Patent Application
20060278689
This invention relates generally to a carton having a reinforced integrated handle opening in an end wall, and particularly, to a carton formed from a single blank.
Carton manufacturers often face the challenge of providing a carton having ergonomic handle openings that are sufficiently strong to withstand the stress generated by the weight of articles enclosed. This is particularly so when the handle is integral to the end wall of the carton and when the burst strength of the material comprising the end wall is insufficient to avoid failure of the handle and the end wall itself. One approach to resolving this quandary is to construct the carton from a stronger material such as corrugated board or from a sheet of material of a relatively higher caliper. As fully enclosed cartons typically have six walls (top, sides, bottom, and ends) that are formed from a single sheet of material, and cost tends to increase according to the strength and thickness of material used to construct the carton walls, this approach is an expensive one because it effectively amounts to reinforcing all because it effectively amounts to reinforcing all of the walls of the carton irrespective of the relative magnitude of the forces borne by each wall.
According to another approach, additional material is applied to or around the handle as needed to its integrity as well as that of the end wall. For instance, a handle aperture in a carton end wall may be reinforced by outlining its edges with an additional layer of sheet material. However, it is often preferable to form a carton from a single sheet of material rather than to attach additional components to a carton or carton blank.
What is needed is a carton that is formed from a single blank, and which provides a reinforced integrated handle opening disposed in an end wall, where the carton walls are efficiently constructed without wasting expensive material in carton walls that are less likely to fail.
The various embodiments of the present invention overcome the shortcomings of the prior art by providing a sleeve type carton formed from a single sheet of paperboard or other foldable sheet material, the carton having a handle opening disposed in an end wall, wherein at least the weight bearing portion of the periphery of the handle opening is reinforced by three layers of sheet material.
More specifically, the various embodiments of the exemplary carton include a top panel, a first side panel hingedly connected to the top panel, a bottom panel hingedly connected to the first side panel, a second side panel hingedly connected to the bottom panel, and at least one end closure. The end closure is formed from a top end flap hingedly connected to the top panel, the top end flap including a handle opening disposed therethrough. The end closure also includes side end flaps hingedly connected to the first and second side panels respectively, each side end flap including a cutout disposed at an outer edge or as an endless edged aperture, the cutout having dimensions complementary to the dimensions of at least part of the handle opening. Each side end flap also includes a reinforcing panel having a reinforcing edge, the reinforcing panel being foldable to place its reinforcing edge in reinforcing proximity to the respective cutout. The top end flap is foldable to at least partially overlie the first and second side end flaps so that the handle opening in the top end flap is in registry with the cutouts in the first and second side end flaps.
In one embodiment, each side end flap includes a notched cutout disposed at an outer edge, the notched cutout having dimensions complementary to the dimensions of at least part of the handle opening. An overlay panel hingedly connected along a transverse edge of each side end flap includes a complementary notched cutout. The overlay panel is foldable along the transverse edge into a face contacting arrangement with the side end flap, such that the cutout in the overlay panel is in registry with the cutout in the side end flap. Each side end flap also includes a reinforcing panel having a reinforcing edge, the reinforcing panel being foldable to place its reinforcing edge in reinforcing proximity to the cutouts in the respective side end flaps and overlay panels, thereby creating a notched cutout that is three plies thick along the hand-engaging portion. The side end flaps at an end of the erected carton are folded inwardly such that the outer edges abut one another and the respective three-ply notched cutouts align to approximate the shape of the handle opening. The top end flap is foldable to at least partially overlie the first and second side end flaps and overlay panels so that the handle opening in the top end flap is in registry with the three-ply notched cutouts in the first and second side end flaps, creating a handle section that is four plies thick along its hand engaging portion.
In an alternative embodiment, each overlay panel is hingedly connected to the respective side end flap along the outer longitudinal edge of the side end flap and includes a cutout that is a mirror image of the cutout in the side end flap. Together, the cutouts in the overlay panel and the adjacent side end flap form an endless edged aperture that is bisected by the outer edge of the side end flap, which is defined by a fold line.
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.
As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples to illustrate aspects of the invention that may be embodied in various and alternative forms. 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 materials or methods have not been described in detail to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but as a basis for the claims and for teaching one skilled in the art to variously employ the present invention.
