BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates to a device and method of manufacture of the device for unitizing a plurality of containers, the carrier having a retainer sheet for engaging a top portion of the containers integrated with a film sleeve for surrounding the containers.  
           [0003]    2. Description of Prior Art  
           [0004]    Conventional container carriers are often used to unitize a plurality of similarly sized containers, such as cans, bottles, jars and boxes, although other packages or containers may be unitized. Plastic ring carriers and box carriers are two such conventional container carriers.  
           [0005]    The plastic ring carrier produces a unitized package for containers using little material. However, the plastic ring carrier, when used alone in most instances, has little or no advertising or promotional printing space. Conversely, the box carrier generally has a relatively large amount of area for promotional graphics. Disadvantageously, the box carrier requires a relatively large amount of material, may permit containers to fall out if it is not maintained in an upright position, and usually shrouds most or all of the actual containers. Therefore, there is a need for a package that incorporates the stability and economy of a ring carrier and the promotional area of a box carrier.  
         SUMMARY OF THE INVENTION  
         [0006]    It is one object of this invention to provide a container carrier that unitizes a plurality of containers into a tight, solid package.  
           [0007]    It is another object of this invention to provide a container carrier that provides a prominent billboard space for merchandising information.  
           [0008]    It is still another object of this invention to provide a container carrier which restricts lateral and vertical movement of the containers with respect to one another.  
           [0009]    It is yet another object of this invention to provide a container carrier that incorporates the stability and economy of a ring carrier and the promotional area of a box carrier.  
           [0010]    It is still another object of this invention to provide a container carrier that utilizes a film sleeve to maintain a tight configuration of unitized containers.  
           [0011]    A carrier according to this invention carries a plurality of containers such as cans or bottles. The carrier unitizes a plurality of containers to create a package. The carrier is a single-piece device comprising a retainer sheet integrated with a film sleeve, each preferably constructed from a flexible, resilient material such as plastic. The retainer sheet preferably has a first thickness different from and thicker than a second thickness of the film sleeve.  
           [0012]    The retainer sheet is formed with a plurality of container receiving openings the number of which depends upon the intended size of the package. The retainer sheet is integrated with the film sleeve preferably along longitudinal sides of the retainer sheet.  
           [0013]    The film sleeve may be designed to create a package open at a bottom of the package or along a lower edge of the carrier. The film sleeve may further include a bottom along a portion of the lower edge of the film sleeve. Each side edge of the film sleeve is preferably bound with a seal. The carrier when formed is preferably generally symmetrical around fold lines of the carrier.  
           [0014]    Containers are inserted within the carrier so that the containers are surrounded by between five and six sides of the package. Each container receiving opening in the retainer sheet preferably engages a container around an upper portion of the container. The rigidity and elasticity of the retainer sheet thereby supports each container.  
           [0015]    The film sleeve is positioned around the plurality of containers, preferably in a stretching engagement with the containers. The film sleeve is preferably printed with graphics, promotional and/or other information related to contents and/or ingredients of package. Therefore, the film sleeve serves both to unitize the plurality of containers and to advertise the nature of the contents of the containers.  
