlL
cc,llvcyor 12 to allow for article movement Ll,~ ,in~e~wcen. A low friction, dead plate having angled lane grooves which co.lc~ùlld with the lane SUBSTITUTE SHEET (RULE 26) ~WO 94120369 21 ~ 3 pcTluss4lo2l76 Sey~atOlS 63 is preferably interposed at the interface between the conveyor 60 and the transport ,-,~cl~Ani~"- 12. Each lane s~ardtor 63 has a terminal portion 64 of a predeterrninP~ length, such that it extends into the path of the article group selection and transport m~ch~ni.~m 12 a fli~t~nre approximately 5 equal to one-third the width of the ~ hAI~;~... 12 conveyance path. Each l ~ .-,i,.~l portion 64 is co~ ed such that it allows longihl~inAlly transported flight structures 74 (described further below) of the article group selection and ~dlL~yUll ",~çhA.,i~", 12 to pass through the angled conveyance lanes. As the flight bars 74 mesh with and pass through the lane sep~ator 10 end portions 64, they engage articles 20 disposed in lanes and rake them onto the lon~ihl-linAl c~ ,e~dllce path of the ..-~çh~ .... 12 and be~ n A-ljacent flight bars 74.
The c~Jlllbilldlion of forces exerted by the flight bars 74, lane ends 64, and CO~l~tyOl~ 60 and 12 serve to select and meter individual articles 20 into 15 pre~ article groups 21 which are fully merged onto the _rticle group selection and l~ lL ",~rhA~ ", 12. The size, ori~,.lL~Iion and f~ f..~ion~ of the reslllt~nt product groups 21 is clep~n~lent upon the ll~ ber of infeed lanes, product fl;-.-l~n~ion~, and the configuration and s~ g of the llight bars 74. For example, in the instant embo-lim-~nt, six (6) lanes of - 20 product are active, and the flight bars 74 are spaced such that the reslllt~nt product group 21 is select~cl of eighteen (18) articles in three rows of six cans each. Lanes may be blocked off by closure means 67 to alter the group SUBSTITUTE SHEET (RULE 26~

2~3Q8 16 21 size and/or oricll~lion. The lane separators 63 and the flight bars 74 are adjustable to provide full variability of product group pdldll~eLel~.
The low article supply mPçh~ni.cm 13 is shown to terTnin~t~ at its infeed end 18 for mating with a comple,.,~ ,y external a~p_la~us, for example an 5 additional infeed conveyor or conveyors. Alternatively, such infeed conveyor may be hll~laLcd with the appalalus 10. Further, although this embodiment utilizes collvcyance lanes which are initially oriented parallel with the rçrn~ining cl~ of the a~aralus 10 and subsequently angle t~wards the article group selection transport ...PchA~ ...12, it is possible to 10 provide an infeed conveyor that is entirely angled as such.
The article group selection and llal~OlL ...Pch~ ... 12 selects article groups 21 and 22 from the first or low article supply IIlP~lA..;~... 13 as set forth above and from the second or high article supply ".Pç~ .-- 19 sed below, and llal~oll~ them linearly dowl~llc~ll with respect to 15 the overall ~lJalaLus 10. The dowl~ ,alll Llalls~oll of article groups 21 and 22 is ~yllcl~ro~ t;d with the carton supply and transport ",~h~"i~", 11 and with the crosslo~iing IllP~'hAll;~ l 16, as desclil~ed further below, to ~rrt~ carton 25 loading. RPferring also to FIGS. 7, 21 and 22, the article group selPctin~ and ll~s~ mP~ ... 12 generally colll~lises a 20 conveyor 73, a plurality of flight bar assemblies 74 fL~ed to and longih-tlin~lly Llal~ollcd on the collvcyor 73, and a plurality of slide plates SUBSTITUTE SHEET (RULE 2~

