CARTON WITH HANDLE

Abstract

A carton including a wall (216a) having a handle (220a) that includes a load bearing edge. The load bearing edge includes a first segment (170a) that is configured to support a substantially vertical load and a second segment (172a) that is configured to support a substantially horizontal load. A first handle flap (160a) is hingedly connected to the first segment, and a second handle flap (162a) that is hingedly connected to the second segment.

Description

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 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. Therefore, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.

SUMMARY

The various embodiments of the present invention overcome the shortcomings of the prior art by providing a handle that is configured to provide a comfortable load-bearing edge. The load-bearing edge is configured to compensate for both horizontal forces and vertical forces that can be applied by the handle to a user's hand. For example, vertical forces may be due to the weight of the articles and horizontal forces may be due to carrying the carton at a slight angle or swinging, pushing, pulling, or sliding the carton. With such movements, 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 opening is generally sized to fit a user's hand and can have various shapes including an elongated slot, trapezoidal, and rectangular. The handle also includes an arrangement of handle flaps that are configured to provide cushioning along the load-bearing edge of the handle. According to an exemplary embodiment, 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.

According to one aspect of the disclosure, an arrangement of handle flaps is configured to fold as a unit. For example, when a first handle flap is folded toward the interior of the carton, the first handle flap folds a second handle flap toward the interior of the carton. According to an exemplary embodiment, an end of a first fold line that hingedly connects the first handle flap to an edge of the handle is adjacent to an end of a second fold line that hingedly connects the second handle flap to the edge of the handle and the first handle flap overlaps the second handle flap.

According to an exemplary embodiment of the disclosure, a wall in which the handle is formed can be a composite wall where an outer handle aperture formed in an outer layer is in registry with an inner handle aperture formed in an inner layer. An outer handle flap is attached to an edge of the outer handle aperture and an inner handle flap is attached to an edge of the inner handle aperture. In an unfolded condition, a portion of the outer handle flap may overlap a portion of the inner handle flap. Accordingly, when the outer handle flap is folded, the outer handle flap can contact the inner handle flap to fold the inner handle flap toward the interior of the carton. Additionally, the outer handle flap can include a portion that folds such that the outer handle flap and the inner handle flap remain in contact as they are each folded toward the interior of the carton. In other words, the outer handle flap and the inner handle flap fold as a unit toward the interior of the carton.

The foregoing has broadly 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.

DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a plan view of a blank for forming a carton, according to a first exemplary embodiment of the disclosure.

FIG. 2 is a perspective view of a carton formed from the blank of FIG. 1.

FIG. 3 is a partial end elevation view of a handle of the carton of FIG. 2, the handle being in an unfolded condition.

FIG. 4 is a partial perspective view of the exterior of the handle of FIG. 3, the handle being in a folded condition.

FIG. 5 is a partial perspective view of the interior of the handle of FIG. 4.

FIG. 6 is a plan view of a blank for forming a carton, according to a second exemplary embodiment of the disclosure.

FIG. 7 is a plan view of a blank for forming a carton, according to a third exemplary embodiment of the disclosure.

FIG. 8 is a partial end elevation view of a handle of the carton of FIG. 7.

FIG. 9 is a partial end elevation view of the handle of FIG. 3 illustrating the insertion of a hand into the handle.

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, one of the illustrated embodiments is a “tray-style” carton and another of the illustrated embodiments is a “box style” carton.

Referring to a first exemplary embodiment illustrated in FIGS. 1-5, a “tray-style” carton 200 (FIG. 2) is formed from a blank 100 (FIG. 1). The illustrated blank 100 is 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 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-cuts, a single half-cut, a cut line, an interrupted cut line, 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 FIG. 1, the blank 100 includes a base panel 110, side panels 112, 114 hingedly connected to side edges of the base panel 110, and end panels 116a, 116b hingedly connected to end edges of the base panel 110. The side panels 112, 114 are hingedly connected to the base panel 110 along fold lines 122, 124 and the end panels 116a, 116b are hingedly connected to the base panel 110 along fold lines 126a, 126b.

