U.S. patent application number 11/941052 was filed with the patent office on 2008-06-05 for carton with handle-reinforcement insert.
Invention is credited to Aaron Bates, John M. Holley, Tsugihiko Suzuki.
Application Number | 20080128479 11/941052 |
Document ID | / |
Family ID | 39474550 |
Filed Date | 2008-06-05 |
United States Patent
Application |
20080128479 |
Kind Code |
A1 |
Bates; Aaron ; et
al. |
June 5, 2008 |
Carton With Handle-Reinforcement Insert
Abstract
A carton includes a substantially tubular structure having an
outer top panel. The carton also has an end wall structure
including an outer top end flap foldably connected to the outer top
panel along its end edge. The outer top end flap includes a handle
opening having a weight-bearing region. The carton also has an
insert including an inner top panel and an inner top end flap. The
inner top panel is disposed in flat-face condition substantially in
registry with the outer top panel. The inner top end flap is
foldably connected to the inner top panel along an end edge of the
inner top panel. The inner top end flap is substantially in
registry with the outer top end flap and has a distal edge disposed
adjacent the weight-bearing region of the handle opening. The
insert further includes at least one auxiliary reinforcement flap
disposed in flat-face condition with the inner top end flap so as
to provide multiple-ply structure adjacent the handle opening
weight-bearing region.
Inventors: |
Bates; Aaron; (Raleigh,
NC) ; Suzuki; Tsugihiko; (Pittsboro, NC) ;
Holley; John M.; (Lawrenceville, GA) |
Correspondence
Address: |
MEADWESTVACO CORPORATION
1021 MAIN CAMPUS DRIVE, CENTENNIAL CAMPUS
RALEIGH
NC
27606
US
|
Family ID: |
39474550 |
Appl. No.: |
11/941052 |
Filed: |
November 15, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11232309 |
Sep 21, 2005 |
|
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|
11941052 |
|
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|
60866031 |
Nov 15, 2006 |
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Current U.S.
Class: |
229/117.16 |
Current CPC
Class: |
B65D 71/14 20130101;
B65D 2571/00728 20130101; B65D 2571/00141 20130101; B65D 2571/0053
20130101; B65D 2571/0066 20130101; B65D 2571/00814 20130101; B65D
2571/0045 20130101; B65D 2571/00524 20130101; B65D 2571/00561
20130101 |
Class at
Publication: |
229/117.16 |
International
Class: |
B65D 5/46 20060101
B65D005/46; B65D 17/28 20060101 B65D017/28 |
Claims
1. A carton comprising: a substantially tubular structure including
an outer top panel; an end wall structure including an outer top
end flap foldably connected to the outer top panel along an end
edge thereof, the outer top end flap including a handle opening
having a weight-bearing region; and an insert including an inner
top panel disposed in flat-face condition substantially in registry
with the outer top panel and an inner top end flap foldably
connected to the inner top panel along an end edge thereof, the
inner top end flap being substantially in registry with the outer
top end flap and having a distal edge disposed adjacent the
weight-bearing region of the handle opening.
2. The carton of claim 1, wherein the insert further includes at
least one auxiliary reinforcement flap disposed in flat-face
condition with the inner top end flap so as to provide multiple-ply
structure adjacent the weight-bearing region.
3. The carton of claim 2, wherein the at least one auxiliary
reinforcement flap is foldably adjoined to the inner top end
flap.
4. The carton of claim 1, wherein the outer top panel includes an
outer access opening and the inner top panel includes an inner
access opening in substantial registry with the outer access
opening.
5. The carton of claim 4, wherein at least one at least partially
removable outer access opening panel substantially fills the outer
access opening and at least one at least partially removable inner
access opening flap substantially fills the inner access
opening.
6. The carton of claim 2, wherein the inner top end flap extends
downwardly from the inner top panel to a lower end edge of the
inner top end flap, and the at least one auxiliary reinforcement
flap is foldably adjoined to the inner top end flap along the lower
end edge and extends upwardly to be disposed in flat-face condition
with an inner surface of the inner top end flap opposite to an
outer surface of the inner top end flap along which the end wall
structure is disposed.
7. The carton of claim 1, wherein the tubular structure further
includes a pair of opposed side panels, the end wall structure
further includes a pair of side end flaps foldably connected to the
side panels respectively, and the side end flaps are disposed at
least in part along the top end flap, each of the side end flaps
including a handle cutout that is positioned in registry with a
part of the handle opening.