Referring now to the drawings in which like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton having reinforced end handles. The exemplary embodiments of the carton of the present invention are for enclosing, carrying, and dispensing articles such as beverage cans or bottles, although the cartons of the present invention may be utilized to package any suitable article. Generally described, the exemplary cartons are formed from a foldable sheet material such as paperboard, corrugated board, plastic, or the like.
Referring now to
Each of the panels 102, 104, 106, 108 is also hingedly attached at each end edge thereof to end flaps for forming end closures at each end of the erected carton 200, as will be described in greater detail below. Top panel 102 is hingedly connected to top end flaps 120a, 120b at end edges defined by fold lines 122a, 122b. First side panel 104 is hingedly connected to first side end flaps 124a, 124b along end edges defined by fold lines 126a, 126b. Bottom panel 106 is hingedly connected to bottom end flaps 128a, 128b along end edges defined by fold lines 130a, 130b. Second side end panel 108 is hingedly connected to second side end flaps 132a, 132b along end edges defined by fold lines 134a, 134b.
To provide the reinforced end handles H (best shown in
Each of the handle openings 136a, 136b, 144a, 144b, 152a, 152b is an aperture defined by an endless edge (138a, 138b, 150a, 150b, 154a, 154b, respectively) that defines an ergonomic shape suitable for receiving the fingers of a user's hand so that the carton 200 can be lifted and carried easily. In the embodiment shown, the shape chosen includes an upper arch that conforms to the fingers of a hand. As depicted, the upper arch is defined by fold lines 142a, 142b, 148a, 148b, 158a, 158b, which enable cushioning flaps 140a, 140b, 146a, 146b, 156a, 156b to fold inward to cushion the fingers of the user's hand. Each handle opening 136a, 136b, 144a, 144b, 152a, 152b is elongated so as to have an axis of elongation A, A′, A″. The axes of elongation A of the handle openings 136a, 136b in the top end flaps 120a, 120b are substantially parallel to the end edges of the top panel 102 as defined by fold lines 122a, 122b, although it is contemplated that axes A may be disposed at an angle with respect to fold lines 122a, 122b. The axes of elongation A′ of the handle openings 144a, 144b in the first side end flaps 124a, 124b are substantially perpendicular to the axes of elongation A, and thus in the exemplary embodiment, are also perpendicular to the end edges of the first side panel 104 as defined by fold lines 126a, 126b. The axes of elongation A″ of the handle openings 152a, 152b in the second side end flaps 132a, 132b are also substantially perpendicular to the axes of elongation A, and thus in the exemplary embodiment, are similarly perpendicular to the end edges of the second side panel 108 as defined by fold lines 134a, 134b.
Each set of handle openings 136, 144, 152 also has a lateral axis B, B′, B″ that is perpendicular to axis of elongation A, A′, A″, the handle openings being symmetrical about the lateral axes.
As mentioned above, the handle openings 136a, 144a, 152a have complementary shapes, dimensions, and positions so as to be placed in registry with one another when the end flaps 120a, 124a, 132a are folded to overlie, overlap, or abut one another to form a first end closure 210 (shown in
The dimensions and shapes of the end flaps 120a, 124a, 132a also correlate to be foldable to provide a composite end closure 210 with a reinforced end handle H. The width X of first side end flaps 124a, 124b and second side end flaps 132a, 132b, as defined by the distance from fold lines 126a, 126b, 134a, 134b to the outer edges of the respective end flap is no greater than the lesser of either the length Y of the end edges of top panel 102, as defined by fold lines 122a, 122b or the length Z of the end edges of the bottom panel 106, as defined by fold lines 130a, 130b. The end edges of the bottom panel 106 may be substantially equal in length to the end edges of the top panel 102, thereby creating a carton with a substantially rectangular tubular cross section. Alternatively, the end edges of top panel 102 may differ in length from the end edges of bottom panel 106, thereby creating an carton with a substantially trapezoidal cross section or a gabled tubular cross section (not shown) having shoulders, as is known in the art. The trapezoidal or gabled cross section with a relatively larger base is particularly useful to enclose tapered articles such as beer bottles.
The exemplary carton 200 may be erected around an article or group of articles, or may be at least partially erected and then loaded and sealed. To facilitate an understanding of the configuration of the carton 200, one of potentially many contemplated techniques for erecting the carton 200 will now be described as a series of steps that may be performed substantially simultaneously or in any practical order, with some or all of the steps being performed either manually or automatically, such as by a packaging machine.