The blank 100 is 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 100 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”. 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.

Side end flaps 132a, 132b, 134a, 134b are hingedly connected to opposed ends of side panels 112, 114 along fold lines 136a, 136b, 138a, 138b, respectively. In the illustrated embodiment, the side end flaps 132a, 134a include corner panels 140a, 142a that are defined by the fold line 136a, 138a and a fold line 144a, 146a.

The blank 100 further includes elements that combine to provide handles at opposed ends of the carton 200. The end panel 116a includes a handle aperture 150a and the side end flaps 132a, 134a include handle notches 152a, 154a. Each of the handle aperture 150a and the handle notches 152a, 154a include a handle flap attached along an edge thereof. The handle aperture 150a includes a top handle flap 160a and the handle notches 152a, 154a include side handle flaps 162a, 164a, respectively. The top handle flap 160a is hingedly connected to a top edge of the handle aperture 150a along a fold line 170a and the side handle flaps 162a, 164a are hingedly connected to side edges of the handle notches 152a, 154a along fold lines 172a, 174a, respectively.

The top handle flap 160a includes fold lines 176a, 178a that define a main portion 180a and side portions 182a, 184a. The main portion 180a is hingedly connected to the top edge of the handle aperture 150a and the side portions 182a, 184a are separable from the end panel 116a along severance lines 186a, 188a. The side handle flaps 162a, 164a are separable from the side end flaps along severance lines 190a, 192a, 194a, 196a.

The fold lines 172a, 174a and the fold lines 176a, 178a are configured such that the top handle flap 160a and the side handle flaps 162a, 164a cooperate as described in further detail below.

Referring to FIGS. 1 and 2, an exemplary method of folding and securing the blank 100 to form the carton 200 is now described although a method of erecting the carton 200 is not limited to the steps described herein. Rather, the order of the steps can be altered according to manufacturing requirements, steps may be added or omitted, and means for securing components to one another may vary. For example, although the surfaces of sheet material together are described as being glued together, the sheet material may alternatively be secured together by tape, staples, interlocking folds, hook and loop fasteners, other adhesives, combinations thereof, and the like. The exemplary method can be performed by automatic erecting machinery and/or manually.

The side panels 112, 114 are folded along the fold lines 122, 124 so as to be substantially perpendicular to the base panel 110. The side end flaps 132a, 134a are then folded along fold lines 136a, 138a, 144a, 146a such that the distal end portions of the side end flaps 132a, 134a overlap and such that the corner panels 140a, 142a align with chamfered corners of the base panel 110. The overlapping distal end portions of the side end flaps 132a, 134a are secured together with glue. The end panel 116a is then folded along the fold line 126a to overlap exposed outer surfaces of the end wall portions of the side end flaps 132a, 134a and is secured thereto with glue. In alternative embodiments, the side end flaps do not overlap or are not secured together although the notches approximate an aperture formed in an inner layer defined by the side end flaps as in the first exemplary embodiment. Further, the side end flaps 132a, 134a can form an outer layer of an end wall.

The side end flaps 132a, 134a and end panel 116a are thus secured together to provide a composite end wall 216a of the carton 200. Similarly, the side end flaps 132b, 134b and end panel 116b are secured together to provide a composite end wall 216b of the carton 200. Additionally, the erected side panels 112, 114 provide side walls 212, 214 of the carton 200 and the base panel 110 provides a base wall 210 of the carton 200.

Referring to FIGS. 2 and 3, each of the end walls 216a, 216b includes a handle 220a, 220b. The illustrated handle 220a is formed as the handle aperture 150a and the handle notches 152a, 154a are brought into registry with one another and the top handle flap 160a and the side handle flaps 162a, 164a are arranged to cooperate with one another. The handle notches 152a, 154a provide an inner handle aperture with edges that are offset from the edges of the aperture 150a. Accordingly, the illustrated handle 220a has an edge that is partially defined by edges of the aperture 150a and partially defined by edges of the notches 152a, 154a. For example, the side edges of the notches 152a, 154a defined by fold lines 172a, 174a are offset from the side edges of the aperture 150a and define the side edges of the handle 220a. The trapezoidal shape of the handle 220a distributes the force applied to carry the carton 200 and thus limits the concentration of stress that is typically observed at the corners of slot handles.