Wo 94/20369 PCT/US94/02176 ~ 7 21~33~

75, which are disposed on the conveyor 73 b~LwGen the spaced flight bars 74.
The conveyor 73 runs at a predeterrnin~ speed and inrl~ es a drive sprocket/shaft assembly 76 and an idler sprocket/shaft assembly 77, a pair of 5 parallel endless conveyor chains 78 which are CO~..-P~;~r~ to and revolve about the sprocl~LJshaft assemblies 76 and 77, follmng a longit~ inAlly ex~ g forward or top run 79 and a return or bottom run 80. Idler assembly 77 is disposed just anterior to the area where the first or low article supply ...PçhA.~;~... 13 merges with the article group selection and 10 transport Ill-~lAl~;~lll 12, and marks the beginning of the conveyor 73. The drive s~loc~L/shaft assembly 76 is di~posed ~jacent the end of the crossloA-lin~ chA-~ 16 and marks the end of the collvGyor 73. The collvGyor chains 78 are each ~ul~polLGd by top and bottom longit-l-lin~lly ~rt~nrling chain guides 81, which in turn are col-nPcl~ to the main frame 17 15 via ~y~ illg conveyor ~uyyOlL~ 82.
Rer~lillg also to FIG. 31, the flight bar assemblies 74 are each shown to include a top rail lllc.~er 83 and a bottom rail ~........ .~ker 84 which are co~ cte~ to one ano~llel by vertical spacers 85. The top and bottom 83 and 84 are shown di~osed parallel to one alluL.,l and SPAC;~11Y
sepalalGd by the spacers 85. Each top and bottom .. ~.. l~,er 83 and 84 further has an angled front end 150 and an elongated, rectilin~Ar body 151 ;llA~ in a flat back end. The front end 150 slants or angles inwardly SUBST~TUTE SHEET (RULE 26) Wo 94/20369 PCT/US94/02176 from its leading edge to its trailing edge to enable the flight bars 74 to select individual articles 20 disposed in the article infeed lanes and to separate them from the closely spaced nearest upstream article 20. As is best shown in FIG. 7, a pair of fKed slide plates 152 and 153 are connPct~l to each flight bar 74 assembly. Both the flight bars 74 and the slide plates 152 and 153 are Collllf~ to the flight chains 78 via connection blac~c~ 86. The slide plates 152 and 153 are thin, flat structures with a low friction top surface which support the lower article groups 21 and further permit sliding mo~.llcll~ thereon. Additionally, slotted slide plates 154 are disposed btlwcen ~(ljacf .~t flight bar assemblies 74, each plate 154 in- luding a laterally olic.l~d siot 155.
The height of the flight bar 74 (i.e., the sep~,~t;on ~~ e bc~ the top and bottom ...f~ h~,~ 83 and 84) is a function of the co~ Pi and CO~.Iil;l~f-~ group size and confi~lr~tion. For example, taller cans (12 oz.) 15 re~uire greater flight bar 74 height than a short can (10 oz.), for proper selPctiol- and ~ /Ul~. The width of the top and bottom lllclnbe~ 83 and 84 is a function of the desired r~ iu..~ of the product groups 21 and 22 formed. It is within the purview of this hlvell~ion that the flight bar 74 height and width be fully adjustable to accomm~ t~ various cc,ll~hl(,l and 20 group p ~
As is best shown in FIGS. 7, 8 and 21, a group stabilization ~LIUL;IU~e 161 inr~ ling a pair of lon~h~ in~lly oriented upper and lower guide rails SUBSTITUTE SHEET (RULE 28) ~WO 94/20369 PCT/US94/02176 19 ~ 3 ~ ~

