The disclosures of PCT/US2011/051897, which was filed on Sep. 16, 2011, and U.S. Provisional Patent Application No. 61/403,549, which was filed on Sep. 17, 2010, are hereby incorporated by reference for all purposes as if presented herein in their entirety.
The present disclosure generally relates to cartons for holding containers. More specifically, the present disclosure relates to a carton having a handle.
In one aspect, the present disclosure is generally directed to a carton for containing a plurality of articles. The carton comprises a plurality of panels that extends at least partially around an interior of the carton. The plurality of panels comprises a first top panel, a second top panel, a bottom panel, a first side panel, and a second side panel. The first top panel and the second top panel are at least partially overlapped to form a top wall of the carton. A handle extends in at least the top wall. The handle can comprise at least a first handle portion of the first top panel and a second handle portion of the second top panel. The first handle portion can at least partially overlap the second handle portion, and the second handle portion can comprise a notch that is at least partially overlapped by a overlay portion of the first handle portion.
In another aspect, the disclosure is generally directed to a blank for forming a carton. The blank can comprise a plurality of panels comprising a first top panel, a second top panel, a bottom panel, a first side panel, and a second side panel. The first top panel and the second top panel are for being at least partially overlapped to form a top wall in the carton formed by the blank. The blank further comprises handle features for forming a handle in at least the top wall in the carton formed by the blank. The handle features can comprise at least a first handle portion of the first top panel and a second handle portion of the second top panel. The first handle portion is for being positioned to at least partially overlap the second handle portion when the carton is formed from the blank, and the second handle portion can comprise a notch that is for being at least partially overlapped by a overlay portion of the first handle portion when the carton is formed from the blank.
In another aspect, the disclosure is generally directed to a method of assembling a carton. The method can comprise obtaining a blank comprising a plurality of panels comprising a first top panel, a second top panel, a bottom panel, a first side panel, and a second side panel, and handle features comprising at least a first handle portion of the first top panel and a second handle portion of the second top panel. The second handle portion comprises a notch and the first handle portion comprises a overlay portion. The method further comprises forming an interior of the carton at least partially defined by the plurality of panels and forming a top wall comprising at least the first top panel and the second top panel. The forming the top wall comprises overlapping at least a portion of the second top panel with at least a portion of the first top panel. The overlapping at least a portion of the second top panel with at least a portion of the first top panel comprises at least partially overlapping the second handle portion of the second top panel with the first handle portion of the first top panel to form a handle extending in at least the top wall. The at least partially overlapping at least the second handle portion with the first handle portion comprises at least partially overlapping the notch of the second handle portion with the overlay portion of the first handle portion.
Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.
According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
The present invention generally relates to cartons that contain articles such as containers, bottles, cans, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof.
Cartons according to the present invention can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the invention, the following detailed description describes beverage containers (e.g., aluminum beverage cans) as disposed within the carton embodiments. In this specification, the terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected and upright cartons.
The blank 3 has a longitudinal axis L1 and a lateral axis L2. The blank 3 comprises a bottom panel 11 foldably connected to first and second side panels 13, 15 at lateral fold lines 17, 19, a first top panel 23 foldably connected to the second side panel 15 at a lateral fold line 25, and a second top panel 29 foldably connected to the first side panel 13 at a lateral fold line 31. The first and second top panels 23, 29 will at least partially overlap in the erected carton 5.
The bottom panel 11 is foldably connected to a first bottom end flap 35 and a second bottom end flap 37. The first side panel 13 is foldably connected to a first side end flap 41 and a second side end flap 43. The second side panel 15 is foldably connected to a first side end flap 45 and a second side end flap 47. The first top panel 23 is foldably connected to a first top end flap 51 and a second top end flap 53. The second top panel 29 is foldably connected to a third top end flap 55 and a fourth top end flap 57.
The end flaps 35, 41, 45, 51, 55 extend along a first marginal area of the blank 3, and are foldably connected at a first longitudinal fold line 61 that extends along the length of the blank. The end flaps 37, 43, 47, 53, 57 extend along a second marginal area of the blank 3, and are foldably connected at a second longitudinal fold line 63 that also extends along the length of the blank. The longitudinal fold lines 61, 63 may be, for example, substantially straight, offset, or oblique at one or more locations to account for blank thickness or for other factors. When the carton 5 is erected, the end flaps 35, 41, 45, 51, 55 close a first end 67 of the carton, and the end flaps 37, 43, 47, 53, 57 close a second end 69 of the carton. In accordance with an alternative embodiment of the present invention, different flap arrangements can be used for closing the ends 67, 69 of the carton 5.
The features that comprise the handle 7 include a first handle opening 81 that is in the first top panel 23 and a first handle portion 83 that is in the first top panel adjacent to the first handle opening and a laterally-extending edge 85 of the blank 3. The features that comprise the handle 7 also comprise a second handle opening 91 in the second top panel 29 and a second handle portion 93 that is in the second top panel adjacent to the second handle opening. In one embodiment, the handle features comprise a handle reinforcement flap 97 foldably connected to the second top panel 29. The handle reinforcement flap 97 is foldably connected to the second top panel 29 at three lateral fold lines 101, 103, 105. The handle reinforcement flap 97 is at least partially defined by a first cut 107 between the lateral fold lines 101, 103 and a second cut 108 between the lateral fold lines 103, 105. In the illustrated embodiment, the cuts 107, 108 can form projections 110, 112 (
In the embodiment of
In one embodiment, the handle 7 includes reinforcement tape 125 that can be adhesively applied to the interior surface of the handle portion 93 of the second top panel 29 and/or other portions of the second top panel (
In the illustrated embodiment, the blank 3 comprises stress-relieving areas or patterns 131, 133. The stress relieving patterns 131, 133 each comprise longitudinal score lines 135, 137, a lateral score line 139 connecting respective ends of the longitudinal score lines in the first and second side panels 13, 15, a curved score line 136 connecting respective ends of the longitudinal score lines in the first and second top panel 23, 29, and oblique score lines 138, 140 extending from a respective handle opening 81, 91 in a respective top panel. In one embodiment, the score lines of each of the stress-relieving areas 131, 133 are four point crease/score lines that extend deeper into the thickness of the blank 3 than the score lines forming the fold lines 17, 19, 25, 31, 61, 63. The specific depth of the score lines of the stress-relieving areas 131, 133 can vary but should be generally proportional to the weight or thickness of the material of the blank 3.