The illustrated arrangement of handle flaps is such that the top handle flap 160a overlaps the side handle flaps 162a, 164a and portions of the side end flaps 132a, 134a. The main portion 180a overlaps the side handle flaps 162a, 164a and side portions 182a, 184a of the top handle flap 160a overlap the side handle flaps 162a, 164a and the side end flaps 132a, 134a. The inner layer provided by the side end flaps 132a, 134a permits the main portion 180a to fold inwardly and facilitates folding the side portions 182a, 184a.

The illustrated fold lines 172a, 174a, 176a, 178a are arranged to facilitate folding the top handle flap 160a and the side handle flaps 162a, 164a as a unit. The fold lines 172a, 174a upwardly extend convergently towards one another while the fold lines 176a, 178a upwardly extend divergently away from one another.

The upper ends of the fold lines 172a, 174a are adjacent to opposite ends of the fold line 170a respectively. Typically, the fold lines 170a and 172a, 174a do not substantially overlap or intersect one another. Each of the illustrated fold lines 172a, 174a is disposed at an obtuse angle with respect to the fold line 170a. The angle of the fold lines 172a, 174a contributes to the concave load bearing edge and concave support surface of the handle 220a as viewed from the base of the carton, which is best illustrated in FIGS. 4 and 9. In alternative embodiments, the angle between one of the fold lines 172a, 174a and the fold line 170a can be acute or substantially equal to ninety degrees.

Referring to FIGS. 2-5 and 9, an exemplary method of operation of the handle 220a is now described. The handle 220a can be engaged by inserting a hand H into the handle opening (FIG. 9) and folding the main portion 180a of the top handle flap 160a inwardly along the fold line 170a (FIGS. 4, 5, and 9). As the main portion 180a is folded inwardly, the main portion 180a contacts and folds the side handle flaps 162a, 164a inwardly along the fold lines 172a, 174a. Substantially simultaneously, the side portions 182a, 184a of the top handle flap 160a fold along the fold lines 176a, 178a. The side portions 182a, 184a initially fold due to contact with the side end flaps 132a, 134a and additionally fold as they come into contact with the side handle flaps 162a, 164a. As the main portion 180a is folded so as to be substantially perpendicular to the end wall 216a, the side portions 182a, 184a and the side handle flaps 162a, 164a contact one another and retain one another in folded conditions. As such, the top handle flap 160a and the side handle flaps 162a, 164a fold as a unit.

Referring to FIGS. 3 and 9, the handle 220a includes a load-bearing edge 222a that is configured to cushion a user's hand against both vertical and horizontal loads that are applied by the handle 220a. The illustrated load-bearing edge 222a includes the top and side edges of the handle 220a that are defined by fold lines 170a, 172a, 174a. The illustrated load-bearing edge 222a also includes top and side support surfaces of the handle 220a that are provided by the main portion 180a, the side portions 182a, 184a, and the side handle flaps 162a, 164a. The top and side edges of the handle 220a are substantially continuous and the top and side surfaces of the handle 220a are substantially continuous (see FIG. 4).

Turning to FIG. 6, a second exemplary embodiment of the disclosure is illustrated. The illustrated blank 300 can be folded and secured to form an end loadable and more fully enclosed carton (not shown). The blank 300 includes elements that are substantially similar to those of the handle of the first exemplary embodiment and for clarity the same numerals have been used to identify the handle of the second exemplary embodiment.

