Note: Descriptions are shown in the official language in which they were submitted.
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CARTON WITH HANDLE AND BLANK THEREFOR
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of US Provisional Patent Application Nos.
61/670,377 and 61/702,544, filed July 11, 2012 and September 18, 2012
respectively,
which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
This invention relates generally to cartons and, more specifically, to cartons
with
handles.
BACKGROUND
Cartons for packaging articles such as soft drink cans or bottles are useful
to
enable consumers to transport and store the articles. The cartons generally
include one
or more handles to facilitate gripping and carrying the carton to transport
the articles. As
groups of articles can be heavy, it is desired that the handles are
sufficiently supportive
for the weight of articles contained in the carton and are comfortable and
easy to
engage.
Certain known handle designs include a load-bearing edge that is
uncomfortable.
For example, load-bearing edges that are formed with a cut line can be
uncomfortable
when pressed against a user's hand. This problem is compounded when the
article
weight is high.
In W02010/009293 a carton with reinforced end handles is disclosed in which a
handle is configured to provide a load-bearing edge configured to compensate
for both
horizontal forces and vertical forces that can be applied by the handle or
carton to a
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user's hand. For example, vertical forces may be due to the general weight of
the
articles and horizontal forces may be due to the weight of the carton when
being carried
at a slight angle or when swinging, pushing, pulling, or sliding the carton.
The load-
bearing edge includes top and side edges that the user can engage to move the
carton
or that can come into contact with a user's hand while engaging the handle.
Generally
described, the handle includes an aperture or opening defined in a wall of a
carton that
allows a user to insert fingers or another portion of a hand therethrough.
The handle disclosed in W02010/009293 also includes an arrangement of
handle flaps that are configured to provide cushioning along the load-bearing
edge of
the handle. A top handle flap is hingedly connected to a top edge of the
handle and side
handle flaps are hingedly connected to respective side edges of the handle.
The top
handle flap and the side handle flap are folded toward the interior of the
carton when the
handle is engaged and hinged connections of the folded handle flaps cushion
the load-
bearing edge of the handle.
However, for some applications the cushioning provided by the handle and/or
the load bearing capability of the handle disclosed in W02010/009293 is not
necessarily
as desired. For example, with heavy loads there is a risk that the side handle
flaps
and/or the top handle flap can tear off from the carton or that insufficient
cushioning is
provided. The present invention therefore provides a further improvement in
the field of
package handles.
SUMMARY
The present invention seeks to provide an improvement in handle arrangements
for
packages over those already known.
According to a first aspect of the invention, for which protection is sought,
there is
provided a carton having a composite wall comprising a handle that includes a
load
bearing structure, the load bearing structure is configured to support a
substantially
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vertical load and is configured to support a substantially horizontal load. A
first handle
flap is formed in an outer layer of the composite wall and is hingedly
connected thereto
along a first hinge connection. A second handle flap is formed in an inner
layer of the
composite wall and is hingedly connected thereto along a second hinge
connection that
is substantially out of alignment with the at least one first arcuate fold
line and that
comprises at least one arcuate fold line.
The first hinge connection may be defined by a first arcuate fold line; by a
first pair of
arcuate fold lines disposed proximate to and positioned oppositely to one
another; by a
first linear fold line; or by a first pair of linear fold lines disposed
proximate to and
positioned oppositely to one another.
Optionally, the first hinge connection comprises a first pair of linear fold
lines. The linear
fold lines of the first pair of linear fold lines may be in part parallel to
one another and
may define therebetween a first shaped panel. The first shaped panel is in
some
arrangements an approximately hexagonally-shaped panel. The first
approximately
hexagonally-shaped panel of the load bearing structure may provide a cushion
for a
user's hand when supporting a substantially vertical load.
Alternatively, the first hinge connection may comprise a first pair of arcuate
fold lines.
The arcuate fold lines of the first pair of arcuate fold lines may be disposed
proximate to
and positioned oppositely to each other to define a first substantially leaf-
shaped panel
therebetween. The first leaf-shaped panel of the load bearing structure may
provide a
cushion for a user's hand when supporting a substantially vertical load.
Optionally, the second hinge connection comprises a second pair of arcuate
fold lines.
Optionally, the arcuate fold lines of the second pair of arcuate fold lines
are disposed
proximate to and positioned oppositely to each other to define a second
substantially
leaf-shaped panel therebetween. The second leaf-shaped panel of the load
bearing
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structure may provide a cushion for a user's hand when supporting a
substantially
horizontal load.
A third handle flap may be formed in the inner layer of the composite wall and
may be
hingedly connected thereto along a third hinge connection that is
substantially out of
alignment with the first hinge connection. When provided, the third hinge
connection
may comprise at least one third arcuate fold line and wherein the at least one
third
arcuate fold line is substantially out of alignment with the first hinge
connection.
Further optionally, the third hinge connection comprises a third pair of
arcuate fold lines.
The arcuate fold lines of the third pair of arcuate fold lines may be disposed
proximate
to and positioned oppositely to each other to define a third substantially
leaf-shaped
panel therebetween. The third leaf-shaped panel of the load bearing structure
may
provide a cushion for a user's hand when supporting a substantially horizontal
load.
