Continuous motion packaging system

1. A method of packaging articles, comprising:

moving a series of articles along an article infeed path;

moving a series of cartons received on a carton conveyor along a packaging path adjacent the article infeed path;

directing the articles toward a loading position along the packaging path;

engaging the articles with a series of selector wedges as the articles approach their loading position so as to form article groups;

depositing each of the article groups on a carton contained within a flight of the carton conveyor;

urging a portion of each carton over the groups of articles loaded thereon;

as the cartons are urged over the groups of articles, engaging and tucking gussets of the cartons inwardly with gusset tucking fingers arranged along the selector wedges; and

moving a cam follower along a cam track as the cartons are moved along their carton path of travel, and in response, reciprocating the gusset tucking fingers toward and away from engagement with the gussets of the cartons to cause side panels of the cartons to be folded about the groups of articles.

2. The method of claim 1 and further comprising closing a top panel of each carton about each article group received thereon to form an article package.

3. The method of claim 1 and wherein urging a portion of each carton over the group of articles loaded thereon comprises folding opposing end panels of each carton upwardly and inwardly toward the group of articles and folding a top panel downwardly toward the group of articles.

4. The method of claim 3 and further comprising engaging one of the end panels with the top panel of each carton as the top and end panels are folded toward the group of articles to close the carton thereabout.

5. A system for packaging articles within a series of cartons, comprising:

an article infeed conveyor for feeding a series of articles along a first path of travel;

a carton conveyor having a series of flights in which the cartons are received and conveyed along a second path of travel;

a series of selector wedges mounted in spaced series along said carton conveyor and defining said flights therebetween, said selector wedges adapted to engage and separate the series of articles into article groups received within said flights and each including at least one gusset tucking finger moveable between a non-engaging position and an engaging position projecting into one of said flights so as to engage and tuck a gusset of a carton within said one of said flight as the carton is folded about a group of articles therein;

a guide mechanism mounted along said carton conveyor and adapted to cause the cartons to be folded about the groups of articles in said flights; and

a drive mechanism mounted to each selector wedge and linked to said at least one gusset tucking finger for reciprocating said at least one gusset tucking finger into and out of engagement with the gusset of the carton;

wherein said drive mechanism comprises a drive shaft extending through each of said selector wedges and connected to said at least one gusset tucking finger, and a cam arm for causing rotation of said drive shaft to reciprocate said at least one gusset tucking finger between is engaging and non-engaging positions.

6. A system for packaging articles within a series of cartons, comprising:

an article infeed conveyor for feeding a series of articles along a first path of travel;

a carton conveyor having a series of flights in which the cartons are received and conveyed along a second path of travel;

a series of selector wedges mounted in spaced series along said carton conveyor and defining said flights therebetween, said selector wedges adapted to engage and separate the series of articles into article groups received within said flights and each including at least one gusset tucking finger moveable between a non-engaging position and an engaging position projecting into one of said flights so as to engage and tuck a gusset of a carton within said one of said flight as the carton is folded about a group of articles therein; and

a guide mechanism mounted along said carton conveyor and adapted to cause the cartons to be folded about the groups of articles in said flights, said guide mechanism comprising a folding wheel positioned along said second path of travel and having a series of arms rotated into engagement with an end panel of each carton as each carton is moved along its path of travel so that the end panel is guided upwardly toward a group of articles received on the carton, after which said arms are further rotated to a lowered position to enable said selector wedges to pass thereover.

7. The system of claim 6 and further comprising a series of lane guides extending across said article infeed conveyor for directing the articles in lines toward a loading position along said carton conveyor.

8. A system for packaging articles within a series of cartons, comprising:

an article infeed conveyor for feeding a series of articles along a first path of travel;

a carton conveyor having a series of flights in which the cartons are received and conveyed along a second path of travel;

a series of selector wedges mounted in spaced series along said carton conveyor and defining said flights therebetween, said selector wedges adapted to engage and separate the series of articles into article groups received within said flights and each including at least one gusset tucking finger moveable between a non-engaging position and an engaging position projecting into one of said flights so as to engage and tuck a gusset of a carton within said one of said flight as the carton is folded about a group of articles therein;

a guide mechanism mounted along said carton conveyor and adapted to cause the cartons to be folded about the groups of articles in said flights; and

a cam track extending adjacent said carton conveyor, and wherein each of said selector wedges further includes a cam arm linked to said at least one gusset tucking finger and having a cam follower adapted to engage and move along said cam track for moving said at least one gusset tucking finger between its non-engaging position and its engaging position for tucking the gussets of the cartons within the flights as the cartons are wrapped about their article groups.

9. The system of claim 8 and further comprising a pair of drive shafts extending along each of said selector wedges and a series of gusset tucking fingers positioned along opposite sides of each of said selector wedges, said gusset tucking fingers mounted in spaced series along said drive shafts, and wherein said drive shafts are linked to said cam arm for rotating said drive shafts as said cam follower of said cam arm moves along said cam track.