           [0016]    The carrier is preferably manufactured according to one of several preferred methods wherein a generally continuous length of carriers is formed. In summary, a film substrate and/or film sleeve material is printed with desired graphics and other merchandising information. A retainer sheet material is next joined to the film substrate and/or film sleeve material by heat sealing, extrusion coating, laminating, profile extrusion or glueing the retainer sheet material to the film substrate and/or film sleeve material. The joined retainer sheet material and film substrate and/or film sleeve material are next either folded along a fold line to create a symmetrical double layer or laminated to an identical section of joined retainer sheet material and film substrate and/or film sleeve material thereby creating a carrier blank. Seams are next added by heat sealing or laminating the symmetrical double layer of retainer sheet material and film substrate and/or film sleeve material together. Finally, the carrier is formed by die cutting the double layer of retainer sheet material and film substrate to create container receiving openings and to define a film sleeve and a retainer sheet. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    The above-mentioned and other features and objects of this invention will be better understood from the following detailed description taken in conjunction with the drawings wherein:  
         [0018]    [0018]FIG. 1 is a top view of a carrier for holding a plurality of containers according to one preferred embodiment of this invention;  
         [0019]    [0019]FIG. 2 is a top view of a carrier for holding a plurality of containers according to another preferred embodiment of this invention;  
         [0020]    [0020]FIG. 3 is a perspective view of a package of containers, using a carrier similar to the carrier shown in FIG. 2, according to one preferred embodiment of this invention;  
         [0021]    [0021]FIG. 4 is a top view of a carrier for holding a plurality of containers according to another preferred embodiment of this invention;  
         [0022]    [0022]FIG. 5 is a perspective view of a package of containers, using a carrier similar to the carrier shown in FIG. 4, according to one preferred embodiment of this invention;  
         [0023]    [0023]FIG. 6 is a schematic of a method for making a carrier for holding a plurality of containers according to one preferred embodiment of this invention;  
         [0024]    [0024]FIG. 7 is a schematic of a method for making a carrier, similar to the carriers shown in FIGS. 2 and 3, for holding a plurality of containers according to another preferred embodiment of this invention;  
         [0025]    [0025]FIG. 8 is a schematic of a method for making a carrier for holding a plurality of containers according to yet another preferred embodiment of this invention;  
         [0026]    [0026]FIG. 9 is a schematic of a method for making a carrier for holding a plurality of containers according to yet another preferred embodiment of this invention; and  
         [0027]    [0027]FIG. 10 is a schematic of a method for making a carrier for holding a plurality of containers according to yet another preferred embodiment of this invention. 
     
    
     DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0028]    FIGS.  1 - 10  show carriers  10  for carrying a plurality of containers  5 . Containers  5  as shown in FIGS. 3 and 4 are preferably cans. Although cans are shown in FIGS. 3 and 4, bottles or any other commonly unitized container  5  may be used with carrier  10  according to this invention. Containers  5  are preferably like-sized within a single carrier  10 .  
         [0029]    Carrier  10  unitizes a plurality of containers  5  to create package  1 , such as package  1  shown in FIGS. 3 and 5. Carrier  10  is preferably a single-piece device comprising retainer sheet  15  integrated with film sleeve  30 , each preferably constructed from a flexible, resilient material such as plastic. For the purposes of this specification and claims, a sleeve is defined as a tubelike component capable of fitting over or around a plurality of containers  5 .  
         [0030]    In one preferred embodiment of this invention, retainer sheet  15  is made from low density polyethylene. In other embodiments, a higher density polyethylene is preferable having a different thickness. Retainer sheet  15  preferably has a first thickness, such as between 0.008-0.020″, possibly thinner than the thickness of traditional plastic ring carriers. As discussed in additional detail below, retainer sheet  15  is preferably cut, using means known to those skilled in the art such as a stamping die, to form a plurality of container receiving openings  20  in retainer sheet  15 . Two or more container receiving openings  20  are formed in retainer sheet  15  in longitudinal rows and one or more transverse ranks. In one preferred embodiment of this invention shown in FIGS.  2 - 5 , container receiving openings  20  are configured in two rows of three ranks. Retainer sheet  15  may include other configurations of container receiving openings  20  depending on the size of package  1  desired.  
         [0031]    Retainer sheet  15  is integrated with film sleeve  30  to form a single-piece carrier  10 , as described in detail below. According to one preferred embodiment of this invention, film sleeve  30  has a second thickness that is thinner than the first thickness of retainer sheet  15 , such as 0.004″ to 0.006″. The total thickness of retainer sheet  15  may range between approximately 0.008-0.026″ according to one preferred embodiment of this invention. Film sleeve  30  may exhibit different elasticity and different rigidity than retainer sheet  15 . Film sleeve  30  may comprise a stretchable low density polyethylene (LDPE) film or similar material known to those having ordinary skill in the art.  
         [0032]    In one preferred embodiment of this invention, shown in FIGS. 6, 8,  9  and  10 , handle  50  is integrated within retainer sheet  15 . Handle  50  preferably has a same or similar thickness as retainer sheet  15 . In one preferred embodiment of this invention, shown in FIGS. 6 and 8, handle  50  is integrated between longitudinal rows of container receiving openings  20 . Alternatively, package  1  may be carried using bands  55  formed between container receiving openings  20  as shown in FIGS. 3 and 5.  