In some arrangements, the first hinge connection of the carton may comprise a
first pair
of linear fold lines. The linear fold lines of the first pair of linear fold
lines define a first
substantially hexagonally-shaped panel therebetween and the second hinge
connection
may comprise a second pair of arcuate fold lines and the arcuate fold lines of
the
second pair of arcuate fold lines may define a second substantially leaf-
shaped panel
therebetween and converge at either end of the second leaf-shaped panel. A
third
handle flap may be formed in the inner layer of the composite wall and may be
hingedly
connected thereto along a third hinge connection. The third hinge connection
may
comprise a third pair of arcuate fold lines. The arcuate fold lines of the
third pair of
arcuate fold lines may define a third substantially leaf-shaped panel
therebetween and
may converge at either end of the third leaf-shaped panel. A notional axis
through the
first hexagonally-shaped panel may be disposed at an acute angle relative to a
notional
axis through the converged ends of the second leaf-shaped panel and may be
disposed
at an acute angle relative to a notional axis through the converged ends of
the third leaf-
shaped panel.
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In other arrangements, the first hinge connection may comprise a first pair of
arcuate
fold lines. The arcuate fold lines of the first pair of arcuate fold lines may
define a first
substantially leaf-shaped panel therebetween and may converge at either end of
the
first leaf-shaped panel. The second hinge connection may comprise a second
pair of
arcuate fold lines and the arcuate fold lines of the second pair of arcuate
fold lines may
define a second substantially leaf-shaped panel therebetween and may converge
at
either end of the second leaf-shaped panel. A third handle flap may be formed
in the
inner layer of the composite wall and may be hingedly connected thereto along
a third
hinge connection. The third hinge connection may comprise a third pair of
arcuate fold
lines and the arcuate fold lines of the third pair of arcuate fold lines may
define a third
substantially leaf-shaped panel therebetween and may converge at either end of
the
third leaf-shaped panel. A notional axis through the converged ends of the
first leaf-
shaped panel is optionally disposed at an acute angle relative to a notional
axis through
the converged ends of the second leaf-shaped panel and is disposed at an acute
angle
relative to a notional axis through the converged ends of the third leaf-
shaped panel.
The first handle flap is optionally defined in part by the first hexagonally-
shaped panel
and at least in part by a line of separation that arches upwardly away from
each of two
ends of the first hexagonally-shaped panel, then downwardly away from the
first
hexagonally-shaped panel and along a substantially straight line.
Alternatively, the first handle flap is defined in part by the first leaf-
shaped panel and at
least in part by a line of separation that arches upwardly away from each end
of the first
leaf-shaped panel, then downwardly away from the first leaf-shaped panel and
along a
substantially straight line.
The first handle panel may be substantially-crown-shaped.
Optionally, the line of separation that arches upwardly away from each end of
the first
leaf-shaped panel is shaped to form an edge at each end of the first
substantially leaf-
shaped panel, the edges at the ends of the first leaf-shaped panel being
shaped to abut
the adjacently disposed second substantially leaf-shaped and third
substantially leaf-
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shaped panels when the handle is used and the first, second and third handle
panels
are displaced inwardly of the carton. Said edges may be shaped to fit against
the
second and third substantially leaf-shaped panels, when those second and third
substantially leaf-shaped panels are disposed at an acutely inwardly folded
angle.
The first handle flap, second handle flap and the third handle flap are
preferably
configured to fold as a unit and to retain one another in a folded condition
and together
provide a substantially continuous hand support structure when folded.
Said edges of the first handle flap may at least partially define a portion of
the first
handle flap that is configured to be substantially in flat face contact with
the second
handle flap and third handle flap respectively in the folded condition.
The first handle flap, second handle flap and third handle flap may provide a
substantially concave structure in the folded condition.
Optionally, the first handle flap comprises a handle initiating section
defined by a
substantially trapezoidal weakened arrangement and the second and third handle
flaps
are shaped and sized such that the substantially trapezoidal weakened
arrangement of
the first handle flap does not overlap the second and third handle flaps
before the
handle is folded and deployed.
Optionally, the carton comprises a series of main panels including a top panel
and a
bottom panel interconnected by first and second side panels to form a
substantially
tubular structure, at least one of the ends of the tubular structure being at
least partially
closed by said composite wall and wherein the inner layer of the composite
wall
comprises first and second side end closure panels hinged to the first and
second side
panels respectively and disposed side by side in substantially the same plane,
the
second handle flap being formed from the first side end closure panel and the
third
handle flap being formed from the second side end closure panel and wherein
the outer
layer of the composite wall comprises a top end closure panel hinged to the
top panel,
the first handle flap being formed from the top end closure panel.
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Optionally, the second handle flap terminates short of an edge of the inner
layer in
which the second handle flap is formed.
Optionally, the second and third handle flaps terminate short of an edge of
the side end
closure panel in which they are formed, wherein
According to another aspect of the disclosure for which protection is sought,
there is
provided a blank for forming a carton. The blank may comprise an inner and an
outer
layer for forming a composite wall of the carton. The inner and outer layers
may
comprise components for forming a handle that includes a load bearing
structure, the
load bearing structure configured to support a substantially vertical load and
configured
to support a substantially horizontal load. A first handle flap may be formed
in an outer
layer of the composite wall and may be hingedly connected thereto along a
first hinge
connection. A second handle flap may be formed in the inner layer of the
composite wall
and may be hingedly connected thereto along a second hinge connection that is
substantially out of alignment with the first hinge connection and that
comprises at least
one arcuate fold line.
Within the scope of this application it is expressly intended that the various
aspects,
embodiments, examples and alternatives set out in the preceding paragraphs, in
the
claims and/or in the following description and drawings, may be taken
independently or
in any combination thereof. For example, features described in connection with
one
embodiment are applicable to all embodiments, unless such features are
incompatible.
DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example only,
with
reference to the accompanying drawings, in which:
FIG. 1A is a plan view of a blank for forming a carton, according to a first
exemplary embodiment of the disclosure;
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FIG. 1B is an enlarged view of a portion of the plan view of Figure 1A;
FIG. 2A is a plan view of a blank for forming a carton according to a second
exemplary embodiment of the disclosure;
FIG. 2B is an enlarged view of a portion of the plan view of Figure 2A;
FIGS. 20 and 2D are plan views of a composite end wall of a carton formed from
the blank of Figure 2A wherein the overlapping outer top and bottom panels are
only
shown in dotted outline to illustrate the overlaid arrangement of the various
elements of
the handle;
FIG. 3 is a perspective partial end view of a carton formed from a blank
according to a third embodiment of the invention that is similar but not
identical to the
blank of FIG. 2A;
FIG. 4 is a partial perspective end view of the exterior of the handle of FIG.
3, the
handle being pushed into a folded condition;
FIG. 5 is a partial perspective end view of the exterior of the handle of FIG.
4 in a
deployed condition;
FIG. 6 is a partial perspective end view of the interior of the handle of FIG.
5 in
an at least partially deployed condition;
FIG. 7 is a plan view of a blank for forming a carton having a handle
structure
according to a fourth exemplary embodiment of the disclosure;
FIGS. 8 and 9 are plan views of a composite end wall of a carton formed from
the
blank of Figure 7 wherein the overlapping outer top and bottom panels are only
shown
in dotted outline to illustrate the overlaid arrangement of the various
elements of the
handle; and
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FIG. 10 is a plan view of a blank for forming a carton having a handle
structure
according to a fifth exemplary embodiment of the disclosure.
DETAILED DESCRIPTION
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.
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. In the embodiments detailed herein, the
term
carton refers, for the non-limiting purpose of illustrating the various
features of the
invention, to a container for grouping, carrying, and dispensing articles,
such as
beverage cans or bottles. However, it is contemplated that the teachings of
the
disclosure can be applied to other containers. Generally described, the
illustrated
embodiments depict "fully-enclosed end-loading-style" cartons.
A first exemplary embodiment is illustrated in FIGs. 1A and 1B; a second
illustrative embodiment is shown in Figures 2A-2C; a third illustrative
embodiment is
shown in Figures 3 to 6; a fourth illustrative embodiment is shown in Figures
7, 8 and 9;
and a fifth arrangement is illustrated in Figure 10. The blanks 10, 110, 310
of Figures
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1A, 1B; 2A, 2B; 8 and 9 respectively are similar to each other and to a blank
(not
shown) used to form the carton 200 illustrated in Figures 3 to 6. The blanks
10, 110,
310 are each suitable for forming a "fully-enclosed end-loading-style" carton
200, such
as that shown in FIG. 3. As referred to already, the focus of the invention is
a composite
handle structure that is formed in at least two overlapping layers of
material. The handle
structures shown in the Figures vary only in minor ways and therefore the
Figures will
be referred to collectively in a general description of the invention. The
handles shown
may be employed in other carton structures, for example tray-style cartons.
Additionally,
the handles may be utilized in fully-enclosed cartons of the "gable-top"
style. A fifth
embodiment of the disclosure is shown in Figure 10, wherein a blank 410 is
provided for
forming such a gable-topped carton for housing bottles. The differences in
this
embodiment are described further below.
The blanks 10, 110, 310, 410 are each substantially symmetric such that
opposed ends thereof are substantially similar. For clarity, like references
have been
used with a suffix "a" or "b" affixed to distinguish one end of the blank 10,
110, 310, 410
from the other. The description of an element or group of elements having a
suffix "a" is
generally suitable for a like-numbered element or group of elements having a
suffix "b"
and vice versa. In certain instances, only one of like elements may be
described unless
a description of other or all of the like elements is useful for understanding
the invention.
The end closure structures in this optionally illustrated embodiment are
identical and
therefore only one of the composite end closure structures will be described
in detail, it
being understood that the other end closure structure, and more specifically
the handle
arrangement therein, is identical. It will be understood that a carton may
comprise only
one or more than two such handles even though two handle structures are
illustrated.
The illustrated blanks 10, 110, 310, 410 and carton 200 are formed of a single
sheet of suitable substrate. As used herein, the term "suitable substrate"
includes all
manner of foldable sheet material including paperboard, corrugated board,
cardboard,
plastic, combinations thereof, and the like. In the illustrated embodiments, a
unitary
blank is used to form a carton, although it should be recognized that two or
more blanks
may be used to form a carton. The illustrated blanks are each configured to
form a
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carton for packaging an exemplary arrangement of exemplary articles. It is
envisaged
that the blanks can be alternatively configured to form a carton for packaging
other
articles and/or different arrangements of articles.
As used herein, the term "fold line" refers to all manner of lines that define
hinge
features of the blank, facilitate folding portions of the blank with respect
to one another,
or otherwise indicate optimal panel folding locations for the blank. A fold
line may be a
scored line, an embossed line, or a debossed line.
As used herein, the term "severance line" refers to all manner of lines that
facilitate separating portions of the substrate from one another or that
indicate optimal
separation locations. A severance line may be a frangible or weakened line, a
cut line,
or a slit.
It should be understood that severance lines and fold lines can each include
elements that are formed in the substrate of the blank including perforations,
a line of
perforations, a line of short slits, a line of half-depth-cuts, a single half-
cut, a cut line, an
interrupted cut line, an alternating line of fold and half-depth cuts, slits,
scores, any
combination thereof, and the like. The elements can be dimensioned and
arranged to
provide the desired functionality. For example, a line of perforations can
have different
degrees of weakness such that the line of perforations can be a fold line
and/or a
severance line. In other words, the line of perforations can be designed to
facilitate
folding and resist breaking, to facilitate folding and facilitate breaking
with more effort, or
to facilitate breaking with little effort.