8. The carton of claim 7, wherein the tubular structure further
includes a bottom panel, the end wall structure further includes a
bottom end flap foldably connected to an end edge of the bottom
panel, and the side end flaps are disposed at least in part along
the bottom end flap.
9. The carton of claim 1, wherein the tubular structure further
includes a pair of opposed side panels, and the insert is hingedly
connected to one of the side panels.
10. A carton, comprising: an outer top panel; first and second side
panels hingedly connected the outer top panel; a bottom panel
hingedly connected to the first and second side panels; an end wall
including a top end flap hingedly connected to the outer top panel
and having a handle opening with a weight bearing region; first and
second side end flaps hingedly connected to the first and second
side panels respectively; and a bottom end flap hingedly connected
to the bottom panel; and an insert including an inner top panel
defined by side edges and end edges, and a handle panel structure
hingedly connected to the inner top panel along one of the end
edges, wherein a reinforcing portion of the handle panel structure
is placed in reinforcing proximity to the weight bearing region of
the handle opening.
11. The carton of claim 10, wherein the reinforcing portion of the
handle panel structure comprises an inner top end flap, and each
side end flap comprises a cutout having dimensions complementary to
the dimensions of at least part of the handle opening.
12. The carton claim 11, wherein the inner top end flap of the
handle panel structure is disposed in substantial alignment with
the weight bearing region of the handle opening.
13. The carton of claim 10, wherein the insert further includes at
least one auxiliary reinforcement flap disposed in flat-face
condition with the reinforcing portion of the handle panel
structure so as to provide multiple-ply structure adjacent the
weight-bearing region.
14. The carton of claim 13, wherein the at least one auxiliary
reinforcement flap is foldably adjoined to the reinforcing portion
of the handle panel structure.
15. The carton of claim 11, wherein the inner top panel extends
entirely along the length of the carton.
16. The carton of claim 11 wherein the insert further includes a
second handle panel structure hingedly connected to the inner top
panel.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/232,309 filed on Sep. 21, 2005, the
entirety of which is incorporated herein by reference. This
application also claims the benefit of the filing date of U.S.
Provisional Application Ser. No. 60/866,031, filed on Nov. 15,
2006, the entirety of which is incorporated herein by
reference.
TECHNICAL FIELD
[0002] This invention relates to cartons. More specifically, the
invention relates to a handle-reinforcement insert for a carton
having end-wall or side-wall handles.
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, 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 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 region 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] According to an embodiment of the invention, a carton having
a substantially tubular structure is provided. The tubular
structure includes an outer top panel. The carton also has an end
wall structure for at least partially closing an end of the tubular
structure. The end wall structure includes an outer top end flap
foldably connected to the outer top panel along an end edge of the
outer top panel. The outer top end flap includes a handle opening
having a weight-bearing region. The carton also has an insert
including an inner top panel and an inner top end flap. The inner
top panel is disposed in flat-face condition substantially in
registry with the outer top panel. The inner top end flap is
foldably connected to the inner top panel along an end edge of the
inner top panel. The inner top end flap is substantially in
registry with the outer top end flap and has a distal edge disposed
adjacent the weight-bearing region of the handle opening.
[0008] In a preferred embodiment, the insert may further include at
least one auxiliary reinforcement flap disposed in flat-face
condition with the inner top end flap so as to provide multiple-ply
structure adjacent the handle opening weight-bearing region. In
this embodiment, the at least one auxiliary reinforcement flap may
be foldably adjoined to the inner top end flap. In this embodiment,
the inner top end flap may extend downwardly from the inner top
panel to its lower end edge, and the at least one auxiliary
reinforcement flap may be foldably adjoined to the inner top end
flap along the lower end edge. The at least one auxiliary
reinforcement flap may extend upwardly to be disposed in flat-face
condition with the inner surface of the inner top end flap opposite
to the outer surface of the inner top end flap along which the end
wall structure is disposed.
[0009] In another preferred embodiment, the outer top panel may
include an outer access opening and the inner top panel may include
an inner access opening in substantial registry with the outer
access opening. In such an embodiment, at least one at least
partially removable outer access opening panel may substantially
fill the outer access opening and at least one at least partially
removable inner access opening flap may substantially fill the
inner access opening.
