Patent Grant
9033210
The present disclosure generally relates to cartons for holding beverage containers or other types of articles. More specifically, the present disclosure relates to cartons having a reinforced handle and other features.
In general, one aspect of the disclosure is 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 top panel, a bottom panel, a first side panel, and a second side panel. The carton further comprises at least three first end flaps respectively foldably attached to respective panels of the plurality of panels. The at least three first end flaps cooperate to close a first end of the carton and the at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel. The carton further comprises a handle in the first end of the carton for grasping and carrying the carton. According to this aspect of the disclosure the first side end flap comprises a first main panel, a first handle feature for forming the handle, a first reinforcement portion above the first handle feature, and a reinforcement flap foldably connected to the first reinforcement portion. Furthermore, the second side end flap comprises a second main panel, a second handle feature for forming the handle, and a second reinforcement portion above the second handle feature. Additionally, the reinforcement flap is downwardly folded to at least partially overlap the second reinforcement portion to reinforce the handle.
In another aspect, the present disclosure is generally directed to a blank for forming a carton having a reinforced handle. The blank comprises a plurality of panels comprising a top panel, a bottom panel, a first side panel, and a second side panel. The blank further comprises at least three first end flaps respectively foldably connected to respective panels of the plurality of panels. The at least three first end flaps are configured to cooperate to close a first end of a carton formed of the blank, and the at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel. The blank further comprises features for forming a handle in the at least three first end flaps. The first side end flap comprises a first main panel, a first handle feature for forming the handle, a first reinforcement portion above the first handle feature, and a reinforcement flap foldably connected to the first reinforcement portion. Furthermore, the second side end flap comprises a second main panel, a second handle feature for forming the handle, and a second reinforcement portion above the second handle feature. Additionally, the reinforcement flap is configured to be downwardly folded to at least partially overlap the second reinforcement portion to reinforce the handle.
In another aspect, the present disclosure is generally directed to a method of forming a carton having a reinforced handle. The method comprises obtaining a blank comprising a plurality of panels. The plurality of panels comprises a top panel, a bottom panel, a first side panel, and a second side panel. The blank further comprises at least three first end flaps respectively foldably connected to respective panels of the plurality of panels. The at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel. The first side end flap comprises a first main panel, a first handle feature, a first reinforcement portion above the first handle feature, and a reinforcement flap foldably connected to the first reinforcement portion. The second side end flap comprises a second main panel, a second handle feature, and a second reinforcement portion above the second handle feature. The method further comprises forming at least a portion of an interior of the carton by folding the plurality of panels, folding the at least three first end flaps to at least partially close a first end of the carton, at least partially forming the handle from the first handle feature and the second handle feature, and downwardly folding the reinforcement flap to at least partially overlap the second reinforcement portion to reinforce the handle.
Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims.
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. Further, 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 disclosure generally relates to cartons that contain articles such as containers, bottles, cans, etc., and handle reinforcement features of such cartons. The articles can be used for containing 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 can include, but are not limited to, glass or other breakable material; 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 disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes beverage containers (e.g., glass beverage bottles) 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 carton 5 has first and second ends 7, 9 that have a reinforced handle 10 at each respective end of the carton. In the illustrated embodiment, the carton 5 can have product protection features 111 at least somewhat similar to the product protection features shown and described in the above-noted incorporated-by-reference patent applications. Additionally, the carton 5 could be without product protection features, or with a differing number of product protection features, without departing from the disclosure.
Turning back to
The bottom panel 15 is foldably connected to a first bottom end flap 33 and a second bottom end flap 35. The first side panel 21 is foldably connected to a first side end flap 43 and a second side end flap 45. The second side panel 17 is foldably connected to a first side end flap 37 and a second side end flap 39. The top panel 25 is foldably connected to a first top end flap 47 and a second top end flap 49. The attachment flap 29 is foldably connected to a first attachment end flap 53 and a second attachment end flap 55.
