EP3317187A1

EP3317187A1 - System and method for forming a foldable package housing individually wrapped articles

Info

Publication number: EP3317187A1
Application number: EP16818654.2A
Authority: EP
Inventors: James William WOLFF; Josef VRANA; Yoichiro Ishikawa; Gabriela FRATTA; Dennis Rybolt; Justin Nunez
Original assignee: WM Wrigley Jr Co
Current assignee: WM Wrigley Jr Co
Priority date: 2015-06-30
Filing date: 2016-06-29
Publication date: 2018-05-09
Anticipated expiration: 2036-06-29
Also published as: EP3317187A4; CN107709171B; EP3317187B1; CN107709171A; WO2017004163A1; PL3317187T3

Abstract

A system for forming a foldable package is provided. The system includes a first conveyor device includes at least one lug that defines a first slot and a second slot on opposing sides of the lug. The first slot is sized to receive a first set of individually wrapped articles and the second slot is sized to receive a second set of individually wrapped articles. The first conveyor device is configured to advance the individually wrapped articles towards a loading station. The system further includes a feeder device configured to position a sheet of packaging material over the individually wrapped articles at the loading station. The sheet of packaging material is for coupling to the individually wrapped articles. Moreover, the lug has a width such that a predefined distance is defined between the first and second sets of individually wrapped articles when coupled to the sheet of packaging material.

Description

SYSTEM AND METHOD FOR FORMING A FOLD ABLE

PACKAGE HOUSING INDIVIDUALLY WRAPPED ARTICLES

BACKGROUND

[0001] The field of the present disclosure relates generally to individually wrapped articles such as chewing gum and, more specifically, to systems and methods of manufacturing a foldable package for containing a plurality of individually wrapped articles.

[0002] Packaging of confectionery products and other consumable products is important for marketing and display of the products. It is desirable to present an attractive and distinctive package with space for brand names, graphics and text, while at the same time being fully functional and appealable to the consumer for carrying. Packaging must also serve practical needs such as keeping the products from being damaged during shipping, keeping the products fresh, and in some cases providing a reusable and re-closable container, for example, when not all of the products are likely to be consumed at one time.

[0003] It is also desirable to provide a package that is convenient for use as a portable package and that may be reconfigured by the consumer into a different and more convenient format, shape or size, so that, for example, the package will fit conveniently in a pocket or purse. Further, it is desirable that the package can be reduced in size after part of the product has been consumed. It is also desirable to have a package that can reduce in size if the consumer wants to take only a portion of the package with them, for various events or for general consumer convenience.

[0004] It is also desirable to provide a package capable of displaying the products in an aesthetically pleasing manner to catch the eye of consumers and to provide generous space for branding, graphics, other indicia and textual information. It is further desirable that the package remain neat and attractive after having been opened and reconfigured by the consumer. BRIEF DESCRIPTION

[0005] In one aspect, a system for forming a foldable package housing individually wrapped articles is provided. The system includes a first conveyor device including at least one lug that at least partially defines a first slot and a second slot on opposing sides of the at least one lug. The first slot is sized to receive a first set of individually wrapped articles and the second slot is sized to receive a second set of individually wrapped articles. The first conveyor device is configured to advance the individually wrapped articles towards a loading station. The system further includes a feeder device configured to position a sheet of packaging material over the individually wrapped articles at the loading station. The sheet of packaging material is for coupling to the individually wrapped articles. Moreover, the at least one lug has a width such that a predefined distance is defined between the first and second sets of individually wrapped articles when coupled to the sheet of packaging material.

[0006] In another aspect, a method of manufacturing a foldable package housing individually wrapped articles is provided. The method includes arranging the plurality of individually wrapped articles on a first conveyor device that includes at least one lug. The at least one lug at least partially defines a first slot and a second slot on opposing sides of the at least one lug, and the plurality of individually wrapped articles are arranged on the first conveyor device such that a first set of individually wrapped articles is received within the first slot, and such that a second set of individually wrapped articles is received within the second slot. The method further includes advancing, with the first conveyor device, the individually wrapped articles towards a loading position, positioning a sheet of packaging material over the individually wrapped articles, and coupling the individually wrapped articles to the sheet of packaging material. The at least one lug has a width such that a predefined distance is defined between the first and second sets of individually wrapped articles when coupled to the sheet of packaging material. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is block diagram of an example packaging system for use in packaging a plurality of individually wrapped articles.

[0008] FIG. 2 is a side view of a conveyor system that may be used in the packaging system shown in FIG. 1.

[0009] FIG. 3 is a perspective view of the conveyor system shown in FIG.