[0010] In a further preferred embodiment, the tubular structure may
further include a pair of opposed side panels, the end wall
structure may further include a pair of side end flaps foldably
connected to the side panels respectively, and the side end flaps
may be disposed at least in part along the top end flap. Each side
end flap may include a handle cutout that is positioned in registry
with a part of the handle opening. In this embodiment, the tubular
structure may further include a bottom panel, the end wall
structure may further includes a bottom end flap foldably connected
to an end edge of the bottom panel, and the side end flaps may be
disposed at least in part along the bottom end flap.
[0011] The foregoing has outlined some of the aspects and features
of the present invention, which should be construed to be merely
illustrative of various potential applications of the invention.
Other beneficial results can be obtained by applying the disclosed
information in a different manner or by combining various aspects
of the disclosed embodiments. 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
[0012] FIG. 1 illustrates blanks for forming a carton of the first
embodiment according to the present invention.
[0013] FIG. 2 is a longitudinal cross-section of an erected carton
formed from the blanks of FIG. 1.
[0014] FIG. 3 is a perspective view of a carton of the second
embodiment formed while using one or more insert blanks.
[0015] FIG. 4 is a plan view of a blank for forming a carton of the
third embodiment according to the present invention.
[0016] FIG. 5 is a plan view of blanks for forming a carton of the
fourth embodiment, according to the present invention.
[0017] FIG. 6 is a perspective view of a carton with a
handle-reinforcement insert in accordance with the fifth embodiment
of the present invention;
[0018] FIG. 7 is a plan view of a blank for forming the external
tubular structure of the carton of FIG. 6;
[0019] FIG. 8 is a plan view of the handle-reinforcement insert
placed inside the carton of FIG. 6; and
[0020] FIG. 9 is a view taken along line 9-9 of FIG. 6.
DETAILED DESCRIPTION
[0021] 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.
[0022] 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 panel structure that reinforces a handle opening
formed in an end wall of the carton. The reinforcing portion of the
handle panel structure aligns with the weight bearing portion of
the handle opening.
[0023] 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. 1 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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 panel structures 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.
[0029] Each handle panel structure 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.
[0030] 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
panel structure 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.
[0031] With reference now to FIGS. 1 and 2, 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 panel structure 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.
[0032] 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.
[0033] 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.
[0034] Upon erecting the handle panel structure 152a and
positioning the top inner panel 151 adjacent to the top outer panel
108 of the tubular carton, the handle panel structure 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 panel structure 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 panel structure 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.
[0035] As shown in FIG. 2, the handle panel structure 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 panel structure 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.
[0036] 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 panel structure 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] Referring now to FIG. 5, 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 panel structures 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 panel structures 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 panel structures 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.
[0044] However, it is preferred that the thickness of each handle
panel structure 654a, 654b is limited so that the handle panel
structure 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 panel structures
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
panel structure 654a, 654b and by the cutouts C formed in the side
end panels 622a, 622b, 624a, 624b.
[0045] Referring to FIG. 6, therein is illustrated a substantially
tubular carton 10 with a handle-reinforcement insert in accordance
with a further embodiment of the invention. The carton 10 is formed
from a blank 412 that is illustrated in FIG. 7. Referring now
simultaneously to FIGS. 6 and 7, but with particular attention
directed to FIG. 7, a blank 412 and the carton 10 formed therefrom
are suitably constructed of a single sheet of substrate. Suitable
substrates include, but are not limited to, all manner of foldable
sheet material such as paperboard, corrugated board, cardboard,
plastic, or the like. The carton may include a water resistant
coating on at least one surface. In the exemplary embodiment, the
blank is particularly designed for packaging beverage bottles. It
is envisaged that other articles and/or different arrangements of
articles may be contained within the carton and that the blank may
therefore be sized accordingly.
[0046] Referring further to FIGS. 6 and 7, the blank 412 includes a
series of foldably interconnected panels that are erected to form a
substantially tubular carton 10. A joinder flap 421 is foldably
adjoined to bottom panel 420 along a first side edge thereof. A
first side panel 422 is foldably adjoined to the bottom panel 420
along a second side edge opposite the joinder flap 421. In turn,
the side panel 422 is foldably adjoined to a top panel 424. A
second side panel 426 is also foldably adjoined to the top panel
424 along a side edge thereof. The two side panels 422, 426 are
disposed on opposite sides of the top panel 424 along respective
opposing side edges thereof. The top panel 424 is also referred to
herein below as an "outer top panel" to distinguish its
relationship with the exemplary embodiment of an insert that will
be described below. The interconnected series of wall panels 420,
422, 424, 426 of the blank 412 have end flaps that form end closure
in the erected carton 10. Bottom end flaps 430a, 430b are foldably
adjoined to the bottom panel 420 along opposing end edges thereof.