Referring to FIGS. 1A, 2A and 7, the blanks 10, 110, 310 comprise a series of
main panels comprising: a base panel 14, 114, 314 first and second side panels
12,
112, 312, 16, 116, 316 hingedly connected to foldable side edges 36, 38, 136,
138, 336,
338 of the base panel 14, 114, 314; and a top panel 18, 118, 318 hingedly
connected to
the second side panel 16, 116, 316 along fold line 40, 140, 340. A glue panel
44, 144,
344 is hingedly connected along fold line 42, 142, 342 to the other side edge
of the top
panel 18, 118, 318. The glue panel 44, 144, 344 is provided for connecting the
top
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panel 18, 118, 318 to the first side panel 12, 112, 312 in forming a part
formed carton
which can be erected into an open-ended tubular structure.
End closure panels 20a, 20b, 22a, 22b, 24a, 24b, 26a, 26b; 120a, 120b, 122a,
122b, 124a, 124b, 126a, 126b; 226b, 222b, 224b, 220b; 320a, 320b, 322a, 322b,
324a,
324b, 326a, 326b; are hingedly connected to foldable end edges 31a, 31b, 33a,
33b,
35a, 35b, 37a, 37b; 131a, 131b, 133a, 133b, 135a, 135b, 137a, 137b; 331a,
331b,
333a, 333b, 335a, 335b, 337a, 337b; of the first side panel 12, 112, 212, 312,
base
panel 14, 114, 214, 314, second side panel 16, 116, 216, 316, and top panel
18, 118,
218, 318 respectively. The end closure panels 20a, 22a, 24a, 26a; 120a, 122a,
124a,
126a; 320a, 322a, 324a, 326a co-operate together to form a composite end
closure
structure for the tubular carton formed from the main panels 12, 14, 16, 18;
112, 114,
116, 118; 212, 214, 216, 218; 312, 314, 316, 318. The end closure panels 20b,
22b,
24b, 26b; 120b, 122b, 124b, 126b; 220b, 222b, 224b, 226b; 320b, 322b, 324b,
326b co-
operate together to form another composite end closure structure for the
tubular carton.
The blanks 10, 110, 310 and carton 200 further include elements that combine
to
provide handles 58, 158, 258, 358 (also referred to as handle arrangements 58,
158,
258, 358 and handle structures 58, 158, 258, 358) in the end closure
structures at
opposed ends of a carton formed from a blank 10, 110, 310. The top-end closure
panel
26b, 126b, 226b, 326b includes a first outer handle flap 68b, 168b, 268b, 368b
(best
viewed in Figures 1B, 2B and 3). The first handle flap 68b, 168b, 268b, 368b
is movable
out of the plane of the top end closure panel 26b, 126b, 226b, 326b to form a
handle
aperture, through which a user may insert part of their hand (H) (see Figure
4) for
grasping a carton 200 by a handle structure 258.
The first outer handle flap 68b, 168b, 268b, 368b comprises an arrangement of
fold lines, weakened lines and cut lines. The first outer handle flap 68b,
168b, 368b
(also referred to as top handle flap 68b, 168b) is hingedly connected to the
top end
closure panel 26b, 126b, 226b, 326b proximate an upper portion of the handle
aperture
by virtue of a first hinge connection. Optionally, in some embodiments, the
first hinge
connection is formed as or may comprise an arcuate fold line 60b, 160b, 260b,
360b.
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The first hinge connection may also include a further optional arcuate fold
line 61b,
161b, 261b, 361b that is disposed proximate to and opposite to the arcuate
fold line
60b, 160b, 260b, 360b. Between the arcuate fold lines 60b, 61b; 160b, 161b;
260b,
261b; and 360b, 361b a first, at least substantially or approximately,
elliptically-shaped
panel 62b, 162b, 362b is thereby defined. The elliptically shaped panel 62b,
162b; 362b
may also be described as being a leaf-shaped panel having two converging arc-
shaped
sides. Preferably, the arcuate fold lines 60b, 61b; 160b, 161b; 260b, 261b;
and 360b,
361b converge such that the, at least substantially or approximately,
elliptically-shaped
panel 62b, 162b, 362b (or leaf-shaped panel 62b, 162b, 362b) has pointed
rather ends.
In other envisaged embodiments, the converging arcuate fold lines 60b, 61b;
160b,
161b; 260b, 261b; and 360b, 361b may converge at a point or may not quite meet
one
another and may converge at a rounded portion or straightened edge portion. It
is
preferred that the further fold line 61b, 161b, 261b, 361b is provided to pre-
determine
where the first handle panel 68b, 168b, 268b, 368b will crease when in use.
However,
the further fold line 61b, 161b, 261b, 361b is optional. The first arcuate
fold line 60b,
160b, 260b, 360b and further fold line 61b, 161b, 261b, 361b when provided,
together
form a first pair of fold lines.
The first handle flap 68b, 168b, 368b is defined in part by the first
substantially-
elliptically shaped panel 62b, 162b, 362b and in part by a line of separation
81b, 181b,
281b, 381b. The line of separation 81b, 181b, 281b, 381b may be a continuous
cut line
(as in Figure 2A); a continuous perforate line; or a cut-line or perforate
line interrupted
by one or more connecting nick portions 73b, 273b, 373b as in Figures 1B, 3
and 7).