162 and 163, and lateral adjll~tmPnt structures 163 is disposed on the outer or lateral side of the article group selection and LldlL~pu~ mPch~ni~m 12.
The lower guide rail 162 extends from the upstream end of the mlochAn;!i", 12 to a point anterior to a point on the m~çhAni~m 12 at which the upper 5 group 22 is formed. The upper guide rail 162 extends throughout the region on the article group selection and Lldl~oll ",~chA,.i~", 12 at which the upper group 22 is formed. The upper and lower rails 162 and 163 are disposed at predeL~,~.nilled vertical levels, beLweell the upper and lower members 83 and 84 of the flight bars 74, to contact the base and upper article sub-groups 21 10 and 22 l~,SpC.,Liv~ly. The lateral eYt~n~ion ~lictAn~e of the rails 162 and 163 is adjustable by means of the lateral a~ L~ ;lules 164 for varying article group 23 sizes.
Refellil.g to E~GS. 5 and 19 the divider plAr~ .PrhA";~", 15 deposits a divider sheet 24 on the top suRace of lower or base article group 15 21 formed and traveling on the article group selection and Lla~O.
",~rhA.,;~." 12. The divider pl~ ."r"~ chA--i~-ll 15 is shown to be di~osed above the article group selection and Llal~spull ,n~ell~";~." 12 at a pre~3e~ 1 point dOwl~Ll~ from where the base article group 21 is first fully formed. The divider P1A~ rhAII;~ 5 preferably - 20 COlll~)liSCS a rotary placer .. Pch~ .n 92 of the type .. -A-.--r~ ed and sold by Applicants' a~i n~e and having a pair of apex positions with vacuum control llltlll~ 94. A power mAg~7inP 93 is shown op~,lalively CO--..fCI~l SUESTITUTE SHEET ~RULE 26) .

