U.S. patent application number 11/232309 was filed with the patent office on 2007-01-11 for carton with handle reinforcement structure.
Invention is credited to Aaron Bates, James Knotts, Tsugihiko Suzuki.
Application Number | 20070007325 11/232309 |
Document ID | / |
Family ID | 37617394 |
Filed Date | 2007-01-11 |
United States Patent
Application |
20070007325 |
Kind Code |
A1 |
Suzuki; Tsugihiko ; et
al. |
January 11, 2007 |
Carton with handle reinforcement structure
Abstract
A carton with a handle opening formed in an end wall includes
one or more inserts--each being hingedly connected to a handle
panel structure for reinforcing and improving the ergonomics of the
handle opening. Each handle panel structure includes a reinforcing
portion that reinforces the weight-bearing edge of the handle
opening. In certain embodiments, this reinforcing portion is formed
by folding the multiple panels of the handle panel structure into a
hollow box beam shape with a handle edge that reinforcingly aligns
with the weight-bearing edge of the handle opening to provide
structural integrity. In certain other embodiments, the reinforcing
portion is the outermost edge of the handle panel structure, which
similarly aligns to support the integrity of the handle opening.
The handle opening is further cushioned and reinforced by a
punchout flap that folds inward through the handle opening and
wraps around the handle panel structure.
Inventors: |
Suzuki; Tsugihiko; (Duluth,
GA) ; Bates; Aaron; (Powder Springs, GA) ;
Knotts; James; (Roswell, GA) |
Correspondence
Address: |
PARKS KNOWLTON LLC
1117 PERIMETER CENTER WEST
SUITE E402
ATLANTA
GA
30338
US
|
Family ID: |
37617394 |
Appl. No.: |
11/232309 |
Filed: |
September 21, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60696792 |
Jul 7, 2005 |
|
|
|
Current U.S.
Class: |
229/117.16 ;
229/242 |
Current CPC
Class: |
B65D 5/0227 20130101;
B65D 5/46088 20130101; B65D 5/542 20130101; B65D 5/445
20130101 |
Class at
Publication: |
229/117.16 ;
229/242 |
International
Class: |
B65D 5/46 20060101
B65D005/46; B65D 17/00 20060101 B65D017/00 |
Claims
1. A carton, comprising: an outer top panel; first and second side
walls hingedly connected said outer top panel; a bottom wall
hingedly connected to said first side panel and secured to said
second side panel; an end wall, comprising: a top end panel
hingedly connected to said outer top panel and including a handle
opening having a weight bearing portion; first and second side end
panels hingedly connected to said first and second side walls,
respectively; and a bottom end panel hingedly connected to said
bottom panel; and an insert blank, comprising: an inner top panel
defined by side edges and end edges; and a handle structure panel
hingedly connected to said inner top panel along one of said end
edges; wherein a reinforcing portion of said handle structure panel
is aligned with and in reinforcing proximity to said weight bearing
portion of said handle opening.
2. The carton of claim 1, wherein: said handle structure panel
comprises: a first handle structure section; a handle edge hingedly
connected to said first handle structure section; a second handle
structure section hingedly connected to said handle edge; and a
handle attachment section hingedly connected to said second handle
structure section and secured to said inner top panel; and said
reinforcing portion comprises the hinged connection between said
first handle structure section and said handle edge.
3. The carton of claim 1, wherein: said reinforcing portion of said
handle structure panel comprises an end edge; and each side end
flap comprises a cutout having dimensions complementary to the
dimensions of at least part of the handle opening.
4. A carton, comprising: an outer top panel; first and second side
walls hingedly connected said outer top panel; a bottom wall
hingedly connected to said first side panel and secured to said
second side panel; an end wall, comprising: a top end panel
hingedly connected to said outer top panel and including a handle
opening having a weight bearing portion; first and second side end
panels hingedly connected to said first and second side walls,
respectively; and a bottom end panel hingedly connected to said
bottom panel; an insert blank, comprising: an inner top panel
defined by side edges and end edges; a handle structure panel
hingedly connected to said inner top panel along one of said end
edges.
5. The carton of claim 4, said handle structure panel comprising: a
first handle structure section; a handle edge hingedly connected to
said first handle structure section; a second handle structure
section hingedly connected to said handle edge; and a handle
attachment section hingedly connected to said second handle
structure section and secured to said inner top panel; a hinged
connection between said first handle structure section and said
handle edge.
6. The carton of claim 4, wherein the inner top panel extends the
length of the carton.
7. The carton of claim 4 wherein the inner to panel is further
hingedly connected to a second handle structure panel.
8. A carton, comprising: a plurality of panels that cooperate to
form the top, sidewalls, bottom, and ends of said carton; an inner
top panel defined by side edges and end edges; a handle structure
panel hingedly connected to said inner top panel along one of said
edges, wherein said handle structure panel comprises a first handle
structure section; a first handle edge hingedly connected to said
first handle structure section; a second handle structure section
hingedly connected to said first handle edge; and a handle
attachment section hingedly connected to said second handle
structure section and secured to said inner top panel.
9. The carton of claim 8, further comprising an outer top panel
defined by side edge and end edges, positioned adjacent to said
inner top panel.
10. The carton of claim 9, wherein said outer top panel further
comprises a second handle edge and a handle punchout.
11. The carton of claim 10, wherein said out top panel is folded
such that said second handle edge is positioned proximate to said
first handle edge and said punchout is positioned proximate to said
second handle structure.