Optionally, the line of separation 81b, 181b, 281b, 381b extends from inwardly
curved
terminations 66b, 64b; 166b, 164b; 364b, 366b; disposed below and proximate to
ends
of the first substantially-elliptically shaped panel 62b, 162b, 362b. The ends
of the first
substantially-elliptically shaped panel 62b, 162b, 362b are in some
arrangements
defined by the points at which the weakened lines 60b, 61b; 160b, 161b; 260b,
261b,
360b, 361b converge. From the terminations 66b, 64b; 166b, 164b; 366b, 364b
the line
of separation 81b, 181b, 281b, 381b curves upwardly and arcuately.
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In the first illustrated embodiment, the line of separation 81b does not
extend
above the first fold line 60b. It extends along a curvilinear section with the
line of
separation extending away from each end of the first substantially-
elliptically shaped
panel 62b. It then curves back inwardly (proximate to a connecting nick 73b)
and toward
a linear section. The line of separation 81b is preferably, but nevertheless
optionally,
symmetrical. The first handle panel 68b optionally comprises three or more
linked
bulbous curved sections.
In the second, third and fourth illustrated embodiments, the lines of
separation
181b, 281b, 381b again do not extend above the first fold line 160b, 260b,
360b. The
lines 181b, 281b, 381b then follow a curvilinear section wherein the lines of
separation
181b, 281b extend toward each end of the first substantially-elliptically
shaped panel
162b, 262b, 362b and curve more substantially inwardly (proximate a connecting
nick
273b, 373b in the third and fourth embodiments) toward a linear section. The
lines of
separation 181b, 281b, 381b are each symmetrical. The first handle panel 168b,
268b,
368b again optionally comprises three or more linked bulbous curved sections.
An optional weakened arrangement is provided: in part to assist in initiating
the
separation of the first handle flap 68b, 168b, 268b, 368b from the top end
closure panel
26b, 126b, 226b, 326b; and in part to assist with the inward folding of the
first handle
flap 68b, 168b, 268b, 368b when the handle 58, 158, 258, 358 is deployed.
The optional weakened arrangement comprises a linear fold line 76b, 176b, 376b
disposed above and substantially parallel to the linear section of line of
separation 81b,
181b, 281b, 381b. The optional weakened arrangement of the first, second and
third
embodiments optionally comprise a substantially trapezoidal weakened
arrangement of:
fold line 80b, 180b; and angled cut lines 75b, 175b which define portions 78b,
72b, 74b
and 70b (see Figure 1B); and 178b, 172b, 174b and 170b (see Figure 2B). The
cut lines
75b, 175b and fold line 80b, 180b may be omitted. Indeed, in the fourth
embodiment
only horizontal fold line 376b is provided for assisting with the inward
folding of the first
handle flap 368b. In yet further envisaged embodiments horizontal fold line
76b, 176b,
376b is not provided.
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The first handle flap 68b, 168b, 368b is foldable about the first hinge
connection
including the first arcuate fold line 60b, 160b, 260b, 360b, inwardly of the
top end
closure panel 26b, 126b, 226b, 326b. The first substantially elliptically-
shaped panel
62b, 162b, 362b provides a cushioned edge of a three-dimensional load-bearing
structure. The three-dimensional load-bearing structure is further formed and
supported
by inner elements namely second and third handle flaps 46b, 52b; 146b, 152b;
346b,
362b which will now be described with reference to Figures 1A, 2A, 2B, 20, 7,
8 and 9.
Each second and third handle flap 46b, 52b; 146b, 152b; 346b, 352b (also
referred to as inner handle flaps 46b, 52b; 146b, 152b; 346b, 352b) is hinged
to an
inner ply of material of the carton (in this arrangement side end closure
panels 20b, 24b;
120b, 124b; 220b, 224b; 320b, 324b) by a second hinge connection and by a
third
hinge connection. The second hinge connection may include a second fold line
48b,
148b, 348b and the third hinge connection may include a third fold line 54b,
154b, 354b.
Optionally, the second and third fold lines 48b, 148b; 54b, 154b; 348b, 354b
are
arcuate. In other embodiments, the second and third fold lines 48b, 148b, 54b,
154b;
348b, 354b are at least substantially linear or straight.
Preferably, however the second and third fold lines 48b, 148b, 54b, 154b,
348b,
354b are arcuate and the second and third hinge connections further
respectively
include additional arcuate fold lines 47b, 147b, 57b, 157b, 347b 357b disposed
proximate to and opposite to the second and third arcuate fold lines 48b,
148b, 54b,
154b, 348b, 354b. At least substantially-elliptically-shaped panels 50b, 150b,
350b are
formed between the second arcuate fold line 48b, 148b, 348b and the further
arcuate
fold line 47b, 147b, 347b (also referred to as a second pair of fold lines).
At least
substantially-elliptically-shaped panels 56b, 156b, 356b are formed between
the third
arcuate fold line 54b, 154b, 354b and the further arcuate fold line 57b, 157b,
357b. The
panels 50b, 150b, 350b 56b, 156b, 356b may also be described as being leaf-
shaped
panels.
Preferably, the arcuate fold lines 47b, 147b, 347b, 57b, 157b, 357b converge
such that the at least substantially or approximately elliptically-shaped
panels 50b,
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150b, 350b, 56b, 156b, 356b (or leaf-shaped panels 50b, 150b, 350b, 56b, 156b,
356b)
have pointed (rather than rounded) ends. In other envisaged embodiments, the
converging arcuate fold lines 48b/47b, 148b/147b, 348b/347b may converge at a
point
or may not quite meet one another and may converge toward a rounded portion or
straightened edge portion. Otherwise the second and third handle flaps 46b,
52b; 146b,
152b are free of connection from the adjacent side end closure panels 20b,
24b; 120b,
124b; 220b, 224b, 320b, 324b or at least separable therefrom (by separation of
a
perforation or connecting nick) so that the second and third handle flaps 46b,
52b; 146b,
152b; 346b, 352b can be folded out of the plane of the adjacent side end
closure panels
20b, 24b; 120b, 124b; 220b, 224b, 320b, 324b and inwardly of the carton, in co-
operation with the folding of the partially overlapping first handle flap 68b,
168d, 368d.