When the carton 5 is erected, the end flaps 33, 37, 43, 47, 53 close the first end 7 of the carton, and the end flaps 35, 39, 45, 49, 55 close the second end 9 of the carton. In accordance with an alternative embodiment of the present disclosure, different flap arrangements can be used for closing the ends 7, 9 of the carton 5.
The end flaps 33, 37, 43, 47, 53 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 35, 39, 45, 49, 55 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, or offset at one or more locations to account for blank thickness or for other factors.
The blank 3 has a lateral fold line 65 extending through side end flap 37, second side panel 17, and side end flap 39 so that each of these flaps and panels may be folded along the fold line 65 to have an upper portion that tapers inward relative to a lower portion. A lateral fold line 67 extends through the side end flap 43, first side panel 21, and side end flap 45 so that each of these flaps and panels may be folded along the fold line 67 to have an upper portion that tapers inward relative to a lower portion. The blank 3 includes four diamond corners 71 that comprise a first fold line 73 in a respective end flap 37, 39, 43, 45 and a second fold line 73 in a respective side panel 17, 21. The fold lines 73, 75 of the diamond corners 71 are shaped, arranged and positioned to create a corner of the carton 5 that is in a tight fit with the container C adjacent the corner. In one embodiment, the fold lines 65, 67 allow the side panels 17, 21 and ends 7, 9 of the carton 5 to angle inward toward the interior of the carton 5. The diamond corners 71 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.
In one embodiment, the top panel 25 of the blank 3 can have a width and a length less than a respective width and length of the bottom panel 15. In the illustrated embodiment, the narrower width of the top panel 25 than the bottom panel 15 causes the side panels 17, 21 to taper so that the bottom of the side panels are spaced further apart than the top of the side panels. The tapered side panels 17, 21 allow the carton 5 to contact the containers C at both the bottom and top of the containers. The shorter length of the top panel 25 as compared to the bottom panel 15 causes both ends 7, 9 of the carton 5 to be shaped to contact both the top and bottom of the containers C housed in the carton to restrain the movement of the containers in the carton. The bottom panel 15 and/or top panel 25 can be otherwise shaped, arranged, and/or configured without departing from the disclosure. For example, the bottom panel 15 and top panel 25 could have the same width, the same length, or both the same width and length without departing from the disclosure.
The blank 3 comprises features that form the reinforced handle 10 of the carton 5. In one embodiment the features include a handle flap 81 foldably connected to a respective top end flap 47, 49 at a longitudinal fold line 83. In one embodiment, the handle flap 81 is formed by a cut 85 extending from respective ends of the fold line 83. The cut 85 has a longitudinal portion 87 that is generally parallel to the fold line 83 and spaced apart therefrom, a concave portion 89 at a respective end of each longitudinal portion 87, and a convex portion 91 extending between a respective concave portion 89 and a respective end of the longitudinal fold line 89. In one embodiment, the handle flap 81 has a longitudinal fold line 93 extending across the flap and spaced apart from the longitudinal fold line 83 and a v-shaped fold line 95 extending from the longitudinal fold line 93 to the longitudinal portion 87 of the cut 85. The handle flap 81 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.
The handle features of the blank 3 further comprise a handle feature 105 in a respective end flap 43, 45 attached to a first main panel 74, 76 and the first side panel 21. The handle features of the blank 3 further comprise a handle feature 107 in a respective end flap 37, 39 attached to a second main panel 77, 79 and the second side panel 17. The handle features comprise a first reinforcement portion 109 of the end flap 43, 45 above or adjacent the handle feature 105 and a second reinforcement portion 113 of the end flap 37, 39 above or adjacent the handle feature 107. The handle features comprise a first handle reinforcement flap 115 foldably connected to a respective reinforcement portion 109 of the end flaps 43, 45 at an extension 27a of the fold line 27. The extension of the fold line 27a terminates at a v-shaped notch 117 that is between respective free edges of the first handle reinforcement flap 115 and the first reinforcement portion 109. Further, in one embodiment, the free edges of the first handle reinforcement flap 115 and the first reinforcement portion 109 extend from a respective longitudinal fold line by a distance D1. The reinforcement flaps 115 are separated from an adjacent end flap 47, 49 by a cut 119 that extends from the intersection of the lateral fold line 27 with the longitudinal fold lines 61, 63 to a respective free edge of the blank 3.