The blank 300 includes a series of primary panels which define the walls of a tubular structure of a carton (not shown). The primary panels are aligned along a longitudinal axis of the blank 300 and are hingedly connected one to the next along fold lines that extend transversely with respect to the longitudinal axis. Specifically, the primary panels include a top panel 310, a first side panel 312, a base panel 314, and a second side panel 316. The top panel 310 is hingedly connected to the first side panel 312 along a fold line 320, the first side panel 312 is hingedly connected to the base panel 314 along a fold line 322, and the base panel 314 is hingedly connected to the second side panel 316 along a fold line 324. The blank 300 further includes an edge flap 318 that facilitates securing the endmost primary panels to one another. In the exemplary embodiment, the edge flap 318 is hingedly connected to the top panel 310 along a fold line 326.

End flaps are hingedly connected to opposite ends of each primary panel along fold lines. The end flaps can be folded and secured to form end closure structures at respective open ends of the tubular structure of the carton and thereby define end walls of the carton. Top end flap 330a is hingedly connected to top panel 310 along fold line 340a, first side end flap 332a is hingedly connected to first side panel 312 along fold line 342a, bottom end flap 334a is hingedly connected to base panel 314 along fold line 344a, and second side end flap 336a is hingedly connected to second side panel 316 along fold line 346a.

The top end flap 330a includes a handle aperture 150a with a top handle flap 160a attached to the top edge thereof along a fold line 170a and the side end flaps 332a, 336a include side handle flaps 162a, 164a attached to side edges thereof along fold lines 172a, 174a.

The blank 300 includes a severance line 350 that defines a detachable portion 352 of the blank 300. The detachable portion 352 is dimensioned and positioned such that, as the blank 300 is erected to form the carton, the detachable portion 352 can be at least partially separated from the carton to provide an opening in the carton through which articles can be dispensed. The detachable portion 352 can have any size or shape so as to provide a suitable opening for dispensing articles and the illustrated version is provided as a non-limiting example.

The blank 300 can be folded and secured to form a collapsed tubular structure by folding the edge flap 318 along the fold line 326 such that the inside surface of the edge flap 318 is in flat face contact with the inside surface of the top panel 310, applying glue or other adhesive to the outside surface of the edge flap 318, and folding the blank 300 along the fold line 322 such that the inside surface of the second side panel 316 is in flat face contact with, and thereby secured to, the outside surface of the edge flap 318. A tubular structure can thereafter be erected from the collapsed tubular structure. The primary panels form the walls of the tubular structure. The tubular structure of the carton includes open ends through which articles can be loaded. It should be understood that the end flaps can be folded outwardly or otherwise so as not to obstruct articles as they are loaded through one or both of the open ends.

The end closure structures of the carton are formed by folding the end flaps as described herein. Side end flaps 332a, 336a are folded inwardly toward the open end of the tubular structure along fold lines 342a, 346a so as to be substantially coplanar with one another. Top and bottom end flaps 330a, 334a are folded inwardly toward to the open end of the tubular structure along fold lines 340a, 344a to be substantially coplanar with one another. The top and bottom end flaps 330a, 334a overlap the side end flaps 332a, 336a and glue is applied to the overlapping portions of the end flaps such that the end flaps can be secured together to form an end closure structure. Thereby, the end closure structures of the carton are formed and the carton is fully erected. The primary panels that define the tubular structure portion and the end closure structures define the walls of the carton. Handles that are substantially similar to those described above and illustrated in FIGS. 3-5 are formed in the end closure structures of the carton.

Referring to FIGS. 7 and 8, a third exemplary embodiment of the disclosure is illustrated that includes an alternative configuration of a handle 520a. The blank 400 is substantially similar to the blank 300 and like numerals will be used to identify like elements although certain of the elements are alternatively configured. The description of the blank 400 will be directed to the alternatively configured elements.

The blank 400 includes a top end flap 330a and a bottom end flap 334a that are configured such that an outer handle aperture 450a of the top end flap 330a and an inner handle aperture 456a of the bottom end flap 334a are in registry when the top end flap 330a and the bottom end flap 334a overlap to form and end closure structure. In the illustrated embodiment, the width W1 of the outer handle aperture 450a is greater than the width W2 of the inner handle aperture 456a. An outer handle flap 460a is hingedly connected to the top edge of the outer handle aperture 450a along a fold line 470a and inner handle flaps 462a, 464a are hingedly connected to side edges of the inner handle aperture 456a along fold lines 472a, 474a. The outer handle flap 460a includes fold lines 476a, 478a.