2.

[0010] FIG. 4 is a side view illustration of a conveyor system in accordance with another embodiment of the disclosure in a first operational position.

[0011] FIG. 5 is a top view illustration of the conveyor system shown in

Fig. 4.

[0012] FIG. 6 is a side view illustration of the conveyor system shown in FIG. 4 in a second operational position.

[0013] FIG. 7 is a top view illustration of an example first conveyor device that may be used with the conveyor system shown in FIG. 2, in accordance with a first embodiment of the disclosure.

[0014] FIG. 8 is a top view illustration of the first conveyor device shown in FIG. 7 at a card loading station.

[0015] FIG. 9 is an end view illustration of an example foldable package formed using the first conveyor device shown in FIG. 7, in accordance with the first embodiment of the disclosure.

[0016] FIG. 10 is a top view illustration of an example first conveyor device that may be used with the conveyor system shown in FIG. 2, in accordance with a second embodiment of the disclosure.

[0017] FIG. 11 is a top view illustration of the first conveyor device shown in FIG. 10 at a card loading station. [0018] FIG. 12 is an end view illustration of an example foldable package formed using the first conveyor device shown in FIG. 10, in accordance with the second embodiment of the disclosure.

[0019] FIG. 13 is a top view illustration of an example first conveyor device that may be used with the conveyor system shown in FIG. 2, in accordance with a third embodiment of the disclosure.

[0020] FIG. 14 is a top view illustration of the first conveyor device shown in FIG. 13 at a card loading station.

[0021] FIG. 15 is an end view illustration of an example foldable package formed using the first conveyor device shown in FIG. 13, in accordance with the third embodiment of the disclosure.

[0022] FIG. 16 is a top view illustration of an example first conveyor device that may be used with the conveyor system shown in FIG. 2, in accordance with a fourth embodiment of the disclosure.

[0023] FIG. 17 is a top view illustration of the first conveyor device shown in FIG. 16 at a card loading station.

[0024] FIG. 18 is an end view illustration of an example foldable package formed using the first conveyor device shown in FIG. 16, in accordance with the fourth embodiment of the disclosure.

DETAILED DESCRIPTION

[0025] The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

[0026] The embodiments described herein relate to a foldable package containing a plurality of individually wrapped articles, such as individually wrapped sticks of chewing gum. The foldable package has either a bi-fold or multi-fold design capable of being easily folded between a closed configuration and an open configuration. As such, a consumer is able to access contents of the foldable package in a convenient and simplified manner. The foldable package is generally formed from a single sheet of packaging material having the individually wrapped articles adhered thereto, thereby resulting in minimal packaging material being used to form the foldable package. Forming the foldable package from a single sheet of packaging material also results in a slim profile when in the closed configuration, which makes it easier for the consumer to store or transport the foldable package. Moreover, unfolding the foldable package to access the contents thereof provides a revealing feature for the consumer, and also provides opportunities for including aesthetically appealing packaging designs when the package contents are revealed.

[0027] A system and method of manufacturing the foldable package are also described herein. In one embodiment, the system includes a conveyor device having a lug and chain type device. The lug and chain type device includes at least one lug that separates sets of individually wrapped articles from each other. The at least one lug has a width such that a predefined distance is defined between the sets of individually wrapped articles when coupled to the sheet of packaging material. As such, the system and method described herein enable multiple foldable packages to be formed in a high-speed and continuous manner.

[0028] FIG. 1 is block diagram of an example packaging system 100 for use in packaging a plurality of individually wrapped articles. In the example embodiment, packaging system 100 includes, in succession, an article wrapping station 102, an adhesive application station 104, a card loading station 106, a folding station 108, and a package wrapping station 1 10. Packaging system 100 also includes a conveyor system 1 12 that facilitates advancing the individually wrapped articles along the packaging process. Alternatively, the stations may be sequenced in any manner that enables packaging system 100 to function as described herein.

[0029] Generally described, in operation, article wrapping station 102 facilitates individually wrapping a plurality of articles (not shown in FIG. 1) for packaging in a sheet of wrapping material. The articles can include a consumable product such as, but not limited to, sticks of chewing gum. Moreover, an example wrapping material includes, but is not limited to, a foil material having a decorative design on at least one surface thereof. Alternatively, article wrapping station 102 can be used to wrap any single-serve, single-use, or non-perishable product.