3~ PCT/US94/02176 to the placer 92 to provide a continuous supply of divider sheets 24 thereto.
Although a rotary-type placer is yl~fe~led for divider sheet plArem~nt other plA~e n~t means may be substituted to practice the basic method of this invention.
S Refe.li,lg again to FIGS. 7, 8 and 21, a divider hold down assembly 168 inr!urling a pair of medial and lateral rails 169 and 170 and adj~ .f -l structures 171is di~osed above a se~ "l of the article group selection and Ll~ol~ h~ni~,,, 12, e~t~n~1ing dowl~LI~,alll from a point immPrli~t~ly posterior to the point of pl~re n~t of the divider sheet 24 by the placer 92.
10 The medial rail 169 has a AntP~rior se~.l which in~ le5 a top h, 169 with an u~lullled fOlv~al-l Iip 174 and a side ..~ e, 173 with a plow confi~ l ;oll, and a rail shaped posterior se~ 175. This confi~-~-, l ;o.- is ~lecignPd to engage and fold down the medial flap on the divider sheet 24, formed by a pc;lrulalion or scolelille, and to hold the flap down over ~he 15 medial edge of the lower article sub-group 21 to stabilize the position of the divider sheet 24 during dowl~Ll-,al,l Llal~oll and lateral lllov~lllellL of the upper article sub-group 22 across the divider sheet 24 top surface. The lateral rail 170 extends a pre(~ ict~nre dOwl~Ll._alll to stabilize the lateral edge region of the divider sheet 24 prior to lateral merging of the 20 upper group 22 across the divider sheet 24. The ~Llu~;lul~; of the divider hold down assembly 168 has been shown to yield a ~ul)sl;~..l;Ally flat divider sheet 24 for illlyl~v~d article group 22 lll~ lg lh~,leacross, especially in SUB~T~JTE SHEET (RUEE 26) _Wo 94/2036g PCT/US94/02176 ~ell,oard divider sheets 24 constructed with recycled materials which tend not to lay flat when unstabilized.
Referring again to FIGS. 5, 6 and 13, the second or high article supply IllPch~ lll 14 provides a plurality of input individual articles 20 to the 5 ily~aldlUs 10 at a second preclç~el .I.i..~d level or height and at a predç~ cl point dow.~L e~l~ from the low article supply Ill~Ch~ lll 13.
The "~lorh,l..;~." 14 iS also shown to co--,ylise a pa* of conveyors 100 and 101, each being disposed about a drive sprocket/shaft assembly and an idler sprocket/shaft assembly. The COnvt;y(il~ 100 and 101 may consist of a 10 plurality of individual tracks or paths or ~ ivt;ly a unitary, wider path or belt. Articles 20 tlal~ull~d on the top, fOl~va~ run of the conveyors 100 and 101 are sepz.i1lP~ into a plurality of single file paths by lane sep~a~uls 102. Each lane sep~alor 102 is shown to be an l~pst~n~ling wall of a height ~..rrir;p~ll to guide the flow of one or more co..l~ 20 on the collveyol~ 100 and 101, and which is sllcpçn~l~d above the co.. veyo~s 100 and 101. The lane S~y~t~l~ 102 form product co~v~allce lanes which angle tO~valds the article group selection and cG..vc;y~lce ,nP~ l 12 at an approach angle of apL,l~,~i..lately 20-25 degrees with respect to the longi~ in~l axis of the ,.,çç~ ,l, 12. The Coll~t;yc,l~ 100 and 101 are ~ 20 disposed parallel with the article group selection and tl~lSpOlL COllveyOl 12.
Conveyor 101 is further disposed ;.. ~ç~ ely adjacent the article group selection and Ll~s~Olt collv~yol 12 to allow for article 20 movement SUBSTITUTE SHEET (RULE 26) Wo 94/20369 ~ PCT/US94/02176 '3 22 the,ei~,between. A dead plate region is also preferably ~Itili7P(l Each lane scpald~or 102 has a terrnin~l portion 103 of a p~A~Ir.~inPd length such that it extends into the path of the article group selection and L~dn~
IIIPGh~ ... 12 a predetermined ~ict~n~e. Each telll i.lal portion 103 is S CollsLluc~t:d such that it allows the longi~ in~lly L,dl~yO.l~d flight structures 74 of the article group selection and Ll~ oll ",Pç~ ", 12 to pass through the angled co,l~eyance lanes. As the flight structures 74 mesh with and pass through the lane se~aldtor end portions 103, they engage articles 20 disposed in lanes and rake them onto the longit~l~lin~l conveyance path of the 10 "~çl-~ ", 12.
The co,..bi~tion of forces exerted by the flight bars 74, lane ends 103, and co,.~, u,~ 100, 101 and 73 serve to select and meter individual articles 20 into p,~A~ upper article groups 22 which are merged onto the divider sheet 24 on top of the lower or base article group 21 traveling on the 15 article group selection and Lldl~lJGll ~ oc~ 12. The size, oli~ ion and ~ he~al rl;.. -~ions of the reslllt~nt upper product groups 22 is ~epe~ ont upon the llulll~e~ of infeed lanes, pl'oslu~;L ~ eions~ and the configuration and spacing of the flight bars 74. The divider sheet 24 provides a low friction base surface upon which the upper group 22 is 20 L,a~ sely, slidably moved to form a stacked group 23. Lanes may be blocked off by closure means 104 to alter the group 22 size and/or SU8STITUTE SHEET (RULE 26~