The exemplary process of erecting the carton is performed in two stages. The first stage is performed typically as part of the process of manufacturing the carton 200. In the first stage, a blank is cut, folded and then secured into a flattened tubular condition so that it can be shipped to a packing facility as a sleeve. The following are the details: In plant equipment (IPE) at the manufacturing site cuts the blank 100 from a single sheet of foldable sheet material as described above, and cut, scores, imprints or otherwise defines fold lines, severance lines, and cutout sections. For instance, the edges 138a, 138b, 150a, 150b, 154a, 154b of handle openings 136a, 136b, 144a, 144b, 152a, 152b may be defined by weakened severance lines enabling the center sections to be punched out, or the 138a, 138b, 150a, 150b, 154a, 154b may be defined by cut lines with the center sections being removed and discarded before the carton 200 is erected.
After the blank 100 is cut out in the form shown in
At this point, the blank 100 is configured as shown in
The second stage of erecting the carton 200 may be performed at a bottling or packaging facility. The flattened blanks 100 are loaded into a packaging machine, which in known fashion, disposes top panel 102 opposite bottom panel 106 and disposes first side panel 104 opposite second side panel 108 so that the carton 200 is configured as a tubular sleeve having a substantially rectangular as shown in
Articles are loaded into the carton 200 through one or both of the now open ends, and then the ends are sealed. The ends of the carton 200 are substantially identical, with similar parts being identified using the same element number modified by the suffix “a” or “b”, where element numbers ending in “a” are associated with end closure 210, and elements identified with “b” are associated with end closure 212. Accordingly, formation of only one of the end closures 210, 212 will be described in detail below.
As can be seen in
Once the carton 200 is fully erected as shown in
Those skilled in the art will readily appreciate that reinforcement is most needed along the weight-bearing portion of a handle opening in a carton. A second embodiment, carton 700 will now be described to exemplify the principles and teachings of the present invention. Carton 700 is formed from blank 600 (
Generally, carton 700 differs from carton 200 principally by the substitution of cutouts 652a, 652b, 644a, 644b for handle openings in the side end flaps 632a, 632b, 624a, 624b, and by the alternative configuration of reinforcing panels 660a, 660b, 664a, 664b, which are partially detached along respective severance lines 663a, 663b, 666a, 666b, folded along respective fold lines 662a, 662b, 667a, 667b (which lie along the upper edges of the respective side end flap) and secured in a face contacting arrangement with the underlying portion of respective side end panels 632a, 632b, 624a, 624b. A portion of the edge of each of the reinforcing panels 660a, 660b, 664a, 664b is thereby placed in reinforcing proximity to the weight-bearing portion of cutout 652a, 652b, 644a, 644b. In the embodiment shown, and with reference to
The elements of blank 600 and carton 700 are otherwise substantially identical to the corresponding elements of blank 100 and carton 200. For instance, bottom panel 206 is substantially identical to bottom panel 606, and top wall 202 is substantially identical to top wall 702.
Referring now to
Each of the panels 802, 804, 806, 808 is also hingedly attached at each end edge thereof to end flaps for forming end closures at each longitudinal end of the erected carton 1100, as will be described in greater detail below. Bottom panel 802 is hingedly connected to bottom end flaps 820a, 820b at end edges defined by fold lines 822a, 822b. First side panel 804 is hingedly connected to first side end flaps 824a, 824b along end edges defined by fold lines 826a, 826b. Top panel 806 is hingedly connected to bottom end flaps 828a, 828b along end edges defined by fold lines 830a, 830b. Second side end panel 808 is hingedly connected to second side end flaps 832a, 832b along end edges defined by fold lines 834a, 834b.
Each of the side end flaps 824a, 824b, 832a, 832b is hingedly connected at a transverse edge to an overlay panel and a reinforcing panel for forming the reinforced end handles, as will be described in greater detail below. First overlay panels 83a, 836b are hingedly connected to the lower edges of first side end flaps 824a, 824b along fold lines 838a838b, respectively. The first overlay panels 83a, 836b are formed at least in part from the first side end flaps 824a, 824b. The first overlay panels 83a, 836b are separated or separable from the first side end flaps 824a, 824b by severance lines 840a, 840b, respectively, and separated or separable from the bottom end flaps 820a, 820b by severance lines 842a, 842b, respectively. The blank 800 may include apertures 844a, 844b to facilitate folding the overlay panels 836a, 836b and reduce the amount of material used. Similarly, second overlay panels 846a, 846b are hingedly connected to the lower edges of the second side end flaps 832a, 832b along fold lines 848a848b, respectively. The second overlay panels 846a, 846b are formed at least in part from the second side end flaps 832a, 832b. The second overlay panels 846a, 846b are separated or separable from the second side end flaps 832a, 832b by severance lines 850a, 850b, respectively.