12. A carton, comprising: a plurality of panels that cooperate to
form the top, sidewalls, bottom, and ends of said carton; a top
panel defined by side edges and end edges; a handle structure panel
hingedly connected to said top panel along one of said edges,
wherein said handle structure panel comprises a first handle
structure section; a first handle edge hingedly connected to said
first handle structure section; a second handle structure section
hingedly connected to said handle edge; and a handle attachment
section hingedly connected to said second handle structure section
and secured to said top panel.
13. The carton of claim 12, further comprising a bottom panel
defined by side edge and end edges, positioned opposite said top
panel.
14. The carton of claim 13, further comprising a bottom end panel
hingedly connected to said bottom panel.
15. The carton of claim 14, wherein said bottom end panel further
comprises a second handle edge and a handle punchout.
16. The carton of claim 15, wherein said bottom end panel is folded
to position said second handle edge proximate to said first handle
edge and said punchout proximate to said second handle
structure.
17. A carton, comprising: a plurality of panels that cooperate to
form the top, sidewalls, bottom, and ends of said carton; a top
panel defined by side edges and end edges and hingedly connected to
one of said plurality of panels; a handle structure panel hingedly
connected to said top panel along one of said edges, wherein said
handle structure panel comprises a reinforcing portion that is
aligned with and in reinforcing proximity to said weight bearing
portion of the said handle opening.
18. The carton of claim 17, further comprising a bottom panel
defined by side edge and end edges, positioned opposite said top
panel.
19. The carton of claim 18, further comprising a bottom end panel
hingedly connected to said bottom panel.
20. The carton of claim 19, wherein said bottom end panel further
comprises a second handle edge and a handle punchout.
21. The carton of claim 20, wherein said bottom end panel is folded
to position said second handle edge proximate to said first handle
edge and said punchout proximate to said second handle structure.
Description
RELATED APPLICATION
[0001] This application claims the benefit of the filing date of
U.S. Provisional Application Ser. No. 60/696,792, entitled "Carton
with Handle Reinforcement Structure," filed on Jul. 6, 2005 under
35 U.S.C. .sctn.111(b), the entirety of which is incorporated
herein by reference.
TECHNICAL FIELD
[0002] This invention relates generally to a carton having a
reinforced handle in an end wall, and particularly, to a carton
having a handle opening reinforced by a handle structure panel that
allows the carton to be used to carry heavier loads.
BACKGROUND OF THE INVENTION
[0003] Cartons for encasing and dispensing multiple articles such
as beverage bottles or cans are useful for enabling consumers to
transport, store, and access the articles for consumption. To
facilitate carrying such cartons, carton it is desirable to include
handles that are sufficiently strong to withstand the stress
generated by the weight of articles enclosed. Handles are typically
integral to or attached to a wall of the carton. The handles should
also be ergonomic--distributing the weight of heavy articles if
needed to minimize the user's fatigue, and preventing undue
pressure or stress on any portion of the user's hand that engages
the handle.
[0004] Another challenge arises when the burst strength of the
material comprising the adjacent wall is insufficient to avoid
detaching the handle or tearing the wall itself. One potential
solution is to construct the carton from a stronger material, such
as corrugated board, or from sheet material having a relatively
higher caliper. As fully enclosed cartons typically are formed from
a single sheet of material, and cost tends to increase according to
the strength and thickness of material used to construct the carton
walls, this approach is expensive because it effectively amounts to
reinforcing all six walls (top, sides, bottom, and ends) of the
carton irrespective of the relative magnitude of the forces borne
by each wall.
[0005] According to another approach, an additional layer of sheet
material is used as an insert that that reinforces the integrity of
a handle as well as that of the end wall. For instance, a handle
opening in an end flap of an end wall of a carton may be reinforced
by overlaying an insert over the handle opening and securing the
insert to the end flap. To avoid obstructing the handle opening,
the insert must have a similar or somewhat larger opening that is
aligned with the handle opening to reinforce its edges. Similarly,
additional apertures or cutouts are often required in side flaps to
prevent overlapping or obstructing the handle aperture. However,
handle openings reinforced using this approach have exposed edges
that are relatively keen, which may produce discomfort for the user
who inserts fingers into the handle opening to lift the carton.
Moreover, by overlaying an insert over an endless edged handle
opening, the entire periphery is reinforced even though only the
weight bearing portion of the handle opening needs such
reinforcement. Furthermore, precise alignment of the apertures and
cutouts in the side end flaps with the handle opening and the
insert opening is difficult to accomplish on high-speed out plant
equipment (OPE) such as at a bottling facility, as part of the
process of erecting and loading the cartons.
[0006] What is needed is a carton that has a reinforced end handle
that accommodates heavier loads without failing and is ergonomic
and comfortable to use, where the carton walls are efficiently
constructed without wasting expensive material in carton walls that
are less likely to fail or by reinforcing portions of the handle
that do not bear weight.
SUMMARY OF THE INVENTION
[0007] The various embodiments of the present invention overcome
the shortcomings of the prior art by providing a carton formed from
a single sheet of paperboard or other foldable sheet material, the
carton having a handle opening disposed in at least one end wall,
wherein at least the weight bearing portion of the handle opening
is reinforced by an insert that includes a handle structure panel
formed from the same or an additional sheet of material as the
carton. All or a portion of the insert including the handle
structure panel is secured to the top and/or the end wall, and a
reinforcing portion of the handle structure panel is aligned in
reinforcing proximity to the weight-bearing edge of the handle
opening. Advantageously, the handle structure panel can be
assembled and secured within the carton in alignment with the
weight-bearing portion of handle opening prior to the carton being
loaded into a packaging machine to be erected and loaded. As
another advantage, the configuration provides a multi-ply hand
engaging surface that is more comfortable for the user,
particularly in combination with a hand cushioning flap or a hollow
core arrangement.