~Wo 94/20369 PCTIUS94/02176 2321!~3~

orientation. The lane s~al~tols 103 and the flight bars 74 are adjustable to provide full variability of product group paldllletel~.
Refe.lu~g to FIGS. 32 and 33, a portion of an altc.n&tive embodirrtent of the stacked article cartoning apparanls 205 is shown wherein upper article sub-groups 206 are deposited on the top surface of divider sheet 207 on lower article sub-group 200 to form a stacked article group 209. In this embo-limPnt, an upper stream 210 of article sub-groups 206 is disposed above and in lon~ihl~in~l ~lignmPnt with a lower stream 211 of article sub-groups 208. The upper stream 210 is shown to include a dead plate 212 across which the upper article sub-groups 206 are moved by the action of upper pusher bars 213. The lower stream 211 in~ltldPs a conveyor 214 and flight bars 215. As shown, the upper article sub-groups 206 are dr~ed dhe~Lly, vertically on top of the divider sheet 207 as they move over the le~ l edge 216 of the dead plate. T~ngi~ in~l movement of the upper and lower article sub-groups 206 and 208 is s~llcl~rol~ed.
The article group lateral Lla~r or crossloading ,.,~çh~ lll 16 is ~yllcl~o~i~d with the afo,~ Pcl a~p~aluS 10 el~mPnt~ to move completed, stacked article groups 23 traveling on the article group selçctio~
and lla~yOl~ conveyor 12 into aligned cartons 25 Lla~ g on the carton supply and Llal~ conveyor 11. R~r~ ";llg to FIGS. 7, 18, 22 and 26-30, the crosslo~1ing IllPch~l~;xlll 16 basically colll~,lises a plurality of loader arm assemblies 110, a flight chain and guide tube assembly 111 to which the SUBSTITUTE SHEET (RULE 26) Wo 94/20369 PCT/US94/02176 ~5~3~ 24 loader arm assemblies 110 are att~rhPd at predeterrnined intervals, and which provides a longihl~lin~l movement component thereto, and a control cam assembly 112 which provides a predet~ h~ed transverse motion component to the loader arm assemblies 110.
The flight chain and guide tube assembly 110 has a fOl~val-l or top run 113 and a return or bottom run 114 and culll~lises drive and idler sprocket/shaft assemblies 115 and 116 and a pair of spa~i~lly parallel flight chains 117 and 118 which are co,..,F~lrd to and revolve about the sprocket/shaft assemblies 115 and 116. The flight chains 117 and 118 are 10 m~ in a rectilin~r configuration on both the top and bottom runs 113 and 114 by chain guides 119 and 120, which are linked to the frarne 17 via vertical support ..~ ,s 121.
Pairs of elongated guide tubes 122 are di~l osed at pre~l~L~ d intervals along the flight chains 117 and 118, each guide tube 122 being lS di~ ly co~ F~ d at one end to the outer flight chain 118, and at its opposiLe end to the inner flight chain 117 so that they are oriented Llal~v~l~ely with respect to the axis of the a~ aLus 10 and to the dowl~Ll.,alll or fol ~va~ run of the crossloader 16. The guide tubes 122 have a low friction exterior surface to provide slidable support of the loader arm assemblies 110. The pairs of closely spaced tubes 122 increase the stability of transverse mov~ ,.lL of the arm assemblies 110. Further stability is ~in.od by the guide blocks 123 (co~ cl~d to the inner ends of the guide SUBSTITUTE SHEET(RULE 26) _WO 94/20369 PCT/US94/02176 21~'33~

