CA2610666A1 - Carton with handle-reinforcement insert - Google Patents

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.

Description

CARTON WITH HANDLE-REINFORCEMENT INSERT
TECHNICAL FIELD
[0001] 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

[0002] Cartons for encasing and dispensing multiple articles such as beverage botties 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.

[0003] 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.

[0004] According to another approach, an additional layer of sheet material is used as an insert that reinforces the integrity of a handle as weli 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.

[0005] 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

[0006] 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. 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.

[0007] In a preferred 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.

[0008] 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.

[0009] 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.

[0010] 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

[0011] FIG. 1 is a perspective view of a carton with a handle-reinforcement insert in accordance with an exemplary embodiment of the invention;

[0012] FIG. 2 is a plan view of a blank for forming a carton in accordance with an exemplary embodiment of the invention;

[0013] FIG. 3 is a plan view of a handle-reinforcement insert in accordance with an exemplary embodiment of the invention; and [0014] FIG. 4 is a sectional view of a packaged carton with a handle-reinforcement insert in accordance with an exemplary embodiment of the invention taken along line 4-4 of FIG. 1.

DETAILED DESCRIPTION

[0015] 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. As used herein, the word "exemplary" is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. 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 components, systems, 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 to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0016] Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton. Generally described, the carton includes a tubular structure portion defined by a top wall structure, side walls, and a bottom wall and end closure structures which define end walls at the open ends of the tubular structure portion.

[0017] Referring first to FIG. 1, therein is illustrated a substantially tubular carton 10 with a handle-reinforcement insert in accordance with an exemplary embodiment of the invention. The carton 10 is formed from an exemplary embodiment of a blank 12, which blank 12 is illustrated in FIG. 2. Referring now simultaneously to FIG. 1 and FIG. 2, but with particular attention directed to FIG.
2, a blank 12 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.

[0018] Referring to now further to FIG. 1 and FIG. 2, the blank 12 includes a series of foldably interconnected panels that are erected to form a substantially tubular carton 10. A joinder flap 21 is foldably adjoined to bottom panel 20 along a first side edge thereof. A first side panel 22 is foldably adjoined to the bottom panel 20 along a second side edge opposite the joinder flap 21. In turn, the side panel 22 is foldably adjoined to a top panel 24. A second side panel 26 is also foldably adjoined to the top panel 24 along a side edge thereof. The two side panels 22, 26 are disposed on opposite sides of the top panel 24 along respective opposing side edges thereof. The top panel 24 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 20, 22, 24, 26 of the blank 12 have end flaps that form end closure in the erected carton 10. Bottom end fiaps 30a, 30b are foldably adjoined to the bottom panel 20 along opposing end edges thereof.
First side end flaps 22a, 22b are foldably adjoined to the first side panel 22 along opposing end edges thereof. Outer top end flaps 34a, 34b are foldably adjoined to the outer top panel 24 along opposing end edges thereof. Second side end flaps 36a, 36b are foldably adjoined to the second side panel 26 along opposing end edges thereof.

[0019] An access opening 40 for the erected carton 12 extends across the outer top panel 24 and into at least one of the side panels 22, 26. The access opening 40 is defined by a frangible line or other weakened line of severance.
An at least partially removable outer access opening panel 43 substantially covers the outer access opening 40 to help create a substantially fully-enclosed carton 10. Partial and full handle openings 42a, 42b, 44a, 44b, 46a, 46b are defined in respective side end flaps 22a, 22b, outer top end flaps 34a, 34b, and side end flaps 36a, 36b to collectively form opposing handle openings in the erected carton 12. Handle flaps 45a, 45b that are at least partially removable may be disposed in the outermost full handle openings 44a, 44b to help provide a fully-enclosed erected carton 12.