[0008] More specifically, the exemplary carton incorporating the
various aspects of the invention is formed from a carton blank that
includes a bottom panel, a first side panel hingedly connected to
the bottom panel, an outer top panel hingedly connected to the
first side panel, a second side panel hingedly connected to the
outer top panel. When the carton is erected, these panels become
the top, bottom, and side walls of the carton. The carton blank
also includes several end panels that form at least one end wall
structure. Each end wall structure is formed from a bottom end
panel hingedly connected to the bottom panel and a top end flap
hingedly connected to the outer top panel. The top end flap
includes a handle opening disposed therethrough. The handle opening
is formed by partially detaching a handle punchout by tearing,
cutting, punching out or otherwise partially excising a section of
the carton blank along a handle severance line. The end wall
structure also includes side end flaps hingedly connected to the
first and second side panels respectively, each side end flap
having dimensions tailored to avoid interfering with or overlapping
the handle opening.
[0009] In certain embodiments of the invention, the insert is
formed from an insert blank that includes an inner top panel to
which a handle structure panel is hingedly connected along each of
its opposing end edges. The reinforcing portion of the handle
structure panel includes an end edge that is aligned with and in
reinforcing proximity to the weight bearing portion of the said
handle opening. Each handle structure panel is foldable, preferably
via in-plant equipment (IPE). The IPE also places the outside
surface of the top inner panel in face contacting arrangement with
the inside surface of the outer top panel, aligning the hinged
connections between the inner top panel and each handle structure
panel with the fold line that hingedly connects the outer top panel
to the respective top end flap. The outside surface of the handle
structure panel is secured to the inside surface of the top end
flap in alignment with and proximity to the weight bearing portion
of the handle opening in the top end flap. Alternatively, instead
of a single inner top panel, dual inserts are positioned near
either end of the carton, with each insert including a handle
structure panel as described above.
[0010] In addition, each side end flap includes a cutout having
dimensions that are complementary to the dimensions of at least
part of the handle opening. The bottom panel is secured to the
second side panel to place the partially erected carton into a
collapsed tubular configuration.
[0011] When the carton is erected, preferably via out-plant
equipment such as a packaging machine, the walls of the collapsed
tubular carton are pulled apart and the side end flaps are folded
toward the interior of the carton. The bottom and top end flaps are
folded toward the interior of the carton as well. The top end flap
forms the outermost ply of the reinforced composite handle.
[0012] In a certain alternative embodiments, the handle structure
panel includes a first handle structure section that is defined
from the inner top panel by a hinged connection and is made easily
foldable, with respect to the inner top panel, by a succession of
spaced fold apertures or fold lines, or a combination of spaced
apertures and fold lines. A handle edge is hingedly connected along
a fold line to the first handle structure section. The handle edge
is hingedly connected along a fold line to second handle structure
section, which is hingedly connected along a fold line to a handle
structure attachment. Each handle structure panel is foldable,
preferably via in-plant equipment (IPE), into a collapsed hollow
core structure which can be held in place by securing the inside
surface of handle structure attachment to the inside surface of
inner top panel. The IPE also places the outside surface of the top
inner panel in face contacting arrangement with the inside surface
of the outer top panel, aligning the hinged connections between the
inner top panel and each first handle structure with the fold line
that hingedly connects the outer top panel to the respective top
end flap. The outside surface of the first handle structure is
secured to the inside surface of the top end flap in alignment with
and proximity to the weight bearing portion of the handle opening
in the top end flap. The bottom panel is secured to the second side
panel to place the partially erected carton into a collapsed
tubular configuration.
[0013] When the carton is erected, preferably via out-plant
equipment such as a packaging machine, the walls of the collapsed
tubular carton are pulled apart and the side end flaps are folded
toward the interior of the carton. The bottom end flaps are folded
toward the interior of the carton as well. When the top end flaps
are folded toward the interior of the carton, the collapsed hollow
core structure is forced into the shape of a box beam, with the
handle edge forming the lower edge of the box beam shape, and the
first and second handle structure sections forming the sides of the
box beam shape. The first and second handle structures are
substantially parallel to the top end panel, creating the
intermediate plies of the reinforced composite handle. The top end
flap forms the outermost ply of the reinforced composite
handle.
[0014] The box beam shape provides additional structural integrity
to the weight bearing portion of the handle opening in addition to
the additional layers of sheet material. However, other hollow core
configurations are contemplated as well, including but not limited
to, a beam having semicircular or triangular cross section with one
surface of the beam being secured to the top end flap in alignment
with the weight bearing portion of the handle opening.
[0015] According to one aspect of the invention, the handle
structure panel may be just long enough to reinforce the weight
bearing portion of the handle opening, or may extend along the top
end flap as long as the entire width of the outer panel, which may
be co-extensive with the width of the end wall of the carton.
[0016] According to another aspect of the invention, the handle
punchout that is partially detached to form the handle opening is
foldable into the interior of the carton to wrap around the
reinforcing portion of the handle panel structure, forming the
innermost ply of the reinforced composite handle. A handle edge
portion of the handle punchout further reinforces and cushions the
hand-engaging portion as it is placed in registry with the
reinforcing portion of the handle structure panel.