First side end flaps 432a, 432b are foldably adjoined to the first
side panel 422 along opposing end edges thereof. Outer top end
flaps 434a, 434b are foldably adjoined to the outer top panel 424
along opposing end edges thereof. Second side end flaps 436a, 436b
are foldably adjoined to the second side panel 426 along opposing
end edges thereof.
[0047] An access opening 440 for the erected carton 412 extends
across the outer top panel 424 and into at least one of the side
panels 422, 426. The access opening 440 is defined by a frangible
line or other weakened line of severance. An at least partially
removable outer access opening panel 443 substantially covers the
outer access opening 440 to help create a substantially
fully-enclosed carton 10. Partial and full handle openings 442a,
442b, 444a, 444b, 446a, 446b are defined in respective side end
flaps 432a, 432b, outer top end flaps 434a, 434b, and side end
flaps 436a, 436b to collectively form opposing handle openings in
the erected carton 412. Handle flaps 445a, 445b that are at least
partially removable may be disposed in the outermost full handle
openings 444a, 444b to help provide a fully-enclosed erected carton
412.
[0048] The carton 10 is erected by folding the series of
interconnected panels 420, 421, 422, 424, 426 with respect to one
another and affixing the joinder flap 421 to the end most side
panel 426. The joinder flap 421 and second side panel 426 may be
adjoined by suitable means for affixing surfaces of a substrate to
one another such as, but not limited to, application of an adhesive
or the like. It is to be noted that the invention contemplates that
different ones of the panels 420, 422, 424, 426 may occupy endmost
positions without affecting the effectiveness or operation of the
invention and without departing from the scope or spirit of the
invention.
[0049] Referring now to FIG. 8, therein is shown in plan view an
exemplary embodiment of a handle-reinforcement insert 500 for
reinforcing the handle regions of the carton of FIG. 6. The insert
500 includes a central portion, which for convenience is referred
to as an inner top panel 524. Inner top end flaps 534a, 534b are
foldably adjoined to the inner top panel 524 along opposing end
edges thereof. Relief elements are disposed along each region of
joinder 560 of the end edge of the inner top panel and a respective
inner top end flap 534a, 534b. Although the relief region of
joinder 560 may consist of many different types and numbers of
relief elements, a suitable combination of relief structures 562,
566 and relief apertures 564 are illustrated in FIG. 3. The
exemplary embodiment includes flanking relief structures 562 and
centrally disposed relief structures 566. Each relief structure
562, 566 includes at least one weakened line for promoting folding,
such as an interrupted cut line. Other suitable weakened lines
include but are not limited to scores and perforations. The
parallel, spaced weakened lines of the relief members 562, 566 that
are illustrated in the exemplary embodiment are particularly
suitable for receiving, accommodating and promoting folding with
respect to the crowns of bottles B. Although each relief structure
562, 566 in the exemplary embodiment includes three parallel
weakened lines that promote folding, the invention may be
effectively practiced with more than or less than three lines. The
precise location of the relief apertures 564 and relief structures
562, 566 may be varied without departing from the spirit and scope
of the invention. Auxiliary reinforcement flaps 544a, 544b are
foldably adjoined to respective inner top end flaps 534a, 534b
along respective fold lines 538a, 538b. Weakened lines of severance
540, 541, including but not limited to frangible lines or
interrupted cut lines, define inner access panels 543a, 543b in the
inner top panel 524. The inner access panels 543a, 543b are at
least partially removable so as to create an inner access opening
through the inner top panel 524 that is substantially in registry
with the outer access opening 40 defined in the outer top panel 24.
Lifting of the removable inner access panels 543a, 543b is easily
initiated by insertion of a finger or other indexing article
through the tear-initiation aperture 525 provided.