         [0033]    Film sleeve  30  is preferably integrated with retainer sheet  15  along longitudinal sides  17  of retainer sheet  15 . In one preferred embodiment of this invention, film sleeve  30  is not connected along two lateral edges  18  of retainer sheet  15 . Film sleeve  30  is preferably printed with, on one or both sides, UPC and proof of purchase labels, graphics, and promotional and/or other information related to contents and/or ingredients of package  1 . Film sleeve  30  may additionally be at least partially transparent to effectively display the nature of containers  5 . Therefore, film sleeve  30  serves the dual purposes of retaining containers  5  within a tightly assembled package  1  and advertising marketable features of the containers  5  and/or package  1 .  
         [0034]    In one preferred embodiment of this invention shown in FIG. 2, film sleeve  30  is open along lower edge  33  of carrier  10 . As shown in FIG. 1, lower edge  33  of carrier  10  may further include bottom  35  of film sleeve  30 . Each side edge  37  of film sleeve  30  is preferably bound with seal  40 . Therefore, film sleeve  30  extends from openable lower edge  33  of carrier to seals  40  on either side edge  37  of film sleeve to retainer sheet  15  at a top portion of carrier  10 .  
         [0035]    As shown in FIGS. 1 and 2, carrier  10  is preferably generally symmetrical around fold lines  25 . As discussed in detail below, carrier  10  is manufactured so that retainer sheet  15  and film sleeve  30  are each preferably symmetrical around fold lines  25 .  
         [0036]    Carrier  10  is applied to a plurality of containers  5  to form package  1 , shown in FIGS. 3 and 5. Containers  5  are inserted within carrier  10  which bounds containers  5  around between five and six sides of package  1 . Each container receiving opening  20  preferably engages container  5 , preferably around chime  7  or similar upper portion of container  5 . The rigidity and elasticity of retainer sheet  15  supports container  5  within container receiving opening  20 . A top portion of package  1  is therefore at least partially covered by retainer sheet  15 .  
         [0037]    As shown in FIGS. 3 and 5, film sleeve  30  is positioned around the plurality of containers  5 . Preferably, film sleeve  30  is stretchingly engaged with containers  5  and the combination of container receiving openings  20  and sleeve  30  prevents skewing or lateral movement of containers  5  with respect to each other. In one preferred embodiment of this invention, shown in FIGS. 2 and 3, film sleeve  30  covers at least a portion of four horizontal sides of package  1 .  
         [0038]    Containers  5  are positioned within package  1  so that film sleeve  30  is flat and tight with respect to containers  5  and prominent with respect to package  1 . Film sleeve  30  is preferably sized to stretch when slid over a plurality of containers  5 . Such a configuration of film sleeve  30  results in package  1  having a prominent display area or “billboard” for advertising, information, graphics and other marketing material.  
         [0039]    In another preferred embodiment of this invention, shown in FIGS. 1, 4 and  5 , film sleeve  30  covers at least a portion of a bottom of package  1 . Film sleeve  30  preferably covers at least a portion of the bottom of package  1  when one or more containers  5  are not engaged with container receiving openings  20 . For instance, carrier  10  shown in FIG. 1 requires bottom  35  because retainer sheet  15  includes only two container receiving openings  20  in carrier  10  that holds more than two containers  5 . Carrier  10  shown in FIG. 5 also requires bottom  35  because, of the twelve containers  5  in package  10 , the lower six containers  5 ′ in package  1  are not supported around chime  7  by retainer sheet  15 . Therefore, bottom  35  provides support for those containers  5  not supported within container receiving openings  20 .  
         [0040]    As shown in FIGS.  3 - 5 , package  1  may additionally contain pull tab  45  and/or line of perforation  47  positioned within film sleeve  30 . Using an arrangement such as shown in FIGS.  3 - 5 , package  1  may be opened by pulling pull tab  45  across longitudinal side  17  of package  1  thereby tearing line of perforation  47  to access containers  5 .  
         [0041]    A package according to FIGS. 4 and 5 will have the novel characteristic of having an upper level of containers  5  removable from a lower level of container  5 ′ while keeping the upper level of containers  5  integrated as a sub-package and permitting the lower level of containers  5 ′ to be freely removable for individual consumption or storage.  