[0017] According to yet another aspect of the invention, the insert
blank may be integral to the carton blank. More to the point, the
outer top panel is hingedly connected along a fold line to the
first side panel, which is hingedly connected along a fold line to
the bottom panel, which is hingedly connected along a fold line to
the second side panel, which is hingedly connected along a fold
line to the insert blank. The handle structure panel is assembled
as described with respect to the embodiments described above, and
the carton is configured in a collapsed tubular state by securing
the insert blank to the outer top panel in a face contacting
arrangement as described above.
[0018] In another alternative embodiment, the insert blank is
substituted for the outer top panel, with the handle structure
panels replacing the top end flaps, and the handle openings being
disposed through bottom end flaps, which are extended in length.
Thus, the first side panel is hingedly connected along a fold line
to the top panel, which comprises the insert blank. The top panel
is hingedly connected along a fold line to the second side panel,
which is hingedly connected along a fold line to the bottom panel.
The handle structure panel is assembled and secured as described
above, and the carton is configured in a collapsed tubular state by
securing the bottom panel to the first side panel. To erect the
carton, each collapsed hollow core structure is erected as it is
folded toward the interior of the carton, and the corresponding
bottom end flap is folded and secured thereto in overlapping
relationship. The handle edge of the hollow core structure is
aligned with and in reinforcing proximity to the weight bearing
portion of the handle opening.
[0019] Certain of the embodiments include a dispenser formed at
least in part from the top wall of the carton, which may extend
onto the side walls as well. The dispenser is formed by at least
partially removing a detachable portion that is defined by a tear
line that can be easily broken by tear initiation means, such as
push tabs, tear tabs, or tear strips, or any combination thereof.
The carton is opened by breaking the tear lines and removing the
detachable portion to access the articles within the carton. In
embodiments having an inner top panel, a means for carton access is
formed in the inner top panel, which may be defined by at least a
second tear line and a second detachable portion or portions that
are fully or partially detachable from the carton. In these
embodiments, the carton is opened by removing the first detachable
portion and then by breaking the second set of tear lines to gain
access to the articles within.
[0020] Accordingly, other aspects and a more comprehensive
understanding of the invention may be obtained by referring to the
detailed description of the exemplary embodiments taken in
conjunction with the accompanying drawings, in addition to the
scope of the invention defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates embodiments of carton blanks, according
to the present invention.
[0022] FIG. 2 is a longitudinal cross-section of an erected carton
according to the present invention, formed from the blanks of FIG.
1.
[0023] FIG. 3 is a perspective view of an embodiment of an erected
carton, according to the present invention.
[0024] FIG. 4 is a plan view of another embodiment of a carton
blank, according to the present invention.
[0025] FIG. 5 is a plan view of another embodiment of a carton
blank, according to the present invention.
[0026] FIG. 6 is a plan view of another embodiment of a carton
blank, according to the present invention.
[0027] FIG. 7 is a plan view of another embodiment of a carton
blank, according to the present invention.
DETAILED DESCRIPTION
[0028] As required, detailed embodiments of the present invention
are disclosed herein. It must be understood that the disclosed
embodiments are merely exemplary of the invention that may be
embodied in various and alternative forms, and combinations
thereof. The figures are not necessarily to scale, and some
features may be exaggerated or minimized to show details of
particular components. In other instances, well-known materials or
methods have not been described in detail in order to avoid
obscuring the present invention. Therefore, specific structural and
functional details disclosed herein are not limited but serve as a
basis for the claims, and for teaching one skilled in the art to
variously employ the present invention.
[0029] With regard to the drawings, wherein like numerals indicate
like elements throughout the several views, the drawings illustrate
several exemplary embodiments of a carton that is particularly
useful for enclosing and carrying relatively heavy articles such as
large glass bottles. Generally speaking, the exemplary cartons are
formed from any foldable material, but preferably foldable sheet
material such as paperboard, corrugated board, plastic,
combinations or laminates of these materials, and the like. Each of
the exemplary cartons includes an insert or other reinforcing panel
including a handle structure panel that reinforces a handle opening
formed in an end wall of the carton. The reinforcing portion of the
handle structure panel aligns with the weight bearing portion of
the handle opening.
[0030] Referring now to FIG. 1, there is shown an embodiment of a
carton blank 100 and an insert blank 150, according to the present
invention. The carton blank 100 includes at least four primary
panels for forming the carton 200 shown in FIG. 2. The panels of
the carton blank 100 include an edge panel 102, a bottom panel 104,
a first side panel 106, an outer top panel 108, and a second side
panel 110. The panels 102, 104, 106, 108, 110, inclusive, are
hingedly connected one to the next. More specifically, the edge
panel 102 is hingedly connected to the bottom panel 104 along fold
line 112. The bottom panel 104 is hingedly connected to the first
side panel 106 along fold line 114. The first side panel 106 is
hingedly connected to the outer top panel 108 along fold line 116.
And the outer top panel 108 is hingedly connected to the second
side panel 110 along fold line 118. In FIG. I a unitary blank 100
is shown; those skilled in the art will understand that two or more
blanks may be used to form the illustrated blank 100 as well as all
the blanks taught and claimed herein.