First reinforcing panels 852a, 852b are hingedly connected to the upper edges of first side end flaps 824a, 824b along fold lines 854a, 854b, respectively. The first reinforcing panels 852a, 852b are formed at least in part from the first side end flaps 824a, 824b respectively. The first reinforcing panels 852a, 852b are separated or separable from top end flaps 828a828b by severance lines 856a, 856b, respectively, and separated or separable from first side end flaps 824a, 824b by severance lines 858a858b, respectively. Similarly, second reinforcing panels 860a, 860b are hingedly connected to the upper edges of second side end flaps 832a, 832b along fold lines 862a, 862b, respectively. The second reinforcing panels 860a, 860b are formed at least in part from the second side end flaps 832a, 832b. The second reinforcing panels 860a, 860b are separated or separable from top end flaps 828a828b by severance lines 864a, 864b, respectively, and separated or separable from second side end flaps 832a, 832b by severance lines 866a, 866b, respectively. The blank 800 may include apertures 868a868b to facilitate folding the reinforcing panels 852a, 852b and may include apertures 870a, 870b to facilitate folding the reinforcing panels 860a, 860b, respectively. In alternative embodiments, overlay panels and reinforcing panels may be separate pieces of sheet material that are applied as laminates to the side end flaps.
To provide the reinforced end handles (not shown) on each end of the carton 1100, handle openings and notched cutouts having complementary dimensions and positions are provided in at least some of the end flaps and overlay panels. More specifically: top end flaps 828a828b include handle openings 872a, 872b; first side end flaps 824a, 824b include notched cutouts 874a, 874b; first overlay panels 836a, 836b include notched cutouts 876a, 876b; second side end flaps 832a, 832b include notched cutouts 878a878b; and second overlay panels 846a, 846b include notched cutouts 880a, 880b, respectively.
As mentioned above, the handle opening 872a and notched cutouts, 874a, 87a, 878a880a have complementary shapes, dimensions, and positions so as to be placed in registry with one another when the overlay panels 83a, 846a and the end flaps 824a, 828a832a are folded to overlie, overlap, or abut one another to form a first end closure 1110 (not shown). Similarly, the handle opening 872b and notched cutouts, 874b, 876b, 878b, 880b are complimentarily shaped, dimensioned, and positioned so as to be placed in registry with one another when the overlay panels 836b, 846b and the end flaps 824b, 828b, 832b are folded to overlie, overlap, or abut one another to form a second end closure 1112 (obstructed in
The exemplary carton 1100 may be erected around an article or group of articles, or may be at least partially erected and then loaded and sealed. To facilitate an understanding of the configuration of the carton 1100, one of potentially many contemplated techniques for erecting the carton 1100 will now be described as a series of steps that may be performed substantially simultaneously or in any practical order, with some or all of the steps being performed either manually or automatically, such as by a packaging machine.
The exemplary process of erecting the carton is performed in two stages. The first stage is performed typically as part of the process of manufacturing the carton 1100. In the first stage, a blank is cut, folded and then secured into a flattened tubular condition so that it can be shipped to a packing facility as a sleeve. The following are the details: In plant equipment (IPE) at the manufacturing site cuts the blank 800 from a single sheet of foldable sheet material as described above, and cut, scores, imprints or otherwise defines fold lines, severance lines, and cutout sections. For instance, the edges 873a, 873b, 875a, 875b, 877a, 877b, 879a, 879b, 881a, 881b of handle openings 872a, 872b and notched cutouts 874a, 874b, 876a, 876b, 878a878b, 880a, 880b may be defined by frangible lines or perforations enabling the center sections to be punched out, or may be defined by cut lines with the center sections being removed and discarded before the carton 1100 is erected.
