System and method for forming and moving an article array

A system for forming and moving an article array comprising:

• a first consolidation area having a first support surface, and a second consolidation area having a second support surface for receiving and arranging rows of articles to form a first article array from a first article array delivery device, and to form a second article array from a second article array delivery device, respectively, the first article array delivery device adapted to simultaneously deliver at least one article row to the first consolidation area while the first consolidation area continuously stabilizingly supports a periphery of the article rows positioned on the first support surface as the article rows are arranged to form the second article array, the second article array delivery device adapted to simultaneously deliver at least one article row to the second consolidation area while the second consolidation area continuously stabilizingly supports a periphery of the article rows positioned on the second support surface as the article rows are arranged to form the second article array;
• wherein the first consolidation area including a first backing plate, a first first consolidation area stabilizer, and opposed first support members, the article rows positioned between the first backing plate, the first first consolidation area stabilizer, and the first support members, the first backing plate and the first first consolidation area stabilizer providing stabilizing support to opposed portions of the periphery of the article rows, and the first support members providing stabilizing support to remaining portions of the periphery of the article rows;
• upon the first first consolidation area stabilizer and the first backing plate moving and stabilizingly supporting the article rows in a first direction while forming the first article array, at least the first backing plate in contact with each article of a corresponding row of the article rows while moving the article rows in the first direction, a second first consolidation area stabilizer providing independent stabilizing support to the portion of the periphery of the article rows stabilizingly supported by the first backing plate prior to the first backing plate moving in a direction opposite the first direction, in preparation of receiving additional article rows in the first consolidation area immediately adjacent the article rows already positioned on the first support surface for forming the first article array;
• wherein upon at least partial formation of the first article array, the second first consolidation area stabilizer discontinues providing stabilizing support to the portion of the periphery of article rows formerly stabilizingly supported by the first backing plate, the portion of the periphery of the corresponding row of articles formerly stabilizingly supported by the first backing plate being stabilizingly supported by a corresponding portion of the periphery of the additional rows of articles, and a portion of the periphery of the additional row of articles being stabilizingly supported by the first backing plate;
• the first backing plate moving the at least partially formed first article array from the first consolidation area and onto a first transfer support surface positioned between the first consolidation area and a collection area;
• a first article array moving device for moving the first transfer support surface in at least a second direction from the first consolidation area toward the collection area, the periphery of the at least partially formed first article array being continuously stabilizingly supported while being moved onto the first transfer support surface, and while the first transfer support surface is being moved in the at least a second direction;
• wherein the second consolidation area including a second backing plate, a first second consolidation area stabilizer, and opposed second support members, the article rows positioned between the second backing plate, the first second consolidation area stabilizer, and the second support members, the second backing plate and the first second consolidation area stabilizer providing stabilizing support to opposed portions of the periphery of the article rows, and the second support members providing stabilizing support to remaining portions of the periphery of the article rows;
• upon the first second consolidation area stabilizer and the second backing plate moving and stabilizingly supporting the article rows in a first direction while forming the second article array, at least the second backing plate in contact with each article of a corresponding row of the article rows while moving the article rows in the first direction, a second second consolidation area stabilizer providing independent stabilizing support to the portion of the periphery of the article rows stabilizingly supported by the second backing plate prior to the second backing plate moving in a direction opposite the first direction, in preparation of receiving additional article rows in the second consolidation area immediately adjacent the article rows already positioned on the second support surface for forming the second article array;
• wherein upon at least partial formation of the second article array, the second second consolidation area stabilizer discontinues providing stabilizing support to the portion of the periphery of article rows formerly stabilizingly supported by the second backing plate, the portion of the periphery of the corresponding row of articles formerly stabilizingly supported by the second backing plate being stabilizingly supported by a corresponding portion of the periphery of the additional rows of articles, and a portion of the periphery of the additional row of articles being stabilizingly supported by the second backing plate;
• the second backing plate moving the at least partial second article array from the second consolidation area and onto one of the first transfer support surface or a second transfer support surface positioned between the second consolidation area and a collection area;
• one of the first article array moving device or a second article array moving device for moving the one of the first transfer support surface or the second transfer support surface in at least a second direction from the second consolidation area toward the collection area, the periphery of the at least partial second article array being continuously stabilizingly supported while being moved onto the one of the first transfer support surface or a second transfer surface, and while the one of the first transfer support surface or the second transfer surface is being moved in the at least a second direction.

A method for forming and moving an article array comprising:

• receiving at least a first row of articles onto a first support surface of a first consolidation area between a movable first stabilizer and a movable first backing plate, the first consolidation area providing continuous stabilizing support to the periphery of the at least first row of articles, the first stabilizer and the first backing plate providing stabilizing support to opposed portions of the periphery of the at least first row of articles;
• the first backing plate and the first stabilizer moving and stabilizingly supporting the at least first row of articles in a first direction, at least the first backing plate in contact with each article of a corresponding row of the at least first row of articles while moving the at least first row of articles in the first direction;
• additionally stabilizingly supporting the portion of the periphery of the at least first row of articles stabilizingly supported by the first backing plate, the additional stabilizing support being independent of the stabilizing support provided by the first backing plate;
• moving the first backing plate in a direction opposite the first direction in preparation of receiving at least a second row of articles;
• receiving the at least second row of articles immediately adjacent the at least first row of articles onto the first support surface between the first backing plate and the at least first row of articles, the periphery of the at least first row of articles and the at least second row of articles being continuously stabilizingly supported, including stabilizing support provided by the first stabilizer and the first backing plate, the at least first row of articles and the at least second row of articles at least partially forming a first article array;
• moving the at least partially formed first article array from the first consolidation area and onto a first transfer support surface positioned between the first consolidation area and a collection area, wherein moving the at least partially formed first article array includes the first stabilizer or a second stabilizer and the first backing plate moving and stabilizingly supporting the first article array in the first direction and onto the first transfer support surface;
• and
• moving the first transfer support surface in at least a second direction from the first consolidation area toward the collection area, the periphery of the at least partially formed first article array being continuously stabilizingly supported while being moved onto the first transfer support surface, and while the first transfer support surface is being moved in the at least a second direction.