[0031] Each of the panels 104, 106, 108, 110 is connected to
opposing and preferably symmetric end panels, defined in part by
fold lines that extend transversely--with respect to the
orientation shown in the figure--along opposite transverse edges of
the respective panel 104, 106, 108, 110. When erected, the end
panels along each edge of the blank cooperate to form a respective
end closure structure. In the embodiments illustrated throughout,
each pair of end panels and end closure structures are sufficiently
identical that like references have been used, with "a" or "b"
affixed to distinguish the components of one end of the carton from
the other. In other words, with regard to the illustrated
embodiments, typically what applies to the elements designated with
an "a" reference applies equally to those elements designated with
a "b" reference. Accordingly, for the sake of clarity, the present
teaching and description will refer to only those elements with the
"a" reference unless a clear understanding of the illustrated
embodiments requires a discussion of an element with a "b"
reference.
[0032] The bottom panel 104 is hingedly connected to bottom end
panel 120a along a fold line 130a. The first side panel 106 is
hingedly connected to a first side end panel 122a along a fold line
132a. The outer top panel 108 is hingedly connected to an outer top
end panel 124a along a fold line 134a. The second side panel 110 is
hingedly connected to a second side end panel 126a along a fold
line 136a.
[0033] The blank 100 further includes a tear line 140 and means for
tear initiation 142. The tear line 140 may be a severance line or
any other weakened line that facilitates access to the interior of
a carton according to the present invention. It is contemplated
that both the tear line 140 and means for tear initiation 142
include, but are not limited to, a line of perforations, a line of
short slits, a line of half cuts, a single half cut, pull tape, rip
cords, and any combination of perforations, slits, score lines,
half cuts, tape, cord, or the equivalent. As understood by those
skilled in the art, the tear line 140 and means for tear initiation
142 assist the user with opening the carton and accessing the
articles therein. As further understood by one skilled in the art,
here the curvature, shape, and/or orientation of the tear line 140
and means for tear initiation 142 are merely design choices. Hence,
the tear line 140 and means for tear initiation 142 elements are
merely illustrative and not limiting.
[0034] The outer top panel end flap 124a further includes elements
that partially define a handle. These elements include a first
handle edge fold line 144a adjacent to one side of a handle edge
145a, and second handle edge fold line 146a adjacent to a distal
side of the handle edge 145a. Preferably, but not necessarily so,
the fold lines 144a, 146a are substantially straight and parallel
to each other. A handle cut line 148a defines the remainder of the
handle. Here the handle is illustrated as a sinuous shape, believed
to be comfortable to the user, but all handle shapes are
contemplated and included in the scope of the claims. When folded
along the fold lines 144a, 146a as described below with reference
to the erection of the carton 200, handle punchout 149a rests
within the erected carton.
[0035] Continuing with reference to FIG. 1, there is shown an
embodiment of a carton insert blank 150 according to the present
invention. The illustrated insert blank 150 includes three panels
for forming, together with the carton blank 100, the carton 200.
The panels of the insert blank 150 include an inner top panel 151,
and two handle structure panels 152a, 152b. Similar to the carton
blank 100 explained herein, the illustrated insert blank 150 is
symmetric and the opposite sides are substantially identical.
Accordingly, substantially identical elements are designated "a" or
"b" and the present discussion will be with reference only to the
elements designated "a" unless otherwise required.
[0036] Each handle structure panel 152a further includes four
panels for reinforcing the improved handle structure. The
illustrated four panels are a first handle structure section 154a,
a handle edge 156a, a second handle structure section 158a, and a
handle structure attachment 160a. The first handle structure
section 154a is hingedly connected to the handle edge 156a along
fold line 162a. The handle edge 156a is hingedly connected to the
second handle structure section 158a along fold line 164a. And the
second handle structure section 158a is hingedly connected to the
handle structure attachment 160a along fold line 166a.
[0037] The insert blank 150 further includes several preferable but
alternatively optional elements, namely, fold apertures 170a and
fold lines 172a. Inner panel 151 is hingedly connected to handle
structure panel 152a along fold apertures 170a. As understood by
those skilled in the art, fold apertures 170a reduce the bulk along
a folded carton edge as well as the resistance of layered panels to
folding. Similarly, fold lines 172a positioned between or in lieu
of the fold apertures 170a may increase the ease of folding. The
insert blank 150 further includes an optional means for carton
access 174. Means for carton access 174 includes at least one tear
line and an optional means for tear initiation, as described above
with regard to the carton blank 100.
[0038] With reference now to FIGS. 2 and 1, one method of erecting
the illustrated carton 200 includes folding and then connecting or
otherwise securing the edge panel 102 to the second side panel 110.
To form a partially erected open ended tubular carton, the edge
panel 102 is secured to the second side 110; preferably such that
the fold line 112 is immediately adjacent to the free edge of the
second side panel 110. The insert blank 150 is then inserted
through the tubular carton and positioned adjacent to the top panel
108. In the illustrated embodiments, the inner top panel 151 is
connected or otherwise secured to the top panel 108, but such
attachment is not required. For the purpose of positioning the
insert 150, the optional fold apertures 170a or optional fold line
172a may be aligned with and placed immediately adjacent to the top
panel fold line 134a. Next, the handle panel structure 152a is
folded to create a hollow core handle by folding the handle
structure section 154a inwardly along the fold apertures 170a
and/or fold lines 172a, the handle edge 156a inwardly along the
fold line 162a, the second handle edge 158a inwardly along the fold
line 164a, and the handle structure attachment 160a outwardly along
the fold line 166a before connecting or otherwise securing the
attachment 160a to the inner panel 151. Fold line 162a is aligned
substantially with fold line 144a so as to reinforce the weight
bearing edge of the handle opening. Thus, the reinforcing portion
of the handle structure panel 152a includes fold line 162a and
handle edge 156a. As used herein, hollow is defined broadly beyond
having a space or cavity inside to include not being attached so
that a space or cavity could exist if adjacent structure sections
were parted.