[0030] After wrapping the articles, conveyor system 1 12 then advances the individually wrapped articles towards adhesive application station 104 for applying adhesive to the wrapping material. The individually wrapped articles are then advanced towards card loading station 106 for coupling the individually wrapped articles to a flat sheet of packaging material. Once coupled, conveyor system 1 12 advances the unfolded package towards folding station 108. The unfolded package is folded from an open configuration to a closed configuration, as will be described in more detail below, and conveyor system 112 advances the folded package towards package wrapping station 1 10. The folded package is then wrapped in a transparent sheet of overwrap material that includes, but is not limited to, a polyvinylidene chloride material. Wrapping the folded package in overwrap material maintains the folded package in a closed position, and seals the contents of the folded package from an ambient environment.

[0031] FIG. 2 is a side view of conveyor system 1 12 that may be used in packaging system 100 (shown in FIG. 1), and FIG. 3 is a perspective view of conveyor system 1 12. As described above, conveyor system 1 12 facilitates advancing individually wrapped articles 114 along the packaging process. More specifically, as shown in FIGS. 2 and 3, conveyor system 1 12 facilitates advancing individually wrapped articles 1 14 from adhesive application station 104, towards card loading station 106, and towards folding station 108. In the example embodiment, conveyor system 112 includes a first conveyor device 116 including a lug and chain device 1 18. Lug and chain device 118 includes a plurality of lugs 120 a chain 122 extending between adjacent lugs 120. The plurality of lugs 120 are spaced from each other and at least partially define slots for receiving individually wrapped articles 1 14 on opposing sides of each lug 120. As such, as will be described in more detail below, first conveyor device 116 receives and collates individually wrapped articles 114 into sets of two or more, for example, within each slot. In an alternative embodiment, first conveyor device 116 can include any conveyance device that facilitates advancing individually wrapped articles 1 14 along the packaging process. [0032] In the example embodiment, packaging system 100 further includes an adhesive application device 124 located at adhesive application station 104, a feeder device 126 located at card loading station 106, an elevating device 128 and a card holder 130 located at card loading station 106, a turning device 132, an inverter device 134, and one or more actuatable folding arms (not shown) located at folding station 108.

[0033] In operation, individually wrapped articles 1 14 are loaded onto first conveyor device 1 16 from article wrapping station 102 (shown in FIG. 1), and first conveyor device 116 advances individually wrapped articles 1 14 towards adhesive application station 104. In one embodiment, the wrapping material is folded on the articles such that a free flap 136 of wrapping material is folded over a first side of each individually wrapped article 1 14. In one embodiment, individually wrapped articles 1 14 are arranged on first conveyor device 116 such that free flap 136 is facing away from first conveyor device 116.

[0034] When at adhesive application station 104, adhesive application device 124 applies an adhesive to individually wrapped articles 114, forming a bead 138 of adhesive on each individually wrapped article 114. First conveyor device 1 16 then advances individually wrapped articles 114 towards card loading station 106, and feeder device 126 positions a sheet 140 of packaging material over individually wrapped articles 114 for coupling to individually wrapped articles 114, and for forming a foldable package. Feeder device 126 contains a plurality of sheets 140 of packaging material such that individually wrapped articles 1 14 can be coupled to each sheet 140 of packaging material in a substantially continuous manner. In an alternative embodiment, the adhesive is applied to sheet 140 of packaging material.

[0035] In the example embodiment, the plurality of lugs 120 have a height greater than a thickness of individually wrapped articles 114. As such, a gap 142 is formed therebetween when sheet 140 of packaging material is positioned over individually wrapped articles 114. First conveyor device 116 then advances individually wrapped articles 1 14 and sheet 140 of packaging material together towards elevating device 128 to facilitate coupling individually wrapped articles 114 to sheet of packaging material, thereby forming an unfolded package 144. More specifically, elevating device 128 biases individually wrapped articles 114 towards sheet 140 of packaging material, which uncouples individually wrapped articles 1 14 from lug and chain device 1 18. For example, in one embodiment, ramp 146 includes an inclined surface that successively guides individually wrapped articles 114 towards sheet 140 of packaging material as they are advanced through card loading station 106. Moreover, card holder 130 biases against sheet 140 of packaging material as individually wrapped articles 1 14 are guided along ramp 146 to create a firm bond therebetween. Lug and chain device 118 is then recirculated to further receive individually wrapped articles 1 14 from article wrapping station 102.