         [0042]    According to one preferred embodiment of this invention, perforated removal strip  49  facilitates the efficient removal of the upper level of containers  5  and retainer sheet  15  from the lower level of containers  5  and sleeve  30 . Perforated removal strip  49  is designed so a single pulling action of tab  45  circumferentially around package  1  will disassociate retainer sheet  15  and upper level of containers  5 ′ from sleeve  30 . Tabs  45  at an end panel of package  1  permit such single pulling action removal from either side of package  1 . FIG. 6 shows carrier  10  according to this preferred embodiment, which is contemplated to be manufactured similar to FIG. 7, described below.  
         [0043]    FIGS.  6 - 10  show methods for manufacturing carrier  10  according to three preferred methods of this invention. The methods shown in FIGS.  6 - 10  demonstrate from right to left the assembly of various components of carrier  10 , each step in the method designated by a letter of the alphabet. Each step of each method of manufacture includes two carriers  10  to demonstrate a representative segment of carriers  10  that are typically formed in a generally continuous length.  
         [0044]    [0044]FIG. 6 shows a method for manufacturing carrier  10  according to one preferred embodiment of this invention. In step [A] film substrate  28  is printed with desired graphics and other merchandising information. In step [B] retainer sheet material  13  is joined to film substrate  28  by glueing or otherwise attaching retainer sheet material  13  to film substrate  28 . In step [C] retainer sheet material  13  and film substrate  28  are folded along fold line  25  to create a symmetrical double layer. In step [D] seams  40  are added by heat sealing or laminating the symmetrical double layer of retainer sheet material  13  and film substrate  28  together. In step [E] carrier  10  is formed by cutting, such as in a punch press, the double layer of retainer sheet material  13  and film substrate  28  to define film sleeve  30  and retainer sheet  15 . Step [F] (not shown) preferably comprises accumulating the continuous strip of carriers  10  by fan folding or rolling about a core. Carriers  10  according to this invention, regardless of the method of manufacture, are not conducive to winding on reels because of the variable thickness between film sleeve  30  and retainer sheet  15 .  
         [0045]    [0045]FIG. 7 shows a method for manufacturing carrier  10  according to another preferred embodiment of this invention. In step [A] film substrate  28  is printed with desired graphics and other merchandising information. In step [B] retainer sheet material  13  is joined to film substrate  28  by extrusion coating, laminating, profile extrusion, or glueing retainer sheet material  13  to film substrate  28 . In step [C] retainer sheet material  13  and film substrate  28  are folded along fold line  25  to create a symmetrical double layer and seams  40  are added by heat sealing or laminating the symmetrical double layer of retainer sheet material  13  and film substrate  28  together. In step [D] carrier  10  is formed by cutting, such as in a punch press, the double layer of retainer sheet material  13  and film substrate  28  to define film sleeve  30  and retainer sheet  15 . Step [E] (not shown) preferably comprises accumulating the continuous strip of carriers  10  by fan folding or rolling about a core.  
         [0046]    [0046]FIG. 8 shows a method for manufacturing carrier  10  according to yet another preferred embodiment of this invention. In step [A] film substrate  28  is printed with desired graphics and other merchandising information. In step [B] retainer sheet material  13  is joined to film substrate  28  by extrusion coating or laminating retainer sheet material  13  to film substrate  28 . In step [C] two identical sheets of retainer sheet material  13  and film substrate  28  are laminated together along lamination lines  42 . Step [C] requires careful registration to align two identical portions of joined retainer sheet material  13  and film substrate  28  prior to lamination. In step [D] seams  40  are added by heat sealing or laminating the two identical sheets of retainer sheet material  13  and film substrate  28  together. In step [E] carrier  10  is formed by cutting, such as in a punch press, the two sheets of retainer sheet material  13  and film substrate  28  to define film sleeve  30  and retainer sheet  15 . Step [F] (not shown) preferably comprises accumulating the continuous strip of carriers  10  by fan folding or rolling about a core.  
         [0047]    Another method for manufacturing carrier  10  for carrying a plurality of containers is shown in FIG. 9. As shown in step [A], film sleeve material  32  is preprinted with appropriate graphics and/or product information. Step [B] shows retainer sheet material  13  provided for incorporation with film sleeve material  32 . Retainer sheet material  13  is either folded and/or comprises a pair of sheets laid on top of each other and then may be laminated and/or sealed prior to incorporation with film sleeve material  32 . Step [C] shows retainer sheet material  13  folded over and connected with respect to film sleeve material  32 , such as with a heat seal  41 , preferably near a periphery of two opposed edges  60  of retainer sheet material  32 . As a result of the above-described steps, retainer sheet material  13  and film sleeve material  32  may be manufactured, printed and shipped separately, i.e. on separate rolls or coils, prior to completion of final carrier  10 .  