[0039] Alternatively, the insert blank 150 may be attached to the
top panel 108 at different times during a sequence of erecting the
tubular carton. In an alternative method of erecting, the handle
panel structure 152a is folded to create the hollow core handle
described herein before being attached to the top panel 108.
Thereafter, the insert blank 150 with erected handle may be
connected or secured to the top panel 108 before or after the edge
panel 102 is connected or secured to the second side panel 110 to
form the tubular carton.
[0040] As best shown in FIG. 2, the handle panel structure 152a is
folded and attached to the inner panel 151 to form a hollow core
handle of substantially parallel sides which, in cross-section,
resembles the shape of a box beam. Alternative hollow core handle
shapes are contemplated herein, including those with an angled
cross-section and those with a curved cross-section. In addition,
alternative handle edges are contemplated herein, including those
comprising only the edge of a single fold line such as 162a or
164a, and those comprising a curved surface.
[0041] Upon erecting the handle structure panel 152a and
positioning the top inner panel 151 adjacent to the top outer panel
108 of the tubular carton, the handle structure panel 152a and top
end panel 124a may resemble the partially folded carton end wall
configuration represented by the dashed lines of FIG. 2. There the
handle structure panel 152a, which may or may not be connected or
otherwise secured to the top end panel 124a, is poised to allow
loading of the articles 202. Here, the articles to be loaded are
beverage containers such as glass bottles. After the articles are
grouped and loaded through either or both of the open ends of the
carton 200, the side end panels 122a and 126a, the bottom end panel
120a, the handle structure panel 152a, and the top end panel 124a
are fully folded and secured together to form the end wall
structure. Thereafter, handle punchout 149a may be pushed inwardly
and upwardly to partially wrap the erected handle panel structure
along the first handle section 154a, the handle edge 156a, and
second handle section 158a. When fully erected, the illustrated
handle structure comprises a hollow core defined by handle panel
sections 154a, 158a and a handle edge 156a, which provides a carton
handle of improved performance and structure integrity. As
understood by those skilled in the art, the hollow core handle
structure is created by the configuration of the material rather
than the composition of the material.
[0042] As shown in FIG. 2, the handle structure panel 152a is
erected as the top end panel 124a is fully folded and secured to
form the end wall structure. In the exemplary embodiment, cutouts C
(shown in FIG. 1) in the side end panels 122a, 126a remove material
such that the at least partially formed handle structure panel 152a
is not obstructed by the side end panels 122a, 126a as the top end
panel 124a is fully folded and secured to form the end wall
structure. The shape and dimensions of the cutouts C are otherwise
merely design choices. For example, the cutouts C may be made such
that a pointed section remains in the side end panels 122a, 126a as
shown in FIG. 1 or, alternatively, the cutouts C may be made such
that the pointed section does not remain as in shown in FIG. 4 for
the side end panels 322a, 325a. An additional example of a cutout C
is shown in FIG. 6.
[0043] FIG. 3 introduces an alternative erected carton 210 that
includes one or more insert blanks 212. Here, the insert blank 212
comprises the same handle structure panel 152a as the insert blank
150 described in FIGS. 1 and 2. Further, the assembly and erection
of the carton 210 is substantially identical to the assembly and
erection of the carton 200 so it is not necessary to teach again
the erecting or assembling of this carton 210, except to point out
that the notable difference between the respective cartons 200, 210
is that the insert blank 212 only partially spans the top panel
108. Accordingly, alternative inserts may be of different lengths
or widths, and may or may not include elements described with
reference to the insert blank 150, best shown in FIG. 1. For
example, the insert 212 does not include means for carton access.
In addition, the insert 212 may or may not be connected or secured
to the top panel 108 or the top end panel 124a. Further, an insert
212 may be located at each end wall structure or, alternatively,
only one insert 212 may be positioned at any location of the carton
for purposes of providing an improved handle.
[0044] Referring now to FIG. 4, there is shown an alternative
embodiment of a unitary carton blank according to the present
invention. This blank 300 includes four primary panels for forming
the walls of a carton including an outer top panel 304, a first
side panel 306, a bottom panel 308, a second side panel 310, as
well as an inner top panel 311 for reinforcing the outer top panel
304. The panels 304, 306, 308, 310, 311, inclusive, are hingedly
connected one to the next. More specifically, the outside top panel
304 is hingedly connected to the first side panel 306 along fold
line 312. The first side panel 306 is hingedly connected to the
bottom panel 308 along fold line 314. The bottom panel 308 is
hingedly connected to the second side panel 310 along fold line
316. The second side panel 310 is hingedly connected to the inner
top panel 311 along fold line 318. In FIG. 4, a unitary blank 300
is shown; those skilled in the art will understand that two or more
blanks may be used to form the illustrated blank 300.
[0045] Each of the panels 304, 306, 308, 310, 311, inclusive, in
hingedly connected to opposing preferably symmetric end panels
defined in part by transverse fold lines disposed along opposite
transverse edges of the respective 304, 306, 308, 310, 311. When
erected, the end panels along each edge of the blank 300 cooperate
to form a respective end closure structure. Similar to the carton
blank 100 taught above, the present illustrated blank 300 is
symmetric and the opposite sides are substantially identical.