[0020] The carton 12 is erected by folding the series of interconnected panels 20, 21, 22, 24, 26 with respect to one another and affixing the joinder flap 21 to the endmost side panel 26. The joinder flap 21 and second side panel 26 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 20, 22, 24, may occupy endmost positions without affecting the effectiveness or operation of the invention and without departing from the scope or spirit of the invention.
[0021] Referring now to FIG. 3, therein is shown in plan view an exemplary embodiment of a handle-reinforcement insert 100 for reinforcing the handle regions of the carton of FIG. 1. The insert 100 includes a central portion, which for convenience is referred to as an inner top panel 124. Inner top end flaps 134a, 134b are foldably adjoined to the inner top panel 124 along opposing end edges thereof. Relief elements are disposed along each region of joinder 160 of the end edge of the inner top panel and a respective inner top end flap 134a, 134b. Although the relief region of joinder 160 may consist of many different types and numbers of relief elements, a suitable combination of relief structures 162, 166 and relief apertures 164 are illustrated in FIG. 3. The exemplary embodiment includes flanking relief structures 162 and centrally disposed relief structures 166. Each relief structure 162, 166 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 162, 166 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 162, 166 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 164 and relief structures 162, 166 may be varied without departing from the spirit and scope of the invention. Auxiliary reinforcement flaps 144a, 144b are foldably adjoined to respective inner top end flaps 134a, 134b along respective fold lines 138a, 138b. Weakened lines of severance 140, 141, including but not limited to frangible lines or interrupted cut lines, define inner access panels 143a, 143b in the inner top panel 124. The inner access panels 143a, 143b are at least partially removable so as to create an inner access opening through the inner top panel 124 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 143a, 143b is easily initiated by insertion of a finger or other indexing article through the tear-initiation aperture 125 provided.

[0022] The insert 100 is not illustrated in exact scale with respect to the exemplary embodiment of a carton 10 and the exemplary embodiment of a blank 12. The invention encompasses an insert 100 of various sizes and configurations. For example, the inner top panel 124 may be equal in width or lesser in width as compared to the width of the outer top panel 24. In addition, the inner top panel 124 may have both a size and configuration substantially equivalent to that of the outer top panel 24. Such equivalency of size and configuration helps facilitate placement of the insert 100 in the erected carton 12.
An inner top panel 124 of substantially the same size and configuration as the outer top panel 24 may more easily be aligned in register with the outer top panel 24. The insert 100 may be suitably employed as taught by the invention by first folding the auxiliary reinforcement flaps 144a, 144b over into face contacting condition with the inner top end flaps 134a, 134b. The invention is more -effective when the auxiliary reinforcement flaps 144a, 144b are adhered to the respective inner top end flaps 134a, 134b. Although the invention is effective if the auxiliary reinforcement flaps 144a, 144b are simply folded over and positioned in flat-face condition with the inner top end flaps 134a, 134b, without being affixed thereto, after placement of the inner top panel 124 of the insert 100 in flat-face condition with the outer top panel 24, the effectiveness of the invention is enhanced if the auxiliary reinforcement flaps 144a, 144b are adhered to the inner top end flaps 134a, 134b prior to alignment and placement of the inner top panel 124 in flat-face condition with.the outer top panel 24.

[0023] The insert 100 may be positioned in the flat or the erected blank 12 in several ways contemplated by the invention. The inner top panel 124 of the insert 100 may or may not be affixed to the outer top panel 24 of the blank 12. If affixed, the inner top panel 124 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 124 may be placed or affixed either before or after erection of the blank 12.

[0024] Referring momentarily back to FIG. 1, a representative outline of the positioned insert 100 is shown in phantom illustration as seen looking through the outer surface of the carton 10.

[0025] Referring now to FIG. 4, the cross-sectional view of the erected carton illustrates the relationship between the handle-reinforcement insert 100 and the erected carton 10. In particular, this view illustrates the manner in which each inner top end flap 134a, 134b cooperates with a respective auxiliary reinforcement panel 144a, 144b 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 ali 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 138a, 138b of the insert 100 about which respective top end flaps 134a, 134b and auxiliary reinforcement flaps 144a, 144b are foldably adjoined to one another helps define an edge (a distal edge) 138a, 138b of the two-ply reinforcement that is disposed adjacent the upper perimeter of the composite handle opening.

[0026] The carton 10 with reinforced handle insert 100 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 100 taught by the present invention provides a means for easily positioning the reinforcement structure of the invention for use.

[0027] 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.

[0028] 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 100 may have an inner top end flap 134a, 134b and associated auxiliary reinforcement flap 144a, 144b or flaps at only one end of the inner top panel 124 but still function effectively in accordance with the teachings of the invention.

Claims (7)

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, the insert further including 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.

2. The carton of claim 1, wherein the at least one auxiliary reinforcement flap is foldably adjoined to the inner top end flap.

3. 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.

4. The carton of claim 3, 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.

5. 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.

6. 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.

7. The carton of claim 6, 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.