REINFORCED HANDLE STRUCTURE AND CARTON

Abstract

A carton (90) has a two part handle structure (H). The two part handle structure includes: a first integrally formed part including two arcuate slots (40, 42) spaced by a gripping portion (50); and a second reinforcing part including a reinforcing member (60) attached to at least the gripping portion of the first integrally formed part of the handle. The reinforcing member is pre-cut such that the profile of the reinforcing member includes at least one curved section that is not aligned with a perimeter of at least one of said two arcuate slots. The reinforcing member is formed from material that is separate from the material from which the first integrally formed part of the handle is formed.

Description

TECHNICAL FIELD

The present invention relates to a reinforced handle structure for a carton, to a kit of parts for forming a carton including a blank and a handle reinforcing member, and to a carton comprising the reinforced handle structure. More specifically, but not exclusively, the present invention relates to a composite reinforced handle structure comprising a race track style handle integrally formed within a panel of the carton that is reinforced by a reinforcing member attached to at least a gripping portion of the race track style handle, wherein the reinforcing member is formed from material that is separate from material from which the race track handle is formed.

BACKGROUND

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers. These packages are often referred to as multi-packs, which are desirable for shipping and distribution purposes and for the display of promotional information. For cost and environmental considerations, such multi-packs need to be formed from as little material as possible and cause as little wastage as possible in the materials from which they are formed. Another consideration is the strength of the packaging and its suitability for holding and transporting large weights of articles. A further consideration is the provision of a handle structure that enables a consumer to comfortably lift the multi-pack when purchasing and transporting home.

The present invention seeks to overcome or at least mitigate the problems of the prior art.

SUMMARY

According to a first aspect of the present invention there is provided a carton comprising a two part handle structure. The two part handle structure comprises a first integrally formed part that comprises two arcuate slots spaced by a gripping portion and a second reinforcing part that comprises a reinforcing member. The reinforcing member is attached to at least the gripping portion of the first integrally formed part of the handle. The reinforcing member has a profile (shaped perimeter) that includes at least one curved section that is not aligned with a perimeter of one of the two arcuate slots and the reinforcing member is formed from material that is separate from the material from which the first integrally formed part of the handle is formed.

Optionally, the reinforcing member is formed from material that is different to the material from which the first integrally formed part of the handle is formed.

Optionally, the reinforcing member is formed from a material having a higher tensile strength compared to the material from which the first integrally formed part of the handle is formed.

Optionally, the reinforcing member is formed from a material having a higher shear resistance compared to the material from which the first integrally formed part of the handle is formed.

Optionally, the reinforcing member is formed from BOPP and the carton and first integrally formed part of the handle is formed from paperboard.

Optionally, the reinforcing member is formed from PET and the carton and first integrally formed part of the handle is formed from paperboard.

Optionally, said part of one of said two arcuate slots comprises a curved edge and a stress point is associated with said curved edge, and wherein the at least one curved section of the reinforcing member is spaced laterally and/or longitudinally from said curved edge.

Optionally, the at least one curved section of the reinforcing member is spaced longitudinally from said curved edge by a distance (X) of between about 1 cm and about 1.4 cm.

Optionally, said part of one of said two arcuate slots comprises a curved edge and a stress point is associated with said curved edge, and wherein the at least one curved section of the reinforcing member has a radius of curvature that is greater than the radius of curvature of said curved edge.

According to another aspect of the invention, there is provided a reinforcing part for use in forming a two part handle structure in a carton, wherein the reinforcing part comprises a reinforcing member having a pressure sensitive adhesive applied thereto and a removable backing sheet covering said pressure sensitive adhesive.

Optionally, the reinforcing member is formed from PET or BOPP.

According to a further aspect of the present invention there is provided a blank for forming a carton comprising a two part handle structure, the blank comprising a top panel and a series of other panels for forming the walls of the carton, the top panel comprising a first integrally formed part of the handle structure that comprises two arcuate slots spaced by a gripping portion and having affixed thereto a second reinforcing part that comprises a reinforcing member attached to at least the gripping portion of the first integrally formed part of the handle. The reinforcing member is pre-cut such that the profile of the reinforcing member includes at least one curved section that is not aligned with a perimeter of at least one of the arcuate slots. The reinforcing member is formed from material that is separate from the material from which the first integrally formed part of the handle is formed.

According to yet a further aspect of the present invention there is provided a carton comprising a two part handle structure, the two part handle structure comprising: a first integrally formed part comprising two arcuate slots spaced by a gripping portion; and a second reinforcing part comprising a reinforcing member attached to at least the gripping portion of the first integrally formed part of the handle. The reinforcing member has a profile that includes at least one curved section having a stress point associated therewith that is laterally and/or longitudinally spaced from a stress point associated with a curved edge of at least one of said two arcuate slots.

Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a plan view from above of a reinforcing member according to an embodiment of the invention and of a blank for forming a carton having a reinforced handle structure comprising an integral race track style handle and the reinforcing member;

FIG. 2 is a perspective view from above of a carton formed from the blank and reinforcing member of FIG. 1;

FIG. 3 is a plan view from above of part of the blank and reinforcing member of FIG. 1 in enlarged view;

FIG. 4 is a plan view from above of part of the blank and reinforcing member of FIG. 1 in enlarged view;

FIG. 5 is a plan view from above of a composite handle structure according to another embodiment of the disclosure; and

FIG. 6 is a plan view from above of a composite handle structure according to a further embodiment of the disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Detailed descriptions of specific embodiments of the package, blanks and cartons are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the packages, blanks and cartons described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any 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 invention.

Referring to FIGS. 1 and 2 there is shown a blank 10 for forming a carton 90 capable of accepting an input of primary products such as, but not limited to, bottles or cans, hereinafter referred to as articles A.

The blank 10 comprises a plurality of main panels 12, 14, 16, 18, 20, hinged one to the next in a linear series. A base panel 12 is hinged to a first side wall panel 14 by a hinged connection such as a fold line 13. A first side wall panel 14 is hinged to a top panel 16 by a hinged connection such as a fold line 15. A top panel 16 is hinged to second side wall panel 18 by a hinged connection such as a fold line 17. A second side wall panel 18 is hinged to a glue panel 20 by a hinged connection such as a fold line 19.

The plurality of main panels 12, 14, 16, 18, 20 of the blank 10 form walls of an open ended tubular structure in a set-up condition. The tubular structure is at least partially closed by end closure structures. The tubular structure has a tubular axis defining a longitudinal direction.

Each of the ends of the tubular structure is at least partially closed by end closure panels which form end walls of the tubular structure. In the illustrated embodiment the ends of the tubular structure are fully closed by end closure panels 22a, 24a, 26a, 28a, 22b, 24b 26b, 28b.

End closure panels 22a, 24a, 26a, 28a are configured to close a first end of the tubular structure and end closure panels 22b, 24b, 26b, 28b are configured to close a second end of the tubular structure.

The first end of the tubular structure is closed by a first end closure panel 22a, a second end closure panel 24a, a third end closure panel 26a and a fourth end closure panel 28a. The first end closure panel 22a is hinged to a first end of the base panel 12 by a hinged connection such as a fold line 23a. The second end closure panel 24a is hinged to a first end of the first side wall panel 14 by a hinged connection such as a fold line 25a. The third end closure panel 26a is hinged to a first end of the top panel 16 by a hinged connection such as a fold line 27a. The fourth end closure panel 28a is hinged to a first end of the second side wall panel 18 by a hinged connection such as a fold line 29a.

The second end of the tubular structure is closed by a fifth end closure panel 22b, a sixth end closure panel 24b, seventh end closure panel 26b and an eighth end closure panel 28b. The fifth end closure panel 22b is hinged to a second end of the base panel 12 by a hinged connection such as a fold line 23b. The sixth end closure panel 24b is hinged to a second end of the first side wall panel 14 by a hinged connection such as a fold line 25b. The seventh end closure panel 26b is contiguously formed with the second end of the top panel 16. The eighth end closure panel 28b is hinged to a second end of the second side wall panel 18 by a hinged connection such as a fold line 29b.

The first end closure panel 22a and the fifth end closure panel 22b each form a minor lower end closure panel at opposing ends of the tubular structure. The third end closure panel 26a forms a minor upper end closure panel and the seventh end closure panel 26b is formed around an article A at an opposing end of the tubular structure, to close that end.

The second end closure panel 24a and the fourth end closure panel 28a each form a major side end closure panel at the first end of the tubular structure. The sixth end closure panel 24b and the eighth end closure panel 28b each form a major side end closure panel at the second end of the tubular structure.

The blank 10 comprises a dispenser D for facilitating access to the contents of the carton 90. The dispenser D comprises a removable corner portion of the carton 90. The dispenser D comprises a plurality of severance lines 60, 70, 74, 76, 78, 80 and 82.