Accordingly, substantially identical elements are designated "a" or
"b" and the present discussion will continue with reference to the
elements designated "a" unless otherwise required.
[0046] The outer top panel 304 is hingedly connected to outer top
end panel 320a along fold line 330a. The first side panel 306 is
hingedly connected to a first side end panel 322a along fold line
332a. The bottom panel 308 is hingedly connected to a bottom end
panel 324a along fold line 334a. The second side panel 310 is
hingedly connected to a second side end panel 325a along fold line
336a. The inner top panel 311 is hingedly connected to a handle
structure section 326a. The handle structure section 326a further
comprises a handle edge 327a, a second handle section 328a, and a
handle structure 329a. The handle structure section 326a is
hingedly connected to the handle edge 327a along a fold line 337a.
The handle edge 327a is hingedly connected to the second handle
section 328a along fold line 338a. The second handle section 328a
is hingedly connected to the handle structure attachment 329a along
fold line 339a.
[0047] The blank 300 further includes two tear lines 340a, 340b and
means for tear initiation 342, similar to the tear line 140 and
means for tear initiation 142, respectively, taught above with
regard to the blank 100. As the respective tear lines 140, 340a,
340b and means for tear initiation 142, 342 are substantially
similar; no new discussion is required here. The inner top panel
311 further includes several preferable but alternatively optional
elements, namely, fold apertures 346a and fold lines 348a. Finally,
the illustrated handle structure section 326a is hingedly connected
to the top inner panel 311 along the fold apertures 346a and fold
lines 348a.
[0048] The outer top panel end flap 320a further includes elements
that partially define a handle. These elements include a first
handle edge fold line 350a adjacent to one side of a handle edge
352a, and a second handle edge fold line 354a adjacent to a distal
side of the handle edge 352a. Preferably, but not necessarily, the
fold lines 350a, 354a are substantially straight and parallel to
each other. A handle cut line 356a defines the remainder of the
handle. Here the handle is illustrated as a sinuous shape, believed
to be comfortable to the user, but all handle shapes are
contemplated and included in the scope of the claims. When folded
along the fold lines 350a, 354a as taught above with reference to
the erection of the carton 200, handle punchout 358a rests within
the erected carton.
[0049] One method of erecting an open ended tubular carton formed
from the blank 300, includes folding and then connecting or
otherwise securing the inner top panel 311 to the inner side of the
outer top panel 304, preferably such that the free edge of the
inner top panel is immediately adjacent to the top panel fold line
312. The remainder of the present method will be easily understood
by those skilled in the art who read the method taught herein with
regard to the erection of the cartons 200, 210, shown in FIGS. 2
and 3.
[0050] Referring now to FIG. 5, there is shown another alternative
embodiment of a unitary carton blank according to the present
invention. This blank 400 includes four primary panels for forming
an open end tubular carton. The panels of this blank 400 include a
first side panel 402, a top panel 404, a second side panel 406, a
bottom panel 408, and an edge panel 410. The panels 402, 406, 408,
410, inclusive, are hingedly connected together. More specifically,
the first side panel 402 is hingedly connected to the top panel 404
along a fold line 412. The top panel 404 is hingedly connected to
the second side panel 406 along a fold line 414. The second side
panel 406 is hingedly connected to the bottom panel 408 along a
fold line 416. The bottom panel 408 is hingedly connected to the
edge panel 410 along a fold line 418. In FIG. 5 a unitary blank 400
is shown; those skilled in the art will understand that two or more
blanks may be used to form the illustrated blank 400.
[0051] Each of the illustrated panels 402, 406, 408, 410,
inclusive, include opposing and preferably symmetrical end panels
defined in part by transverse fold lines disposed along opposite
transverse edges of the panels 402, 406, 408, 410. When erected,
the end panels along each edge of the blank cooperate to form a
respective end closure structure. Similar to the carton blank 100
explained above, the present illustrated blank 400 is symmetric and
the opposite sides are substantially identical. Accordingly,
substantially identical elements are designated "a" or "b" and the
present discussion will continue with reference to the elements
designated "a" unless otherwise required.
[0052] The first side panel 402 is hingedly connected to first side
end panel 420a along a fold line 430a. The top panel 404 is
hingedly connected to a top end panel 422a along a fold line 432a.
The second side panel 406 is hingedly connected to a second side
panel 424a along a fold line 434a. The bottom panel 408 is hingedly
connected to a bottom end panel 426a along a fold line 436a.
[0053] The illustrated bottom end panel 426a further comprises
elements that define a handle. These elements include a first
handle edge fold line 440a adjacent to one side of a handle edge
442a, and a second handle edge fold line 444a adjacent to a distal
side of the handle edge 442a. Preferably, but not necessarily so,
the fold lines 440a, 444a are substantially straight and parallel
to each other. A handle cut line 446a defines the remainder of the
handle. Here the handle is illustrated as a sinuous shape, believed
to be comfortable to the user, but all handle shapes are
contemplated and included in the scope of the claims. When folded
along the fold lines 440a, 444a, as taught above with reference to
the erection of the carton 200, handle punchout 448a rests within
the erected carton.
[0054] The illustrated top end panel 422a further includes four
panels for forming an improved handle structure. Those panels
include a first handle structure section 454a, a handle edge 456a,
a second handle structure section 458a, and a handle structure
attachment 460a. The first handle structure section 454a is
hingedly connected to the handle edge 456a along fold line 462a.