Advantageously, in the fourth embodiment (FIGS. 7, 8 and 9), the second and
third handle flaps 346b, 352b optionally terminate short of (in other words in-
set from)
the outer edge of the side end closure panel 320b, 324b in which they are
formed.
Additionally or alternatively, the second and third handle flaps 346b, 352b
are separated
by a shaped aperture from an edge 351b, 353b of the adjacent side end closure
panel
320b, 326b. These features may enable the second and third handle flaps 346b,
352b
to be more easily folded, inwardly, of said side end closure panels 320b, 324b
whilst at
the same time ensuring that the blank 310 can be handled by processing
machinery.
In the first and second embodiments weakened line 51b, 53b, 151b, 153b is
substantially a cut line having an optional connecting nick portion (not
readily visible in
Figures 1A and 2A). This connecting nick portion maintains the second and
third
handle panels 46b, 52b, 146b, 152b connected to and in the same plane as the
side
end closure panels 20b, 24b, 120b, 124b so that those panels 20b, 24b, 120b,
124b,
46b, 52b, 146b, 152b are maintained, together, in co-planar alignment. As such
the
panels 20b, 24b, 120b, 124b, 46b, 52b, 146b, 152b retain a degree of stiffness
so that
manipulation and handling of the blanks 10, 110 through high-speed processing
lines is
not hindered. For example the processing may be hindered if the second or
third
handle flap 46b, 52b, 146b, 152b, became disconnected from the side end
closure
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panels 20b, 24b, 120b, 124b (by breaking of the nick portion along weakened
line 51b,
53b, 151b, 153b).
However, as is discussed below, upon operation of the handle it is required
that
the second and third handle flaps 46b, 52b, 146b, 152b, 346b, 352b fold
inwardly of the
carton and fold about the pre-defined folding lines 48b, 54b, 148b, 154b,
348b, 354b.
Depending upon the thickness and density of the substrate used to form the
blank 10,
110 and the size (strength) of the connecting nick portion that maintains a
connection
between the second and third handle flaps 46b, 52b, 146b, 152b and the side
end
closure panel 20b, 24b, 120b, 124b, the force required to break the connection
(and
allow the second and third handle flaps 46b, 52b, 146b, 152b to fold as
required) may in
some arrangements cause instead, the second and third handle flaps 46b, 52b,
146b,
152b to fold in a different place. In such an event, the second and third
handle flaps
46b, 52b, 146b, 152b may not provide the requisite load bearing and
cushioning.
Therefore, in the fourth embodiment, the second and third handle flaps 346b,
352b are entirely detached from edge 351b, 353b of the side end closure panels
320b,
324b. To ensure that the second and third handle panels 346b, 352b do not
impede the
automated processing of the blank 310, the second and third handle flaps 346b,
352b
are (proportionally) smaller in size than the second and third handle flaps
46b, 52b,
146b, 152b of the first and second embodiments of the disclosure and/or are
optionally
inset from a notional boundary or edge of side end closure panel 320b, 324b.
The second and third handle flaps 46b, 52b; 146b, 152b; 346b, 352b are
optionally sized and shaped so that their substantially elliptically-shaped
panels 50b,
56b, 150b, 156b, 350b, 356b are disposed at an acute angle relative to the
first
substantially elliptically-shaped panel 62a, 162a, 362a. See Figures 20, 2D, 8
and 9. In
particular see the notional axes Al, A2, A3 shown through each of the first,
second and
third at least substantially elliptically-shaped panels 162a, 150a and 156b in
Figures 20
and 2D. The axis A2 is disposed at an optional acute angle of about 45
relative to axis
Al; the axis A3 is disposed at an optional acute angle of about 45 relative
to axis Al.
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The second and third handle flaps 46b, 52b; 146b, 152b; 346b, 352b are
optionally sized and shaped so that a portion of the second and third handle
flaps 46b,
52b; 146b, 152b; 346b, 352b is disposed in underlying relationship with the
first handle
flap 68b, 168b, 368b.
The second and third handle flaps 46b, 52b; 146b, 152b are optionally sized
and
shaped so that their elliptical portions 50b, 56b, 150b, 156b, 350b, 356b are
not
disposed in underlying relationship with the first elliptical portion 162b of
the first handle
flap 168b (see Figures 20, 8 and 9 for an illustration of this albeit of the
other end of the
carton labeled with suffix `a').
The second and third handle flaps 46b, 52b; 146b, 152b are optionally sized
and
shaped so that the trapezoidal shaped weakened arrangement 80b, 180b, 75b,
175b,
80a, 180a, 75a, 175a, provided to assist in initiating the displacement of the
first handle
flap 68a, 68b, 168a, 168b, is not in overlaying superposition with the second
and third
handle flaps 46b, 52b; 146b, 152b.
The second and third handle flaps are optionally sized and shaped so that a
curved outer edge thereof, 90b, 91b, 190a, 190b, 390a, 390b (see Figures 1A,
2A, 20
and 7) is in alignment with a portion of the line of separation 81b, 181b,
281b, 381b of
the first handle flap 68b, 168b, 268b, 368b or at least proximate or closely
positioned
relative thereto. As such, in the first illustrated embodiment where the
curved portion of
the line of separation 81a curves towards the nick portion 73a, so the
corresponding
part 90b of the second and third handle flaps 46b, 52b are similarly shaped.