         [0048]    As further shown in steps [C] and [D] of FIG. 9, retainer sheet material  13  is further attached with respect to film sleeve material  32  along a pair of opposed edges  60  along an open end  62  of the folded retainer sheet material  13  and a pair of opposed edges  70  along an open end  72  of the folded film sleeve material  32  to form carrier blank  80 . According to a preferred embodiment of this invention, carrier  10  is preferably symmetrically formed about at least one fold line  25 . Pair of opposed edges  60  of retainer sheet material  13  may be sealed, joined, bonded, adhered or any other attachment method known to those having ordinary skill in the art, to pair of opposed edges  70  of film sleeve material. Step [D] additionally shows the attachment of side edges  37  with respect to each other with welds and/or heat seals.  
         [0049]    In steps [E] and [F], additional features of carrier  10  are formed including perforations defining removal strip  49  and the plurality of container receiving openings  20  to complete carrier  10 . Step [F] also may require cutting lower fold line  25  so as to create open end  33  in carrier  10 . As a result, carrier  10  includes an open end  33  sufficiently large to allow film sleeve  30  to be slid over at least a pair of containers  5 .  
         [0050]    Another method for manufacturing carrier  10  for carrying a plurality of containers is shown in FIG. 10. As shown in step [A] film sleeve material  32  is preprinted with appropriate graphics and/or product information. Step [B] shows film sleeve material  32  cut into two discrete sections. Alternatively, this method may start with step [B] wherein two separate sheets and/or coils of film sleeve material  32  are provided for incorporation into carrier  10 . Step [C] shows retainer sheet material  13  provided for incorporation with film sleeve material  32 . Retainer sheet material  13  is either folded and/or comprises a pair of sheets laid on top of each other and then may be laminated and/or sealed prior to incorporation with film sleeve material  32 . Step [D] shows retainer sheet material  13  connected with respect to the two discrete sections of film sleeve material  32  along two sides of retainer sheet material  13 , such as with seals  41 , thereby forming one or more carrier blanks  80 . Like the method shown in FIG. 9, this method permits retainer sheet material  13  and film sleeve material  32  to be manufactured, printed and shipped separately, i.e. on separate rolls, prior to completion of final carrier  10 .  
         [0051]    As further shown in step [E] of FIG. 10, according to a preferred embodiment of this invention, carrier blank  80  is preferably symmetrically formed about at least one fold line  25  or comprises two or more sheets welded and/or laminated with respect to each other. Step [F] additionally shows the placement of laminations or longitudinal seals  42  to create a spine for retainer sheet  15 . Steps [G], [H] and [I] further show the attachment of sealed side edges  37  with respect to each other with welds and/or heat seals as well as additional features of carrier  10  including perforations defining removal strip  49  and the plurality of container receiving openings  20  to complete carrier  10 . As shown in step [H], tear or removal strip  49  is positioned below seal  41 . According to one preferred embodiment of this invention, handle  50  is also formed in carrier  10 .  
         [0052]    As described in the various embodiments of this invention, retainer sheet material  13  and/or retainer sheet  15  may have a first thickness and film sleeve material  32  and/or film sleeve  30  may have a second thickness thinner than the first thickness. Alternatively, the first thickness and the second thickness may be the same. Finally, regardless of the relative thicknesses, retainer sheet material  13  and film sleeve material  32  may have different rigidities and/or elasticities.  
         [0053]    Also as described in the various embodiments of this invention, retainer sheet material  13 , retainer sheet  15 , film sleeve material  32  and/or film sleeve  30  may be shipped on a single coil of material, on separate coils between retainer sheet material  13  and film sleeve material  32  or each on multiple coils for incorporation into carrier  10 .  
         [0054]    While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that carrier  10  is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.
This invention relates to a single-piece carrier for unitizing a plurality of containers with a retainer sheet integrated with a film sleeve. The retainer sheet may comprise a thicker material than the film sleeve. The retainer sheet comprises a plurality of container receiving openings for engaging a top portion of each container while the film sleeve surrounds the plurality of containers. Packages may comprise one or more layers of containers within the film sleeve.