The handle edge 456a is hingedly connected to the second handle
structure section 458a along fold line 464a. And the second handle
structure section 458a is hingedly connected to the handle
structure attachment 460a along fold line 466a. In some
embodiments, the handle punchout 448a is attached or otherwise
secured to the second handle structure 458a.
[0055] The illustrated blank 400 further includes tear line 470 and
means for tear initiation 472, similar to the tear line 140 and
means for tear initiation 142 taught above with regard to the blank
100. As the respective tear lines 140, 470 and means for tear
initiation 142, 472 are substantially similar, no new discussion is
required here.
[0056] One method of erecting an open ended tubular carton formed
from the blank 400 includes folding and then connecting or
otherwise securing the edge panel 410 to the first side panel 402,
preferably such that the free edge of the first side panel is
immediately adjacent to the edge panel fold line 418. The remainder
of the present method will be understood by those skilled in the
art who read the method taught herein with regard to the erection
of the cartons 200, 212, shown in FIGS. 2 and 3.
[0057] Referring now to FIG. 6, there is shown another alternative
embodiment of carton blanks according to the present invention. The
carton blank 500 and the carton insert blank 550 are somewhat
similar to the carton blank 100 and the carton insert blank 150,
respectively, as described above. Accordingly, certain differences
between the carton blanks 100, 500 and between the carton insert
blanks 150, 550 will be described below. A top inner panel 551 and
the handle structure panels 552a, 552b of the carton insert blank
550 are substantially as wide as the outer top panel 508 of the
carton blank 500. Further, each of the side end panels 522a, 522b,
526a, 526b includes a tab T. The carton blank 500 and carton insert
blank 550 are folded and secured to form a carton (not shown)
somewhat as described above for the carton blank 100 and carton
blank insert 150 where each tab T may be captured by or inserted
into a respective end of the hollow box beam portion of an erected
handle structure panel 552a, 552b to provide additional stability
or to otherwise prevent bowing of the top or side walls of the
carton when the carton is lifted.
[0058] It is contemplated that the maximum width of the carton
blank insert 550 may be the same or less than that of the outer top
panel 508 and that the width of the top inner panel 551 may be the
same, more, or less than that of the handle structure panels 552a,
552b. As the width of the top inner panel 551 and the handle
structure panels 552a, 552b near the width of the outer top panel
508, the top panel of the carton becomes stiffer and the area above
the handle is further strengthened. As the width of the outer top
inner panel 551 and the handle structure panels 552a, 552b are
reduced, the amount of material and associated cost is reduced.
[0059] Referring now to FIG. 7, there is shown another alternative
embodiment of carton blanks according to the present invention. The
carton blank 600 and the carton insert blank 650 are somewhat
similar to the carton blank 100 and the carton insert blank 150,
respectively, as described above. Accordingly, certain differences
between the carton blanks 100, 600 and between the carton insert
blanks 150, 650 will be described. The handle reinforcing portion
of the carton insert blank 650 include the outermost edges E of
handle structure panels 654a, 654b. The carton blank 600 is erected
to form a carton (not shown) substantially as described above for
the carton blank 100 and carton insert blank 650 is folded and
secured inside the carton in a similar manner as described with
respect to the carton blank insert 150. More specifically, the
carton insert blank 650 is secured to the carton such that the top
inner panel 651 is secured to the outer top panel 608 and the
handle structure panels 654a, 654b are secured to or otherwise
disposed in a face contacting arrangement with the area above the
handle openings on the top end panels 624a, 624b. Outermost edges E
of the handle structure panels 654a, 654b are reinforcingly aligned
with the fold line 644a. The thickness or caliper of carton insert
blank 650 may correspond to the distance between fold line 644a and
646a, such that when the carton is erected and the punchout 649a is
folded inwardly into the carton, a cushioning surface is formed by
handle edge 645a.
[0060] However, it is preferred that the thickness of each handle
structure panel 654a, 654b is limited so that the handle structure
panel 654a, 654b does not impede the respective top end panels
624a, 624b from overlapping or otherwise being secured to the
inside or outside surface of a respective pair of side end panels
622a, 624a and 622b, 624b, in a face contacting arrangement. Rather
than requiring the cutouts C to avoid the handle structure panels
654a, 654b, the side end panels 622a, 622b, 624a, 624b include
cutouts C that are shaped and positioned to be complementary to the
handle openings of the carton such that the side end panels 622a,
622b, 624a, 624b at least partially reinforce the thickness of the
handle opening in respective side wall of the carton. Thus, the
weight-bearing portion of each handle opening is reinforced at
least in part by the reinforcing portion, edge E, of each handle
structure panel 654a, 654b and by the cutouts C formed in the side
end panels 622a, 622b, 624a, 624b.
[0061] It must be emphasized that the law does not require and it
is economically prohibitive to illustrate and teach every possible
embodiment of the present claims. Hence, the above-described
embodiments are merely exemplary illustrations of implementations
set forth for a clear understanding of the principles of the
invention. Variations, modifications, and combinations may be made
to the above-described embodiments without departing from the scope
of the claims. For example, any of the embodiments described herein
may be implemented with a single insert that extends the entire
length of the top wall, or with an individual insert that is
disposed at or near either or both ends of the carton, as shown in
FIG. 3. All such variations, modifications, and combinations are
included herein by the scope of this disclosure and the following
claims.
* * * * *