[0036] Conveyor system 1 12 then advances unfolded package 144 towards turning device 132 which, in one embodiment, re-orients unfolded package 144 by about 90° into a desired folding orientation. Unfolded package 144 is then advanced towards inverter device 134, which flips unfolded package 144 such that sheet 140 of packaging material is positioned between a surface 148 of folding station 108 and individually wrapped articles 1 14. Sheet 140 of packaging material is then folded upon itself to form a foldable package 150. In the example embodiment, the adhesive is selected such that individually wrapped articles 1 14 are selectively removable from foldable package 150. Moreover, in one embodiment, bead 138 is applied over only a portion of individually wrapped articles 114 such that a free end thereof is grippable by a consumer for removal of individually wrapped articles 114 from foldable package 150.

[0037] In an alternative embodiment, inverter device 134 is omitted from packaging system 100 and sheet 140 of packaging material is folded upon itself to form foldable package 150. Put another way, unfolded package 144 need not be inverted such that individually wrapped articles 1 14 are facing upwards to fold sheet 140 of packaging material upon itself to form foldable package 150.

[0038] FIG. 4 is a side view illustration of conveyor system 1 12 in a first operational position in accordance with another embodiment of the disclosure, FIG. 5 is a top view illustration of conveyor system 112 shown in FIG. 4, and FIG. 6 is a side view illustration of conveyor system 1 12 in a second operational position. In the example embodiment, conveyor system 1 12 includes first conveyor device 1 16 and a second conveyor device 152 positioned to receive individually wrapped articles 1 14 from first conveyor device 116. Second conveyor device 152 further advances individually wrapped articles 114 towards card loading station 106 (shown in FIG. 1). More specifically, in one embodiment, second conveyor device 152 includes rotating members 154 positioned on either side of first conveyor device 116. As will be described in more detail below, lugs 120 have a width such that a predefined distance is defined between adjacent sets of individually wrapped articles when coupled to sheet 140 of packaging material. As such, rotating members 154 rotate at a speed such that the predefined distance is maintained when individually wrapped articles are transferred from first conveyor device 1 16 to second conveyor device 152.

[0039] Referring to FIG. 6, conveyor system 1 12 is in the second operational position such that individually wrapped articles 114 are at card loading station 106 and substantially aligned with feeder device 126. In the example embodiment, elevating device 128 includes a biasing member 156 that actuates when individually wrapped articles 114 are at card loading station 106. As such, biasing member 156 biases individually wrapped articles 114 towards sheet 140 of packaging material simultaneously for coupling thereto.

[0040] FIG. 7 is a top view illustration of an example first conveyor device 158 that may be used with conveyor system 1 12 (shown in FIG. 2), in accordance with a first embodiment of the disclosure, FIG. 8 is a top view illustration of first conveyor device 158 at card loading station 106 (shown in FIG. 2), and FIG. 9 is an end view illustration of an example foldable package 160 formed using first conveyor device 158, in accordance with the first embodiment of the disclosure. In the example embodiment, first conveyor device 158 includes a first lug 162 that defines a first slot 164 and a second slot 166 on opposing sides of first lug 162. Moreover, first conveyor device 158 includes a rear lug 168 that further defines second slot 166. Rear lug 168 includes a stepped portion 170 that mates with sheet 172 of packaging material, as will be described in more detail below. First slot 164 is sized to receive a first set 174 of individually wrapped articles 1 14 and second slot 166 is sized to receive a second set 176 of individually wrapped articles 114. As described herein, a set of individually wrapped articles can include one or more individually wrapped articles 114.

[0041] In addition, first lug 162 has a first width Wl such that a predefined distance is defined between first and second sets 174 and 176 of individually wrapped articles 114 when coupled to sheet 140 of packaging material. The predefined distance is selected to ensure individually wrapped articles 1 14 are properly arranged prior to being coupled to sheet 172 of packaging material. More specifically, referring to FIG. 9, sheet 172 of packaging material is positioned over individually wrapped articles 114. Sheet 172 of packaging material includes a leading edge 178, a trailing edge 180, a top edge 182, a bottom edge 184, and a first fold line 186 and a second fold line 188 defined between leading and trailing edges 178 and 180. Alternatively, as described herein, any fold lines can also be embodied as a score line. First and second fold lines 186 and 188 define a first support panel 190, a first end panel 192 extending from first support panel 190, and a second support panel 194 extending from first end panel 192.

[0042] In the example embodiment, feeder device 126 (shown in FIG. 2) and, more specifically, sheet 172 of packaging material is positioned such that fold lines 186 and 188 do not overlap with individually wrapped articles 114 when coupled to sheet 172 of packaging material. For example, stepped portions 170 of rear lugs 168 mate with trailing edge 180 to orient sheet 172 of packaging material in a proper loading position. As such, first set 174 is aligned with first support panel 190 and second set 176 is aligned with second support panel 194.