tubes 122 via set screws) traveling in a longit~ in~lly oriented guide rail 124 which is linked to the frame 17 via a support 125. As best shown in FIG.
29, lateral retainers 126 are mounted on the top of each guide block 123 to guide the transversely moving arm assemblies 110. The spacing between 5 successive sets (pairs) of tubes 122 corresponds to the spacing beLween the flight bars 74 of the article group selection and Llal~lJull conveyor 12 and of the flight lugs 56 of the carton ~lal~oll coll~yor 11 so that the arm assemblies 110 are aligned to push product groups 23 from beLw~en the flight bars 74 into the cartons 25.
10 The loader arm assemblies 110 are movably mounted on the guide tubes 122, and in a ~ .,.se orientation with respect to the axis of the &ppa~aluS
10. The arm assemblies 110 are conveyed in a dOwl~Ll~,alll, lorlgit~ in~l direction while they ~im-llt~n~Qusly reci~locate in a Lla~ e direction under the control of a cam mPr~ 112 described below. Each loader 15 arm assembly 110 basically colll~lises an elnng~t~l, rectilinP~r base plate 127 and a loading head 128 located at one end of the base plate 127. The base plate 127 is shown to have a rigid, flat, elor~g~t~ Lluclule which is oriented h~ ullL~lly. A rigid stiffing bar 129 is co....~cled to the top surface of the base plate 127, vertically oriented, to hl.;l._ase the rigidity and 20 ~Ill~lh of the arm assembly 110. Preferably, a plurality of bores are tisposed in the stiffing bar 129 to reduce its weight. The inwardly disposed end of the base plate 127 is slidably su~oll~d by the lateral l~Lain~l~ 126 of wO 94/20369 PCT/US94l02176 ~ 3~ 26 the guide block 123. A first or outer bushing block 130 is connected to the bottom of the base plate 127 at its upl)osiL~ end. The first bushing block 130 has a pair of apcl~ules, inrll-ding bushings, through which the guide tubes 122 are slidably extended. A second or inner bushing block 131 is sim~larly S co~ c~cl to the base plate 127 and interfaces with the guide tubes 122 a short ~ e from the first bushing block 130. The bushing blocks 130 and 131 are further col-neclPd by a spreader bar 132 which is oriented and rides in the space b~Lween the guide tubes 122. A rotatable cam follower 133 is connPcted to the bottom of the spreader bar 132. The l~ y traveling cam follower 133 COOl)ClaLt;S with the cam guide assembly 112 to cause the arm assembly 110 cle ..- ..lc to ~ ely reciprocate on the guide tubes 122 and through the lateral ret~inprs 126 of the guide block 123.
The loading head 128 is shown to have two fixed, flat face ...~...hc,~ 134 and 135. As the arm assemblies 110 move folw~d, the face Illrllllle.~ 134 15 and 135 push the article groups fo,~v~rd from the article group selection Ll~S~ul~ COllV~;,)/Ol 12 into the cartons 25. A su~Gll roller 144 is disposed on the bottom of the head 128 to provide su~ull when the head 128 is elrten~lP~l across the article group selection and ~ Ol~ l..Pch~ m 12.
Additionally, a t-shaped guide pin 145 is di~posed on the bottom of the base plate 127 of the arm assembly 110 to mate with the slot 155 in slide plate 154 to laterally stabilize the arm lll~-llbe~ 110 during high speed operation.
The loading head 128 configuration is variable to ill~lr~ce with a wide range SUBSTITUTE ~nEE~ (RULE 26) ~ro 94/2036g 21~ 3 ~ Q 8 of product group 23 configurations. Although in the instant embodiment the head 128 is configured for use with a stacked configuration, the head 128 can be modified for cartoning various other product and product group a,lange",~r1t~, including non-stacked configurations. Head 128 mo~ifir~tion S is accol"l-lished by cha,.ges in the configuration of the face Illclll~-"a 134 and 135. A tr~nCition conveyor 29, shown in FIGS. 2 and 22, is di~osed bclv~ the crossloading ",Pchi.";~... 16 and the carton llal~Oll ...Pch~,.;~...
12 to provide a ll~)Viug base for the movelllellL of the article groups 23 into the lon~ihl-iin~lly collvcyed cartons 25. A fixed dead plate may ~ ;vely 10 be used. The bottom ~ ...hel 84 of the flight bars 74 is elo~g~tPcl to extend across the top run of the transition collvcyor 29 to guide or funnel article groups 23 across the coll~or 29 and into the cartons 25, ~ ll the carton end panels 44.