In the illustrated embodiment, the handle features of the blank further comprise a second handle reinforcement flap 121 foldably connected to a respective base portion 54, 56 of attachment end flaps 53, 55 of the attachment flap 29 at an extension 31a of the lateral fold line 31. In one embodiment, the second handle reinforcement flap 121 is sized so that a free edge of the second handle reinforcement flap 121 is spaced from the lateral fold line 61 by a distance D2. In the illustrated embodiment, the distance D2 is less than the distance D1 such that a notch 123 is created in the blank 3 that is between a respective end flap 53, 55 and a respective end flap 47, 49. The handle reinforcement flaps 121 are separated from an adjacent top end flaps 47, 49 of the blank 3 by a cut 124. In the illustrated embodiment, the top end flaps 47, 49 have notches 125 that are shaped, arranged, and positioned to accommodate the product/article protection features 111 that can be an emboss/deboss area, a bumper, any other product protection feature disclosed in the above-noted incorporated-by-reference provisional patent applications, or any other product protection feature.
As shown in
As shown in
As shown in
As described above, the handle 10 is reinforced by several layers or plies of material. For example, the handle 10 may be reinforced by a plurality of layers of paperboard directly above the handle opening at least partially formed by the cooperating notches 105 and 107, top end flap 47, reinforcement flap 121, reinforcement flap 115, reinforcement portion 109, reinforcement portion 113, attachment end flap 53, and/or handle flap 81. For example, according to one embodiment, the reinforcement flap 115, the first reinforcement portion 109, and the second reinforcement portion 113 form three plies of material located above the handle 10 to reinforce the handle 10. According to another embodiment, the attachment end flap 53, the second reinforcement portion 113, the first reinforcement portion 109, the first reinforcement flap 115, and the second reinforcement flap 121 comprise five plies of material located above the handle 10 to reinforce the handle 10.
In the embodiment of
In one embodiment, the length D1 is at least approximately 5.2 inches (131 mm) and the length D2 is approximately 4.1 inches (104 mm) or less. In the illustrated embodiment, D2 is approximately 80 percent of D1, but D2 could be more or less than listed or shown herein without departing from the disclosure. The dimensions listed herein and/or shown on the drawings are intended to be illustrative of certain embodiments or features of the disclosure and are not intended to limit the scope of the claims unless otherwise noted herein.
In the embodiment of
As shown in
The blank 203 is formed into the carton 210 as shown in
As with the previous embodiment, the end 7 can be closed by other flap positioning sequences and the handle 210 can be formed by other flap positioning sequences without departing from the disclosure. The embodiment of
The cartons 5 of any of the illustrated or non-illustrated embodiments of the disclosure could have other features (e.g., dispenser features, handle features, reinforcement features, etc.) without departing from the disclosure. Also, the cartons 5 could be otherwise shaped, arranged, or configured and the cartons could be configured to hold articles other than beverage containers C without departing from the disclosure.
In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect 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. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.
In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding there along. 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 above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.
The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the 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. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure 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 claims the benefit of U.S. Provisional Application No. 61/627,732, which was filed on Oct. 17, 2011. This application also claims the benefit of U.S. Provisional Application No. 61/630,188, which was filed on Dec. 6, 2011. U.S. Provisional Patent Application No. 61/518,504, filed May 6, 2011, U.S. Provisional Application No. 61/572,638, filed Jul. 19, 2011, U.S. Provisional Patent Application No. 61/627,249, filed Oct. 7, 2011, U.S. Provisional Patent Application No. 61/627,732, filed Oct. 17, 2011, U.S. Provisional Application No. 61/630,188, filed Dec. 6, 2011, and U.S. Non-Provisional application Ser. No. 13/419,740, filed Mar. 14, 2012 are hereby incorporated by reference for all purposes as if presented herein in their entirety.
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