Referring to FIG. 8, a carton 500 formed from the blank 400 includes an end wall 416a that includes a handle 520a. The handle 520a includes the outer handle aperture 450a in registry with the inner handle aperture 456a and the outer handle flap 460a and the inner handle flaps 462a, 464a configured to fold as a unit and provide a cushioned load-bearing edge 522a of the handle 520a. In the illustrated embodiment, the fold lines 476a, 478a are substantially adjacent and parallel to the fold lines 472a, 474a. A main portion 480a of the outer handle flap 460a has a width that is less than the width W2 of the inner handle aperture 456a and side portions 482a, 484a overlap the bottom end flap 334a.

The present invention has been illustrated in relation to a particular embodiment which is 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 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.

Claims

1. A carton, comprising: a wall comprising a handle that includes a load bearing edge, the load bearing edge comprising: a first segment that is configured to support a substantially vertical load wherein a first handle flap that is hingedly connected to the first segment; anda second segment that is configured to support a substantially horizontal load wherein a second handle flap that is hingedly connected to the second segment.

2. The carton of claim 1, wherein the first handle flap and the second handle flap overlap one another.

3. The carton of claim 2, wherein the first handle flap is the outermost one of the first handle flap and the second handle flap.

4. The carton of claim 1, wherein the wall is a composite wall comprising an inner layer and an outer layer.

5. The carton of claim 4, wherein the outer layer comprises the first segment and the inner layer comprises the second segment.

6. The carton of claim 1, wherein the first handle flap and the second handle flap provide a substantially continuous hand support structure when folded.

7. A carton, comprising: a wall that includes a handle, the handle comprising: an edge;a first handle flap that is hingedly connected to a first segment of the edge along a first fold line; anda second handle flap that is hingedly connected to a second segment of the edge along a second fold line, the first handle flap and the second handle flap being configured to fold as a unit and to retain one another in a folded condition.

8. The carton of claim 7, wherein a portion of the first handle flap is configured to be substantially in flat face contact with the second handle flap in the folded condition.

9. The carton of claim 8, wherein the first handle flap further comprises a third fold line and the third fold line at least partially defines the portion.

10. The carton of claim 7, wherein the first handle flap and the second handle flap provide a substantially concave structure in the folded condition.

11. The carton of claim 7, wherein the first fold line is disposed at an obtuse angle with respect to the second fold line.

12. The carton of claim 7, wherein the wall is a composite wall comprising an inner layer and an outer layer, the first handle flap is formed from the outer layer and the second handle flap is formed from the inner layer.

13. The carton of claim 12, wherein the first handle flap overlaps the second handle flaps and portions of the inner layer.

14. The carton of claim 12, wherein the first handle flap comprises a main portion and a side portion, the main portion overlaps the second handle flap, and the side portion overlaps the second handle flap and the inner layer.

15. The carton of claim 12, wherein the handle further comprises a third handle flap hingedly connected to a third segment of the edge along a third fold line, the third handle flap being formed from the inner layer.

16. The carton of claim 15, wherein the wall is an upright wall, and the second and third fold lines extend upwardly convergently towards one another.

17. The carton of claim 16, wherein the upper ends of the second and third fold lines are disposed adjacent to opposite ends of the first fold line respectively.

18. The carton of claim 15, wherein each of the second and third fold lines is disposed at an obtuse angle with respect to the first fold line.

19. The carton of claim 15, wherein the first handle flap comprises a main portion and a pair of side portions hingedly connected to the main portion along fourth and fifth fold lines respectively, the fourth and fifth fold lines upwardly extending divergently away from one another.

20. The carton of claim 15, wherein the inner layer comprises first and second panel portions disposed side by side in substantially the same plane, the second handle flap being formed from the first panel portion, and the third handle flap being formed from the second panel portion.