Note: Descriptions are shown in the official language in which they were submitted.
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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
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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
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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
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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
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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
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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,
26
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
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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
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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
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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.
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[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.