[0043] Referring to FIG. 9, foldable package 160 is formed by folding sheet 172 of packaging material such that first and second sets 174 and 176 of individually wrapped articles 114 are stacked on top of one another. As such, first width Wl (shown in FIG. 7) is selected to be at least equal to twice the thickness of individually wrapped articles 114. Foldable package 160 is then advanced towards package wrapping station 1 10 (shown in FIG. 1) for wrapping with the overwrap material.

[0044] FIG. 10 is a top view illustration of an example first conveyor device 200 that may be used with conveyor system 1 12 (shown in FIG. 2), in accordance with a second embodiment of the disclosure, FIG. 11 is a top view illustration of first conveyor device 200 at card loading station 106 (shown in FIG. 2), and FIG. 12 is an end view illustration of an example foldable package 202 formed using first conveyor device 200, in accordance with the second embodiment of the disclosure. In the example embodiment, first conveyor device 200 includes first lug 162 and a second lug 204 spaced from each other such that second slot 166 is defined between first and second lugs 162 and 204, and such that a third slot 206 is at least partially defined on a side of second lug 204 opposing second slot 166. First conveyor device 200 further includes rear lugs 168 that further define third slot 206. Third slot 206 is sized to receive a third set 208 of individually wrapped articles 114

[0045] First lug 162 has first width Wl and second lug 204 has a second width W2 greater than first width Wl such that a first predefined distance is defined between first and second sets 174 and 176 of individually wrapped articles 114, and such that a greater second predefined distance is defined between second and third sets 176 and 208 of individually wrapped articles 114 when coupled to sheet 210 of packaging material. More specifically, referring to FIG. 11, sheet 210 of packaging material further includes a third fold line 212 and a fourth fold line 214 are defined between leading and trailing edges 178 and 180. As such, a second end panel 216 extends from second support panel 194 and a third support panel 218 extends from second end panel 216.

[0046] In the example embodiment, feeder device 126 (shown in FIG. 2) and, more specifically, sheet 210 of packaging material is positioned such that fold lines 186, 188, 212, and 214 do not overlap with individually wrapped articles 114 when coupled to sheet 210 of packaging material. For example, stepped portions 170 of rear lugs 168 mate with trailing edge 180 to orient sheet 210 of packaging material in a proper loading position. As such, first set 174 is aligned with first support panel 190, second set 176 is aligned with second support panel 194, and third set 208 is aligned with third support panel 218.

[0047] Referring to FIG. 12, foldable package 202 is formed by folding sheet 210 of packaging material such that first set 174 of individually wrapped articles 114 is stacked on top of second set 176, and further folding sheet 210 of packaging material such that third set 208 of individually wrapped articles 114 is stacked on top of first set 174, and indirectly stacked on top of second set 176. As such, first width Wl (shown in FIG. 10) is selected to be at least equal to twice the thickness of individually wrapped articles 114, and second width W2 (shown in FIG. 10) is selected to be at least equal to three times the thickness of individually wrapped articles in addition to the thickness of first support panel 190. Foldable package 202 is then advanced towards package wrapping station 110 (shown in FIG. 1) for wrapping with the overwrap material. [0048] FIG. 13 is a top view illustration of an example first conveyor device 300 that may be used with conveyor system 112 (shown in FIG. 2), in accordance with a third embodiment of the disclosure, FIG. 14 is a top view illustration of first conveyor device 300 at card loading station (shown in FIG. 2), and FIG. 15 is an end view illustration of an example foldable package 302 formed using first conveyor device 300, in accordance with the third embodiment of the disclosure. In the example embodiment, first conveyor device 300 includes first lug 162, second lug 204, and a third lug 304 spaced from second lug 204 such that third slot 206 is defined between second and third lugs 204 and 304, and such that a fourth slot 306 is at least partially defined on a side of third lug 304 opposing third slot 206. Fourth slot 306 is sized to receive a fourth set 308 of individually wrapped articles 114.

[0049] First and third lugs 162 and 304 have first width Wl and second lug 204 has a third width W3 greater than first width Wl such that a first predefined distance is defined between first and second sets 174 and 176 of individually wrapped articles 114 and between third and fourth sets 208 and 308 of individually wrapped articles 114. Further, a greater third predefined distance is defined between second and third sets 176 and 208 of individually wrapped articles 114 when coupled to sheet 310 of packaging material. More specifically, referring to FIG. 14, a fifth fold line 312 and a sixth fold line 314 are defined between leading and trailing edges 178 and 180. As such, a third end panel 316 extends from third support panel 218 and a fourth support panel 318 extends from third end panel 316.