The loader control cam assembly 112 controls the Llal~ e, reciprocal motion of the arm assemblies 110. The loader control cam assembly 112 is generally oriented longit~ in~lly with respect to the overall crosslo~ing ~"~r.h~";.~;"~ 16, and has a top or fOlwaid run 136 and a bottom or return run 137 col~ ollding to the revolving arm assemblies 110. The top run 136 bSlcir:llly CollllJliSe.S an inwardly sloping a~ioach se~...P .I 137, an apex 138, 20 and an ou~w~dly sloping return seE...~ .I 139. In the approach se~ r .l 137, the cam follower 133 is urged inwardly, and drives each arm assembly 110 into moving ell~agclllcllL with a product group 23 until it is loaded in a SUBSTITUTE SHEET (RULE 26) Wo 94l20369 PCrlUS94/02176 _~, ~ 33~ 28 carton 25. A lag segm~r~t 146 of decreased slope is disposed at a pre~eterTninPd point where the loading head 128 first contacts the article group 23 to provide gentle, even ~les~ul~ at this initial contact point. In the return segm~nt 139, the face 128 is retracted from the carton 25 prior to its being reset in the return run 137 of the cam assembly 112. The forward run 136 of the cam assembly 112 co~ lises an outer rail 140 and an inner rail 141 which is spaced from the inner rail 140 a ~ re equivalent to the of the cam follower 133. The follower 133 is di~osed in a cam pathway formed beLwt;en the outer and inner rails 140 and 141 to efÇ~ uate L~ ,e.~e, inward motion to the arm assemblies 110. Preferably, the outer rail 140 is co~nPcted to a pivot point 142 at one end and to a release ,..Fch~ ..., such as a pre,,~uic release cylinder and piston 143 proxil"al~ its o~o~iLe end. The release ",~rh~ni.~", 143 is controlled by a sensing ",Prh~ ..., for example, a photoeye or capacitive ploxillliLy sensor, such that if an excessive force is placed on the outer rail 140, for example due to a j~--",-;--~ of the arm assembly 110, the relezse ~rCh~ 143 will be the outer rail 140 which pivots about point 142.
The bottom or return run 136 of the cam assembly 112 inrl~ es circular guide plates 148 and 149, and a bottom cam rail 147 which contacts the cam follower 133 to further retract and reset the loader arms 110 for further loading cycles. Since the loader arms 110 are s~lbst~nti~lly e~trn~1e~ when they revolve around sl,rocl~t/shaft assembly 115, it is critical that they be SUBSTITUTE SHEET ~RIJLE 26) ~o 94l20369 2 1 ~ ~ 3 Q ~ ~tUS94/02176 s~abilized by the guide pin 145 in slide plate 154 groove 155 during high speed operation.
As shown in FIGS. 2, 6, 7, 9 and 23, lateral and medial flap tuckers 30 and 31 are disposed ~ cent each side of the carton Llalls~oll mPch~nicm 11, 5 one anterior to the loading region to provide a closed carton b~kcide against which the loaded containers may nest, and one posterior to the loading region to allow article group 23 ingress to the carton 25 through its open, n~lnP~ end flaps 44.
Referring to FIGS. 1 and 12, an overhead carton s4ua~ g station 33 is 10 shown di~osed ;.".~.P~ ely dowl~ ll of glue ~ I;n~ 37, immPtli~tely above the carton supply and ll~GlL mPçl~ n~ 12, and e~ a pre~ g lonf~ flin~ l;."re dOwl~ ll. The overhead station 33 assists in m~int~ining the s4ual~ ess of the loaded cartons. The overhead colll~l~,ssioll station preferably co~ lises an endless chain 201 with a 15 plurality of vertical lugs 202 having a bottom dOwl~ ll run of a pred~ ....inP-l lon~itll(1in~ nre and being disposed a pre~ e~ ",i~
vertical ~ L;~ e above the article ~ OlL collveyor 12. The vertically disposed lugs 202 have a pred~ lllLuled configuration such that they aid in ~..~i.-l~;..;-.~ the s.lual.,ness of the cartons 26. One or more cc,llll)iession 20 belts (not shown) may additionally be added for p~c~ge control l~ul~oses.
As shown in ~;IGS. 1, 6, 24 and 25, gluing, side colll~l~ssion and dischalge ..~Pçh~ 32 and 37t 34 and 35 are disposed collseL;uliv~ly, SJ IBSTITUTE SHEET (RULE 26) Wo 94/2Q369 PCT/US94/02176 ~S3~0~ 30 ~