In the
second, third and fourth illustrated embodiments, where the curvilinear
portion of line of
separation 181b, 281b, 381b straightens towards the bottom of the first handle
flap
168b, 268b, 368b so the corresponding part 190a, 290a, 390a of the second and
third
handle flaps 146b, 152b, 246b, 252b, 346b, 352b are similarly shaped (see
Figures 2B,
20, 3, 6, 7, 8 and 9).
A carton 200 is constructed from a blank similar to blanks 10, 110, 310,
optionally
in a typical manner. A manufacturing glue seam is formed by affixing glue
panel 44,
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144, 344 to the inside face of first side panel 12, 112, 312 such that a part-
formed flat-
folded blank is formed. In this part formed condition the flat-form carton may
be
transported to a converting plant whereat it will be erected into an open-
ended tubular
structure and loaded with articles through one or both ends. The ends are then
closed
by forming the composite end wall structures by first folding the side end
closure panels
20b, 24b, 120b, 124b, 220b, 224b, 320b, 324b and then the bottom end closure
panel
22b, 122b, 222b, 322b and then finally the top end closure panel 26b, 126b,
226b, 326b
(as can be seen from Figures 20 and 2D albeit from the other end of the
carton).
To use the handle 58, 158, 258, 358, first of all, if connecting nick portions
73b,
273b, 373b are provided, they must be broken by applying an inwardly directed
force to
the first handle flap 68b, 368b. Once these nicks (or other connections
provided along
line of separation 81b, 281b, 381b) are broken, the first handle flap 68b,
268b, 368b can
be displaced out of the plane of the top end closure panel 26b, 226b, 326b. By
applying
further inward force a user will cause the first handle flap 68b, 168b, 368b
to push the
second and third handle flaps 46b, 52b, 146b, 152b, 246b, 352b, 346b, 352b
inwardly of
the carton 200. The three at least substantially elliptically-shaped panels
62b, 50b, 56b;
162b, 150b, 156b; 362b, 350b, 356b all move inwardly relative to the plane of
the top or
side end closure panel 26b, 20b, 24b; 126b, 120b, 124b; 386b, 320b, 324b from
which
they are formed until the shape of the arcuate fold lines 60b, 48b, 54b; 160b,
148b,
154b; 360b, 348b, 354b and/or the shape of the panels 62b, 50b, 56b; 162b,
150b,
156b; 362b, 350b, 356b resists further inward folding and together the three
at least
substantially elliptically-shaped panels 62b, 50b, 56b; 162b, 150b, 156; 362b,
350b,
356b form a supported three-dimensional load bearing structure which a user
can
comfortable and securely grasp for lifting and carrying the carton 200.
Furthermore, the
risk of failure through tearing of the inner second and third handle flaps
46b, 52b; 146b,
152b; 346b, 352b is reduced because of the use of one or more arcuate-shaped
fold
lines 60b, 61b, 48b, 47b, 54b, 57b; 160b, 161b, 148b, 147b, 154b, 157b; 360b,
361b,
348b, 347b, 354b, 357b. In the set-up handle structure a portion of the first
handle flap
68b, 168b, 368b below the elliptical panel 62b, 162b, 362b is folded
substantially
convexly.
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As referred to above, shaped edges 81b, 181b, 381b (defining the bulbous
portions curving from the terminations 64b, 66b; 164b, 166b; 364b, 366b) of
the first
handle flap 68b, 168b, 368b allow the first substantially elliptical panel
62b, 162b, 362b
to rest and fit against the second and third substantially elliptical panels
50b, 56b, 150b,
156b, 350b, 356b whilst allowing at least some of the remainder of the first
handle flap
68b, 168b, 368b (below panel 62b, 162b, 362b) to fold, substantially opposite
to, (albeit
somewhat convexly), the composite end closure structure 26b, 24b, 22b, 20b;
126b,
124b, 122b, 120b; 326b, 324b, 322b, 320b. The remainder of the first handle
flap 68b,
168b, 368b is spaced from the composite end closure structure by a distance
that is at
least approximately the width of the first elliptical panel 62b, 162b, 362b.
In Figure 6 a
view of the carton 200 from the interior is shown wherein the folded handle
258 is
illustrated. It will be appreciated that in use, the handle 258 may be further
folded, such
that the handle flap 268b may be folded further towards the top end closure
panel 226b.
Referring now to the handle structure shown in Figure 10, the blank 410 is
again
substantially symmetric and opposed ends thereof are substantially similar.
For clarity,
like references have been used with a suffix "a" or "b" affixed to distinguish
one end of
the blank 410 from the other. The description of an element or group of
elements having
a suffix "a" is generally suitable for a like-numbered element or group of
elements
having a suffix "b" and vice versa. In certain instances, only one of like
elements may be
numbered and/or described. Specifically, to avoid obscuring the drawing,
certain
elements of the handle structure are numbered only on one end of the blank 410
and
other elements of the handle structure are only numbered on the other end of
the blank
410.
In Figure 10, there is shown a blank 410, wherein the top panel 418 is smaller
in
area than the bottom panel 414. The blank 410 forms a gable topped style
carton and
the side end closure flap 420a, 424a, 420b, 424b are configured to taper to
provide a
shaped carton (not shown) that more tightly encases a matrixed arrangement of
bottles
(not shown) or other articles having a top portion that is smaller than a
bottom portion.