A carton 90 (see FIG. 2) formed from the blank 10 comprises a composite reinforced handle structure H, that comprises a race track style handle integrally formed within the top panel 16 of the blank 10 and a separate reinforcing member 60 that is attached to at least a gripping portion 50 of the race track style handle. Optionally, the top panel 16 comprises a first part of the composite carrying handle H. The first part may be referred to as a race track style carrying handle. The race track style carrying handle in the top panel 16 comprises a pair of arcuate apertures 40, 42 (also referred to herein as “slots” or “arcuate slots”) which are defined by severance lines 45, 47 and which are separated by a gripping portion 50. Optional cushioning tabs 44, 46 are hinged to the gripping portion 50 by a first fold line 49 and a second fold line 51 respectively.

The term “arcuate slot” as used herein refers to all manner of openings, apertures and holes that are defined by a perimeter that has two curved end edges. Such an arcuate slot may be a substantially oval opening which has two curved end edges and two straight side edges, or which has two curved end edges and at least one curved side edge. When the at least one curved side edge curves to define a portion projecting inward of the arcuate slot, the arcuate slot may take a “sausage shape” or a “banana shape”. In some arrangements, an arcuate slot may include two curved side edges which are significantly longer than its curved end edges. In some arrangements, in blank form, the curved side edges are curved in similar directions or opposite directions. In some arrangements, as shown in FIG. 1, the curved side edges may be curved in similar directions but once the handle is deployed and the cushioning tabs 44, 46 are folded out of the plane of the top panel 16, one of the side edges of each arcuate slot is defined by the respective curved fold line 49 or 51 and thus the side edges of each arcuate slot are curved in opposing directions. The radius of curvature of the side edges of each arcuate slot may be similar or different. Optionally, the radius of curvature of the two end edges may be substantially the same. In the embodiment of FIG. 1, once the handle has been deployed and the cushioning tabs 44, 46 are folded out of the plane of the top panel 16, the two end edges of each arcuate slot are contiguous with each longer side edge in order to form an endless edge or perimeter (including part of fold lines 49, 51) that defines that arcuate slot. In some arrangements, one or more cover panels may be disposed over at least a portion of each arcuate slot and in such arrangements, at least a portion of the perimeter defining that arcuate slot may be provided by a frangible line.

The reinforcing member 60 is formed from material that is separate from material from which the race track handle is formed. The reinforcing member 60 is formed from material that is different from material from which the race track handle is formed. In the present embodiment, the blank 10, including top panel 16 and race track style handle, is formed from paperboard. The reinforcing member 60 is formed from a different material which may have different shear and/or tensile strengths compared to the material from which the panel 16 from which the race track style handle is formed.

For example in the present arrangement the reinforcing member 60 is formed from a material having a high tensile strength, such as, but not limited to biaxially oriented polypropylene (BOPP) and in other embodiments, the reinforcing member 60 is formed from a shear-resistant material, such as but not limited to polyethylene terephthalate (PET). Additionally, the reinforcing member 60 is shaped relative to the apertures 40, 42 and gripping portion 50 to further supplement and complement the strength characteristics of the race track style handle in order that the reinforcing member 60 provides a reinforcement to the race track style handle and provides a composite handle structure H having an increased carrying strength compared to the race track style handle alone. For example, and as shown in FIGS. 1 and 3, the reinforcing member 60 is formed from BOPP, a non-shear resistant material having a higher tensile strength than PET or paperboard. The reinforcing member 60 is of a “dog-bone” shape, having an elongate central portion with curved sides and opposing, generally “T”-shaped end portions.

A pressure activated adhesive is applied to a back-side of the reinforcing member 60, which initially also comprises a backing panel (not shown in Figures). In FIG. 1, the backing panel has been removed and the reinforcing member 60 has been affixed to an inside surface of the top panel 16 using the pressure activated adhesive. The reinforcing member 60 is affixed to the top panel 16 such that the opposed curved sides of the reinforcing member 60 are disposed next to the first and second fold lines 49, 51 which define the edge of the gripping portion 50 of the race-track style carrying handle.

In the absence of a reinforcing member 60, the race track style handle, when tested with a sufficient weight to cause failure, typically fails in a “shear”-failure as indicated by arrows F in FIG. 4. The provision of a BOPP reinforcing member 60 profiled as shown in FIG. 1 (and partially shown in FIGS. 3 and 4) provides an adequate reinforcement of the race track style handle and provides an overall stronger handle structure H, even if the paperboard race track style handle undergoes a shear failure. This is because the reinforcing member 60 is shaped relative to the gripping portion and direction of the shear failure of the paperboard race track style handle, such that the tensile strength of the BOPP reinforcing member 60 reinforces the gripping portion 50 and/or aperture edges 47/49, 45/50 and thus mitigates against failure of the handle structure “H” at loads that would otherwise cause failure of a similar handle structure not benefiting from the reinforcing member 60.