[0050] The insert 500 is not illustrated in exact scale with
respect to the exemplary embodiment of a carton 10 and the
exemplary embodiment of a blank 412. The invention encompasses an
insert 500 of various sizes and configurations. For example, the
inner top panel 524 may be equal in width or lesser in width as
compared to the width of the outer top panel 424. In addition, the
inner top panel 524 may have both a size and configuration
substantially equivalent to that of the outer top panel 424. Such
equivalency of size and configuration helps facilitate placement of
the insert 500 in the erected carton 412. An inner top panel 524 of
substantially the same size and configuration as the outer top
panel 424 may more easily be aligned in register with the outer top
panel 424. The insert 500 may be suitably employed as taught by the
invention by first folding the auxiliary reinforcement flaps 544a,
544b over into face contacting condition with the inner top end
flaps 534a, 534b. The invention is more effective when the
auxiliary reinforcement flaps 544a, 544b are adhered to the
respective inner top end flaps 534a, 534b. Although the invention
is effective if the auxiliary reinforcement flaps 544a, 544b are
simply folded over and positioned in flat-face condition with the
inner top end flaps 534a, 534b, without being affixed thereto,
after placement of the inner top panel 524 of the insert 500 in
flat-face condition with the outer top panel 424, the effectiveness
of the invention is enhanced if the auxiliary reinforcement flaps
544a, 544b are adhered to the inner top end flaps 534a, 534b prior
to alignment and placement of the inner top panel 524 in flat-face
condition with the outer top panel 424.
[0051] The insert 500 may be positioned in the flat or the erected
blank 412 in several ways contemplated by the invention. The inner
top panel 524 of the insert 500 may or may not be affixed to the
outer top panel 424 of the blank 412. If affixed, the inner top
panel 524 may be affixed by various suitable methods of affixing
surfaces of substrates to one another, such as by application of an
adhesive or other suitable means. The inner top panel 524 may be
placed or affixed either before or after erection of the blank
412.
[0052] Referring momentarily back to FIG. 6, a representative
outline of the positioned insert 500 is shown in phantom
illustration as seen looking through the outer surface of the
carton 10.
[0053] Referring now to FIG. 9, the cross-sectional view of the
erected carton 10 illustrates the relationship between the
handle-reinforcement insert 500 and the erected carton 10. In
particular, this view illustrates the manner in which each inner
top end flap 534a, 534b cooperates with a respective auxiliary
reinforcement panel 544a, 544b to form a multiple-ply (two-ply in
this instance) reinforcement structure at a weight-bearing region
of a composite handle opening 42a, 42b, 44a, 44b, 46a, 46b. Each
handle is a composite structure formed from the multiple partial
and full handle openings 42a, 42b, 44a, 44b, 46a, 46b. In general,
the weight-bearing region of a handle opening is the region
immediately above a handle opening. The stress placed upon the side
wall structure of a carton is focused at this region when a
packaged carton is lifted by the handles. As can be seen in FIG. 4,
what is essentially a region of four-ply substrate thickness is
formed just above each composite handle opening. The effectiveness
of the invention is increased when all of the plies of the
substrate at the reinforced region are affixed to one another. As
previously discussed herein, suitable means of affixation of layers
of substrate include application of an adhesive. In the exemplary
embodiment illustrated, the fold line 538a, 538b of the insert 500
about which respective top end flaps 534a, 534b and auxiliary
reinforcement flaps 544a, 544b are foldably adjoined to one another
helps define an edge (a distal edge) 538a, 538b of the two-ply
reinforcement that is disposed adjacent the upper perimeter of the
composite handle opening.
[0054] The carton 10 with reinforced handle insert 500 illustrated
and described herein provide a means for reinforcing the
weight-bearing region of handle openings without unduly increasing
the amount of substrate used to form a package. In addition, the
insert 500 taught by the present invention provides a means for
easily positioning the reinforcement structure of the invention for
use.
[0055] As used herein, the terms "fold line" and "severance line"
refer to all manner of lines indicating optimal respective fold or
cut locations. A fold line is typically a scored line, an embossed
line or a debossed line. Severance lines, and sometimes fold lines,
may be frangible or otherwise weakened lines, perforations, a line
of perforations, a line of short slits, a line of half-cuts, or a
single half-cut. A severance line may also be a cut line or slit.
Fold lines and severance lines may also be some combination of the
above lines, and the like.
[0056] The above-described embodiments are merely exemplary
illustrations of implementations set that 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. All
such variations, modifications, and combinations are included
herein by the scope of this disclosure and the following claims.
For example, multiple auxiliary reinforcement panels may be
employed to create reinforcement plies greater than two-ply. In
another variation of note, the insert 500 may have an inner top end
flap 534a, 534b and associated auxiliary reinforcement flap 544a,
544b or flaps at only one end of the inner top panel 524 but still
function effectively in accordance with the teachings of the
invention.
[0057] 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.
* * * * *