As is known, a diamond-shaped fold arrangement 430a/431a, 435a/437a,
430b/431b,
435b/437b, is used to adjoin the tapering side end closure flaps 420a, 424a,
420b, 424b
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to the first and second side panels 412, 416 respectively. The aforedescribed
features
of blank 410 are entirely optional and are not significant to the operation of
the handle
structure shown therein. It will be recognized that application of the handle
structure of
the fifth embodiment illustrated in Figure 10 is not limited to being in a
blank for forming
a gable-top style carton and it is explicitly envisaged that the handle
structure illustrated
in Figure 10 may be utilized in a square-style fully enclosed carton as shown
in earlier
embodiments and in other styles of carton as well, for example tray-style
cartons.
The handle structure of the fifth illustrated arrangement differs in that the
first
hinge connection for the first handle flap 468a comprises a first pair of
linear fold lines
460b, 461b. First and second linear fold lines 460b, 461b of the first pair of
linear fold
lines 460b, 461b are substantially parallel to one another and defined
therebetween an
approximately hexagonally-shaped panel 462b.
Angled end portions 465b, 463b of the upper most, first fold line 460b connect
the first fold line 460b to a line of separation. The line of separation is
defined by a cut-
line or perforate line interrupted by one or more connecting nick portions.
The line of separation does not extend above the first fold line 460b. It
extends
along a curvilinear section with the line of separation extending away from
each end of
the first approximately hexagonal shaped panel 462b. It then curves back
inwardly
(proximate to a connecting nick) and terminates a linear section. The line of
separation
is symmetrical. The first handle panel 468b optionally comprises two bulbous
curved
sections connected by a flattish top. The second fold line 461d terminates at
each of its
ends on a bulbous part of the line of separation and as such, the
approximately
hexagonally-shaped panel 462b is defined by four fold lines and two cut edges.
The
approximately hexagonally-shaped panel 462b can move inwardly relative to the
end
closure panel 426b and provides a cushion for a user's hand.
Similar to the previous illustrated embodiments, an optional weakened
arrangement is provided: in part to assist in initiating the separation of the
first handle
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flap 468b from the top end closure panel 426b and in part to assist with the
inward
folding of the first handle flap 468b when the handle 58, 158, 258, 358 is
deployed.
In the fifth illustrated embodiment, the optional weakened arrangement
comprises a linear fold line 476b disposed above and substantially parallel to
the linear
section of line of separation. The linear fold line 476b is interrupted by a
substantially
semi-circular or arcuate cut line which defines a substantially semi-circular
or arcuate
aperture or cut-out portion 472b. The aperture or cut-out portion 472b enables
a user to
grasp the handle flap 468a, break the connecting nick portions and fold the
handle flap
468a about linear fold line 476b, first linear fold line 460b and about second
linear fold
line 461b. The first approximately horizontally-shaped panel 462b provides a
cushioned
edge of a three-dimensional load-bearing structure. The three-dimensional load-
bearing
structure is further formed and supported by inner elements namely second and
third
handle flaps 452b, which are similar to those already described in respect of
Figures 7,
8 and 9 and are not therefore described in greater detail.
To ensure that the second and third handle panels 452b do not impede the
automated processing of the blank 410, the second and third handle flaps 452b
are
(proportionally) smaller in size than the second and third handle flaps 452b
of the first
and second embodiments of the disclosure and/or are optionally inset from a
notional
boundary or edge of side end closure panel 420b, 424b.
The second and third handle flaps 452b are optionally sized and shaped so that
their substantially elliptically-shaped or leaf-shaped panels are disposed at
an acute
angle relative to the first substantially hexagonally-shaped panel 462a. The
second and
third handle flaps 452b are optionally sized and shaped so that a portion of
them is
disposed in underlying relationship with the first handle flap 468b.
A carton (not shown) is constructed from a blank 410 in a known manner and
using a similar sequence to that described above.
The handle is used in the same way as described above, albeit with the
substantially hexagonally shaped panel 462b and substantially elliptically-
shaped
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panels of the inner handle flaps 452b moving inwardly, together, relative to
the plane of
the top or side end closure panel 426b, 420b, 424b from which they are formed
until the
shape of the first, second and third pairs of fold lines and/or the shape of
the panels
462b, 456a, resists further inward folding and together the three shaped
panels 462b,
456b form a supported three-dimensional load bearing structure which a user
can
comfortable and securely grasp for lifting and carrying the carton.
The present invention has been illustrated in relation to particular
embodiments
which are intended in all respects to be illustrative rather than restrictive.
Those skilled
in the art will recognize that the present invention is capable of many
modifications and
variations without departing from the scope of the invention. For example, as
used
herein, directional references such as "top", "base", "bottom", "end", "side",
"inner",
"outer", "upper", "middle", "lower", "front" and "rear" do not necessarily
limit the
respective walls of the carton to such orientation, but merely serve to
distinguish these
walls from one another. Any reference to hinged connection should not be
construed as
necessarily referring to a junction including a single hinge only; indeed, it
is envisaged
that hinged connection can be formed from one or more potentially disparate
means for
hingedly connecting materials.
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. All such
variations,
modifications, and combinations are included herein by the scope of this
disclosure and
the following claims.
In other embodiments where the first hinge connection comprises one linear
fold
lines, it is envisaged that a shaped panel may be defined between that linear
fold line
and another fold line that may be linear or arcuate. It is envisaged therefore
that the first
shaped panel may be substantially rectangular or segment-shaped as further non-
limiting examples.
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It will be recognized that as used herein the term arcuate may mean curved,
curvilinear, partially or approximately curved. A series of straight short
fold lines
arranged in a non-linear substantially curved manner can create an arcuate
fold line.
Arcuate may mean semi-circular, but may also mean non-circular, for example,
partially
elliptical, partially oval and otherwise curved or radiused.
24