[0050] In the example embodiment, feeder device 126 (shown in FIG. 2) and, more specifically, sheet 310 of packaging material is positioned such that fold lines 186, 188, 212, 214, 312 and 314 do not overlap with individually wrapped articles 114 when coupled to sheet 310 of packaging material. For example, stepped portions 170 of rear lugs 168 mate with trailing edge 180 to orient sheet 310 of packaging material in a proper loading position. As such, first set 174 is aligned with first support panel 190, second set 176 is aligned with second support panel 194, third set 208 is aligned with third support panel 218, and fourth set 308 is aligned with fourth support panel 318. [0051] Referring to FIG. 15, foldable package 302 is formed by folding sheet 310 of packaging material such that first and second sets 174 and 176 of individually wrapped articles 114 are stacked on top of one another, thereby forming a first folded subassembly 320. Foldable package 302 is further formed by folding sheet 310 of packaging material such that third and fourth sets 208 and 308 of individually wrapped articles 114 are stacked on top of one another, thereby forming a second folded sub-assembly 322, and by folding sheet 310 of packaging material such that first and second folded sub-assemblies 320 and 322 are stacked on top of one another. As such, first width Wl (shown in FIG. 13) is selected to be at least equal to twice the thickness of individually wrapped articles 114, and third width W3 (shown in FIG. 13) is selected to be at least equal to four times the thickness of individually wrapped articles in addition to the thicknesses of first and fourth support panels 190 and 318. Foldable package 302 is then advanced towards package wrapping station 110 (shown in FIG. 1) for wrapping with the overwrap material.

[0052] FIG. 16 is a top view illustration of an example first conveyor device 400 that may be used with conveyor system 112 (shown in FIG. 2), in accordance with a fourth embodiment of the disclosure, FIG. 17 is a top view illustration of first conveyor device 400 at card loading station 106 (shown in FIG. 2), and FIG. 18 is an end view illustration of an example foldable package 402 formed using first conveyor device 400, in accordance with the fourth embodiment of the disclosure. In the example embodiment, first lug 162 has first width Wl, second lug 204 has second width W2 greater than first width Wl, and third lug 304 has a fourth width W4 greater than second width W2 such that a first predefined distance is defined between first and second sets 174 and 176 of individually wrapped articles 114, such that a greater second predefined distance is defined between second and third sets 176 and 208 of individually wrapped articles 114, and such that an even greater fourth predefined distance is defined between third and fourth sets 208 and 308 of individually wrapped articles 114.

[0053] Referring to FIG. 18, foldable package 402 is formed by folding sheet 404 of packaging material such that first set 174 of individually wrapped articles 114 is stacked on top of second set 176. Further, foldable package 402 is formed by folding sheet 404 of packaging material such that first and second sets 174 and 176 of individually wrapped articles 114 are stacked on top of third set 208, and by folding sheet 404 of packaging material such that first, second, and third sets 174, 176, and 208 of individually wrapped articles 114 are stacked on top of fourth set 308. As such, first width Wl (shown in FIG. 16) is selected to be at least equal to twice the thickness of individually wrapped articles 114, second width W2 (shown in FIG. 16) is selected to be at least equal to three times the thickness of individually wrapped articles in addition to the thickness of first support panel 190, and fourth width W4 (shown in FIG. 16) is selected to be at least equal to four times the thickness of individually wrapped articles in addition to the thicknesses of first and second support panels 190 and 194. Foldable package 402 is then advanced towards package wrapping station 1 10 (shown in FIG. 1) for wrapping with the overwrap material.

[0054] This written description uses examples to disclose various implementations, including the best mode, and also to enable any person skilled in the art to practice the various implementations, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A system for forming a foldable package housing individually wrapped articles, said system comprising: a first conveyor device comprising at least one lug that at least partially defines a first slot and a second slot on opposing sides of the at least one lug, the first slot sized to receive a first set of individually wrapped articles and the second slot sized to receive a second set of individually wrapped articles, the first conveyor device configured to advance the individually wrapped articles towards a loading station; and a feeder device configured to position a sheet of packaging material over the individually wrapped articles at the loading station, the sheet of packaging material for coupling to the individually wrapped articles, wherein the at least one lug has a width such that a predefined distance is defined between the first and second sets of individually wrapped articles when coupled to the sheet of packaging material.

2. The system in accordance with Claim 1 , wherein the first conveyor device comprises a first lug and a second lug spaced from each other such that the second slot is defined between the first and second lugs, and such that a third slot sized to receive a third set of individually wrapped articles is at least partially defined on a side of the second lug opposing the second slot.