An exemplary method of erecting the carton 5 is discussed in detail below and shown in
As shown in
In one embodiment, the carton 5 is further formed by folding the second top panel 29, with the folded under and attached reinforcement flap 97, about fold line 31 to the position shown in
In the illustrated embodiment, the overlay portions 137, 139 of the second top panel in combination with the respective notches 117, 119 of the handle reinforcement flap 97 form respective weakened portions of the handle 7 that are adjacent respective corners of the handle opening 91 and the cutout 113. The overlay portions 147, 149 of the first top panel 23 in combination with the respective notches 141, 143 of the second top panel 29 form respective weakened portions of the handle that are adjacent respective corners of the handle opening 81 and the recess 142. When the carton 5 is loaded, assembled, and closed, the handle 7 is activated by grasping the handle at the handle openings 81, 91. When the erected carton 5 carton is lifted, small tears may occur in the overlay portions 137, 139, 147, 149 that are directed generally inward toward the overlapped handle portions 83, 93 and reinforcement flap 97. The strength of the overlapped handle portions 83, 93, reinforcement flap 97, and reinforcement tape 125 in the central portion of the handle 7 stops the tears formed in the weakened areas at the overlay portions 137, 139, 147, 149 from propagating throughout the carton 5. The hook-shaped cuts 109, 111, 121, 123 can also help control and direct tearing in and proximate the handle 7. In this way, the handle 7 is strengthened (e.g., the tearing of the handle is controlled) by the use of the hook-shaped cuts 109, 111, 121, 123 and/or the weakened areas at the overlay portions 137, 139, 147, 149, which are controlled by the shape of the respective notches 117, 119, 141, 143. Accordingly, the notches 117, 119, 141, 143 can provide directed potential tearing in predictable areas. The overlay portions 137, 139, 147, 149 are less reinforced than portions of the handle that are adjacent the notches 117, 119, 141, 143. The notches 117, 119, 141, 143, hook-shaped cuts 109, 111, 121, 123, and overlay portions 137, 139, 147, 149 could be otherwise shaped, arranged, and/or configured without departing from the disclosure. For example, the hook-shaped cuts 109, 111, 121, 123 can be configured so that the lateral portions of the cuts in the illustrated embodiment are oblique or longitudinal. Further, the hook-shaped cuts can be positioned so that the curved portions are otherwise directed (e.g., the curved portions are all directed toward the center of the handle 7).
The partially assembled blank can be assembled into an open-ended sleeve so that containers can be loaded into the sleeve. After loading the containers, the ends 67, 69 of the carton 5 can be closed by at least partially overlapping and adhering the end flaps 35, 41, 45, 51, 55 at the first end 67 of the carton and at least partially overlapping and adhering the end flaps 37, 43, 47, 53, 57 at the second end 69 of the carton. The overlapped top end flaps at each end (e.g., 53, 57 at end 69) are downwardly folded and secured to the side end flaps (e.g., 43, 47) at the same end. The bottom end flap (e.g., 37) can be upwardly folded and secured to the side end flaps (e.g., 43, 47) at the same end. The ends 67, 69 of the carton 5 could be closed by other closing steps and features without departing from the disclosure. Further, the carton 5 can be alternatively loaded, such as by loading the containers after closing either of the ends 67, 69.
In the illustrated embodiment, the handle 7 is formed from the handle features of the blank and comprises three layers of blank material (first handle portion 83, second handle portion 93, and reinforcement flap 97). Additionally, the reinforcement tape 125 acts as an additional layer of material between the handle portion 93 and the reinforcement flap 97. The handle 7 could have other features and could include additional reinforcing layers or portions without departing from the disclosure. The reinforced handle 7 of the present disclosure allows the blank 3 to be made of a relatively thinner material (e.g., material with a 21 caliper thickness) compared to a blank for forming the same size carton that will need an increased thickness (e.g., 24 caliper thickness) to maintain the integrity of the handle when carried.
According to a second embodiment of the disclosure,
According to a third embodiment of the disclosure,
According to a fourth embodiment of the disclosure,
Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure. Further, it is noted that the handle features and stress-relief areas of the various embodiments can be incorporated into a carton having any carton style or panel configuration. The carton styles and panel configurations described above are included by way of example.
The blanks according to the present invention can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.
In accordance with the exemplary embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton package to function at least generally as described above. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
In accordance with the exemplary embodiment of the present invention, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.
The above embodiments may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels or flaps in place.
In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.
The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.
This application is a continuation application of PCT/US2011/051897, filed Sep. 16, 2011, which application claims the benefit of U.S. Provisional Patent Application No. 61/403,549, filed Sep. 17, 2010.
Number | Date | Country | |
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61403549 | Sep 2010 | US |
Number | Date | Country | |
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Parent | PCT/US2011/051897 | Sep 2011 | US |
Child | 13762804 | US |