After the blank 800 is cut out in the form shown in
Then, or about the same time: first reinforcing panel 852a is folded about fold line 854a so that its inside surface is in face contacting arrangement with the underlying portion of the outside surface of first overlay panel 836a and the underlying portion of the inside surface of first side end flap 824a; first reinforcing panel 852b is folded about fold line 854b so that its inside surface is in face contacting arrangement with the underlying portion of the outside surface of first overlay panel 836b and the underlying portion of the inside surface of first side end flap 824b; second reinforcing panel 860a is folded about fold line 862a so that its inside surface is in face contacting arrangement with the underlying portion of the outside surface of second overlay panel 846a and the underlying portion the inside surface of the second side end flap 832a; second reinforcing panel 860b is folded about fold line 862b so that its inside surface is in face contacting arrangement with the underlying portion of the outside surface of second overlay panel 846b and the underlying portion of the inside surface of second side end flap 832b. By this means, the reinforcing panels 852a, 852b, 860a, 860b are secured to the underlying portions of the outside surfaces of overlay panels 836a, 836b, 846a, 846b and to the underlying portions of the inside surfaces of the inside surfaces of side end flaps 824a, 824b, 832a, 832b, respectively.
At this point, the blank 800 is configured as shown in
The first phase of the process is completed by applying adhesive or other securing means to the outside surface of edge flap 816, folding edge flap 816 so that its inside surface is in face contacting arrangement with the inside surface of bottom panel 802, and folding the entire blank 800 along fold line 812 so that the inside surface of top panel 802 is in face contacting arrangement with the inside surface of second side panel 808 and the outside surface of edge flap 816 is secured to the inside surface of second side panel 808.
The second stage of erecting the carton 1100 may be performed at a bottling or packaging facility. The flattened blanks 800 are loaded into a packaging machine, which in known fashion, disposes top panel 806 opposite bottom panel 802 and disposes first side panel 804 opposite second side panel 808 so that the carton 1100 is configured as a tubular sleeve having a substantially rectangular as shown in
Articles are loaded into the carton 1100 through one or both of the now open ends, and then the ends are sealed. The ends of the carton 1100 are substantially identical, with similar parts being identified using the same element number modified by the suffix “a” or “b”, where element numbers ending in “a” are associated with end closure 1110 (not shown) and elements identified with “b” are associated with end closure 1112. Accordingly, formation of only one of the end closures 1110, 1112 will be described in detail below.
As can be seen in
Once the carton 1100 is fully erected, each end closure 1110, 1112 includes a handle, the edges of which being triply reinforced. In other words, a portion of the periphery of the handle as defined by handle opening 872a is substantially aligned with and reinforced by the three-ply cutouts C to make the upper edge of the handle four plies thick. Those skilled in the art will readily appreciate that reinforcement is most needed along the weight-bearing or hand-engaging portion of a handle opening in a carton.
A fourth embodiment will now be described to exemplify the principles and teachings of the present invention. A carton (not shown) is formed from a blank 1200 (as shown in
The elements of blank 1200 and the carton (not shown) are otherwise substantially similar to the corresponding elements of blank 800 and carton 1100. For instance, the bottom panel 802 is substantially identical to bottom panel 1202. Further, the blank 1200 is erected to form the carton by substantially the same process as described above where blank 800 is erected to form the carton 1100.
The present invention has been illustrated in relation to a particular embodiment which is intended in all respects to be illustrative rather than restrictive. 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. Furthermore, the various embodiments demonstrate that the top, sides, and bottom panels may be hingedly connected to one another and secured into a tubular sleeve in any order that provides a top panel opposing a bottom panel and opposing side panels. 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 exemplary cartons preferably have handles at both ends, although it is contemplated to include only one handle disposed in one of the end closures.
Those skilled in the art will also appreciate that any suitable means for securing sheet material may be used, including magnets, non-permanent adhesives, or hook and loop fasteners such as VELCRO®, which is a trademark registered to Velcro Industries B.V. Additionally, although the handle openings of the invention are described as having removable centers, the centers may be only partially removable and may function as finger cushions after being partially detached from the edges of the handle openings.
It must be emphasized that the law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. Accordingly, all such modifications, combinations, and variations are included herein by the scope of this disclosure and the following claims.
This application claims the benefit of the filing of Provisional Patent Application Ser. No. 60/690,412, entitled “Carton with Reinforced End Handles” and filed on Jun. 13, 2005, and of the filing of Provisional Patent Application Ser. No. 60/715,792, entitled “Carton with Reinforced End Handles” and filed on Sep. 9, 2005, the entirety of each being incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60690412 | Jun 2005 | US | |
| 60715792 | Sep 2005 | US |