3. The system in accordance with Claim 2, wherein the first lug has a first width and the second lug has a second width greater than the first width such that a first predefined distance is defined between the first and second sets of individually wrapped articles, and such that a greater second predefined distance is defined between the second and third sets of individually wrapped articles when coupled to the sheet of packaging material.

4. The system in accordance with Claim 2, wherein the first conveyor device further comprises a third lug spaced from the second lug such that the third slot is defined between the second and third lugs, and such that a fourth slot sized to receive a fourth set of individually wrapped articles is at least partially defined on a side of the third lug opposing the third slot.

5. The system in accordance with Claim 4, wherein the first and third lugs have a first width and the second lug has a third width greater than the first width such that a first predefined distance is defined between the first and second sets of individually wrapped articles and between the third and fourth sets of individually wrapped articles, and such that a greater third predefined distance is defined between the second and third sets of individually wrapped articles when coupled to the sheet of packaging material.

6. The system in accordance with Claim 4, wherein the first lug has a first width, the second lug has a second width greater than the first width, and the third lug has a fourth width greater than the second width such that a first predefined distance is defined between the first and second sets of individually wrapped articles, such that a greater second predefined distance is defined between the second and third sets of individually wrapped articles, and such that an even greater fourth predefined distance is defined between the third and fourth sets of individually wrapped articles.

7. The system in accordance with any of the preceding Claims, wherein the sheet of packaging material has at least one fold line or at least one score line defined therein, the feeder device positioned such that the first and second sets of individually wrapped articles do not overlap with the at least one fold line or the at least one score line.

8. The system in accordance with Claim 7, wherein the first conveyor device further comprises at least one rear lug comprising a stepped portion, wherein the stepped portion is configured to mate with the sheet of packaging material such that the first and second sets of individually wrapped articles do not overlap with the at least one fold line or the at least one score line.

9. The system in accordance with any of the preceding Claims, further comprising a second conveyor device positioned to receive the individually wrapped articles from the first conveyor device, the second conveyor device configured to further advance the individually wrapped articles towards the loading station.

10. The system in accordance with Claim 9, wherein the second conveyor device comprises a rotating member configured to rotate at a speed such that the predefined distance between first and second sets of individually wrapped articles defined by the width of the at least one lug is maintained when transferred from the first conveyor device to the second conveyor device.

11. The system in accordance with any of the preceding Claims, further comprising an elevating device configured to bias the individually wrapped articles towards the sheet of packaging material.

12. The system in accordance with Claim 11 , wherein the elevating device comprises a ramp configured to successively guide the individually wrapped articles towards the sheet of packaging material as the first conveyor device advances the individually wrapped articles and the sheet of packaging material.

13. The system in accordance with any of the preceding claims, wherein the first conveyor device further comprises a rear lug configured to couple to the sheet of packaging material, such that the sheet of packaging material advances with the individually wrapped articles.

14. The system in accordance with Claim 1 1, wherein the elevating device is configured to actuate when the individually wrapped articles are at the loading station such that the individually wrapped articles bias towards the sheet of packaging material simultaneously.

15. The system in accordance with any of the preceding claims, wherein the at least one lug has a height greater than a thickness of the individually wrapped articles such that a gap is formed between the individually wrapped articles and the sheet of packaging material when positioned over the individually wrapped articles.

16. A method of manufacturing a foldable package housing individually wrapped articles, said method comprising: arranging the plurality of individually wrapped articles on a first conveyor device that includes at least one lug, wherein the at least one lug at least partially defines a first slot and a second slot on opposing sides of the at least one lug, the plurality of individually wrapped articles arranged on the first conveyor device such that a first set of individually wrapped articles is received within the first slot, and such that a second set of individually wrapped articles is received within the second slot; advancing, with the first conveyor device, the individually wrapped articles towards a loading position; positioning a sheet of packaging material over the individually wrapped articles; and coupling the individually wrapped articles to the sheet of packaging material, wherein the at least one lug has a width such that a predefined distance is defined between the first and second sets of individually wrapped articles when coupled to the sheet of packaging material.

17. The method in accordance with Claim 16, wherein arranging the plurality of individually wrapped articles comprises arranging the plurality of individually wrapped articles such that at least two individually wrapped articles are in each of the first and second sets.

18. The method in accordance with any of Claims 16 and 17, further comprising folding the sheet of packaging material such that the first and second sets of individually wrapped articles are stacked on top of one another.

19. The method in accordance with Claim 18, wherein folding the sheet of packaging material comprises folding the sheet of packaging material along at least one fold line or at least one score line preformed in the sheet of packaging material.