further dow~ and ~cl3~rent the carton supply and transport mPch~nicm 11 to complete the carton flap se~;u~ L process.
As many changes are possible to the embo~limPntc of this invention ~ltili7.ing the tP~ching.c thereof, the descript~ons above, and the arcQmr~nyingS drawings should be i.lleI~ ed in the illustrative and not the limited sense.

SU8STITUTE SHFET ~RlJLE 2~)

Claims (14)

WHAT IS CLAIMED IS:

1. A method for forming stacked article groups, comprising the steps of (a) supplying at least two streams of articles, each at a predetermined vertically distinct level;
(b) forming and longitudinally transporting a stream of first article groups at a first level;
(c) placing a support base on a top surface of each said first article group, said support base being substantially flat and having at least one flap member disposed along an edge thereof, said flap member being foldable over an edge of said top surface of said first article group; and (d) forming a second article group at a second level on top of said support base of each said longitudinally moving first article group, whereby stacked article groups are formed.

2. The method of claim 1, wherein two article streams are supplied, a first said article stream being supplied at a first longitudinal position, and a second article stream being supplied at a second, distinct longitudinal position, said first article group being formed at said first position, said second article group being formed at said second position, and said support base being placed at a position between said first and said second positions.

3. The method of claim 2, wherein said support base has a thin, substantially flat, rectilinear configuration with a - Page 1 of Claims -surface area substantially coextensive with that of the top surface of said first article group.

4. The method of claim 3, wherein said support base further has a flap member disposed along one base edge and defined by a scoreline, said flap member being foldable over one edge of the top surface of said first article group.

5. The method of claim 3, wherein said support base is constructed of paperboard.

6. The method of claim 1, further comprising the step of stabilizing said support base on its operative top position on said first article group

7. The method of claim 1, wherein said infeed articles are further segregated into at least two rectilinear article lanes.

8. The method of claim 7, wherein said article lanes intersect said longitudinal stream at a predetermined angle and wherein said first and second article groups are formed by being raked from said article lanes.

9. The method of claim 1, further comprising the step of placing said stacked article groups in cartons.

10. The method of claim 9, wherein said cartons are provided in a longitudinally oriented stream, synchronized with - Page 2 of Claims -said stacked article groups, and further have open ends facing said stacked article groups.

11. The method of claim 10, wherein said stacked article groups are placed into cartons by laterally loading them into open sides of the cartons.

12. The method of claim 11, wherein the carton is constructed of paperboard and includes an outer structure with top, bottom, front and rear sides, and open ends bounded by end flaps, and wherein the articles are beverage cans.

13. A method of continuously loading cartons with stacked article groups having upper and lower sub-groups of at least one article, comprising the steps of:
(a) supplying an input stream of articles at a first location;
(b) selecting articles at said first location to form a lower article subgroup;
(c) transporting the lower article subgroup longitudinally to a second location;
(d) depositing a base structure on said lower article subgroup prior to its arrival at said second location;
(e) supplying an input stream of articles at said second location;
(f) selecting articles at said second location to form an upper article subgroup on top or the lower article subgroup, which is slidably moved across said base structure, to thereby - Page 3 of Claims -form a stacked article group;
(g) longitudinally transporting said stacked article group;
(h) supplying and longitudinally transporting a carton in spacial synchronization with the stacked article group; and (i) laterally transferring the stacked article group into the longitudinally transported carton.

14. A method for forming stacked article groups, comprising the steps of:
(a) supplying at least two streams of articles, each at a predetermined vertically distinct level and predetermined longitudinally distinct position;
(b) forming and longitudinally transporting a stream of first article groups at a first level;
(c) placing a support base on a top surface of each said first article group; and (d) forming a second article group at a second level while slidingly moving articles over said support base of each said longitudinally moving first article group, whereby stacked article groups are formed.

- Page 4 of Claims -