20. The method in accordance with any of Claims 18 and 19, further comprising wrapping the folded sheet of packaging material in a sheet of overwrap material.

21. The method in accordance with any of Claims 16-20, wherein coupling the individually wrapped articles comprises applying an adhesive to at least one of the individually wrapped articles or the sheet of packaging material.

22. The method in accordance with Claim 21 , wherein applying an adhesive comprises applying the adhesive such that a free end of the individually wrapped articles is not adhered to the sheet of packaging material.

23. The method in accordance with any of Claims 16-22, wherein coupling the individually wrapped articles comprises biasing the individually wrapped articles towards the sheet of packaging material.

24. The method in accordance with Claim 23, wherein biasing the individually wrapped articles comprises: coupling the sheet of packaging material to the at least one lug; and advancing the individually wrapped articles and the sheet of packaging material towards a ramp configured to successively guide the individually wrapped articles towards the sheet of packaging material.

25. The method in accordance with any of Claims Claim 23 and 24, wherein biasing the individually wrapped articles comprises biasing the individually wrapped articles towards the sheet of packaging material simultaneously when in the loading position.

26. The method in accordance with any of Claims 16-25, wherein the individually wrapped articles are wrapped in a wrapping material such that a free flap of wrapping material is folded over a first side of the individually wrapped articles, the method further comprising arranging the plurality of individually wrapped articles such the free flap of the wrapping material faces towards the sheet of packaging material.

27. The method in accordance with any of Claims 16-26, wherein positioning a sheet of packaging material comprises positioning the sheet of packaging material such that at least one fold line or at least one score line defined therein do not overlap with the individually wrapped articles when coupled to the sheet of packaging material.

28. The method in accordance with any of Claims 16-26, further comprising: arranging the plurality of individually wrapped articles on the first conveyor device that includes a first lug and a second lug spaced from each other such that the second slot is at least partially defined between the first and second lugs, and such that a third slot is at least partially defined on a side of the second lug opposing the second slot.

29. The method in accordance with Claim 28, further comprising: arranging a third set of individually wrapped articles in the third slot, wherein the first lug has a first width and the second lug has a second width greater than the first width such that a first predefined distance is defined between the first and second sets of individually wrapped articles, and such that a greater second predefined distance is defined between the second and third sets of individually wrapped articles when coupled to the sheet of packaging material.

30. The method in accordance with Claim 29, further comprising: folding the sheet of packaging material such that the first set of individually wrapped articles is stacked on top of the second set; and folding the sheet of packaging material such that the third set of individually wrapped articles is stacked on top of the first set.

31. The method in accordance with any of Claims 28-30, further comprising: arranging the plurality of individually wrapped articles on the first conveyor device that includes a third lug spaced from the second lug such that the third slot is defined between the second and third lugs, and such that a fourth slot is at least partially defined on a side of the third lug opposing the third slot.

32. The method in accordance with Claim 31, further comprising: arranging a fourth set of individually wrapped articles in the fourth slot, wherein the first and third lugs have a first width and the second lug has a third width greater than the first width such that a first predefined distance is defined between the first and second sets of individually wrapped articles and between the third and fourth sets of individually wrapped articles, and such that a greater third predefined distance is defined between the second and third sets of individually wrapped articles when coupled to the sheet of packaging material.

33. The method in accordance with Claim 32, further comprising: folding the sheet of packaging material such that the first and second sets of individually wrapped articles are stacked on top of one another, thereby forming a first folded sub-assembly; folding the sheet of packaging material such that the third and fourth sets of individually wrapped articles are stacked on top of one another, thereby forming a second folded sub-assembly; and folding the sheet of packaging material such that the first and second folded sub-assemblies are stacked on top of one another.

34. The method in accordance with Claim 31, further comprising: arranging a fourth set of individually wrapped articles in the fourth slot, wherein the first lug has a first width, the second lug has a second width greater than the first width, and the third lug has a fourth width greater than the second width such that a first predefined distance is defined between the first and second sets of individually wrapped articles, such that a greater second predefined distance is defined between the second and third sets of individually wrapped articles, and such that an even greater fourth predefined distance is defined between the third and fourth sets of individually wrapped articles.

35. The method in accordance with Claim 34 further comprising: folding the sheet of packaging material such that the first set of individually wrapped articles is stacked on top of the second set; folding the sheet of packaging material such that the first and second sets of individually wrapped articles are stacked on top of the third set; and folding the sheet of packaging material such that the first, second, and third sets of individually wrapped articles are stacked on top of the fourth set.