The size, shape and position of a reinforcing member 60 formed from a relatively high-tensile or shear resistant material strength may depend upon a number of factors including, but not limited to: the radius of curvature of the apertures 40, 42; the maximum linear length of the apertures 40, 42; the minimum distance between the apertures 40, 42 (across the gripping portion 50); the caliper (thickness and weight) and/or quality of the paperboard (or other paper-based material) from which the racetrack style handle and blank 10 is formed; the size of the blank 10; the tensile strength and/or shear resistance of the material from which the reinforcing member 60 is formed; and the weight and/or thickness of the material from which the reinforcing member 60 is formed.

In the example illustrated in FIG. 1, the blank 10 is formed of paperboard, more specifically an unbleached kraft paperboard with a smooth, glossy surface on its coated side and having a caliper of 0.018 inches (i.e. a thickness of about 457 microns). The blank 10 is sized and arranged to form a carton 90 (see FIG. 2) that can accommodate twelve 12 oz aluminium beverage cans, arranged in two rows of six cans each. As such the bottom, first and second side panels 12, 14, 18 have a length of about 39.5 cm (about 15 9/16″) and a width of between about 12.3 cm (4 27/32″) and about 15.2 cm (5 3/32″). The grain of the paperboard runs in a horizontal direction i.e. parallel to an axis running between fold lines 19 and 13 of the flat form blank 10 (see FIG. 1).

In order to ensure that the reinforcing member 60, when formed of BOPP is of a size, shape and position to provide adequate reinforcement to the racetrack style handle shown in the first example illustrated in FIG. 1, it is preferred, but nevertheless optional if certain dimensional relationships apply. With reference to FIGS. 3 and 4, four dimensions, “X”, “Y”, “Z” and “R” are illustrated. These distances may be defined as follows:

“Y”: the distance between a point on an inner edge 57 of the reinforcing member P4 and a notional line contiguous with an end portion of the “dog-bone” shaped reinforcing member 60 (see FIG. 3). Wherein, P4 may be defined as the intersection of a line 77 tangential to the perimeter of the aperture 42, at the point on the aperture 42 that is closest to the reinforcing member 60, with the edge of the reinforcing member 60;

“Z”: is the length of the end portion of the “dog-bone” shape (see FIG. 3);

“X”: is the distance between a first line 73 and the perimeter or edge 59 of the “dog-bone”-shaped reinforcing member 60. Wherein the first line 73 is tangential to the intersection P3 of an edge of the aperture (slot) 40 and a notional line 75 along the maximum length of that aperture 40 and wherein the distance (X) is measured along a notional line that is perpendicular to the first line 73 and which passes through said intersection P3; and

“R”: is a radius of curvature of the curved segment of the inner edge 57 of the “dog-bone” shaped reinforcing member 60 generally between points P1 and P2 (see FIG. 4).

In various embodiments and in the case of the blank 10 of FIG. 1, the dimensions “X”, “Y”, “Z” and “R” have values falling within the following ranges:

Dimension	Minimum Value	Maximum Value
X	about 1.1 cm	about 1.35 cm
	(about 0.46875″)	(about 0.53125″)
Y	about 1.59 cm	Up to an intersection with an adjacent first
	(about 0.625″)	or second side panel 14, 18 i.e. up to fold
		line 15 or 17.
Z	about 2.1 cm	Up to an end of the top panel 16, as
	(about 0.8281″)	defined by fold line 27a or proximate to
		the dispenser D.
R	about 1.2 cm	about 1.9 cm
	(about 0.5″)	(about 0.75″)

The carton 90 can be formed by a series of sequential folding operations in a straight line machine so that the carton 90 may not be required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements. During loading and assembly of the carton 90, the carton 90 may be orientated such that one of the first and second side panels 14, 18 forms a loading surface. The bases of one or more articles may be in sliding contact with the loading surface when being inserted into the carton 90. The articles may be substantially cylindrical in shape and have a cylindrical axis. The cylindrical axis is orientated perpendicularly to the first side panel 14 and may also be orientated substantially vertically.

The main panel 16 forms the top panel (top wall) 16 when the handle structure H is in use as a carrying handle by a user and this top wall 16 is optionally, disposed adjacent to the sides of the articles. In this orientation the top wall 16 is not disposed substantially planar to the tops or bottoms of the articles held within the carton 90. In other words the cylindrical axis of the articles is substantially parallel with the plane of the top wall 16 of the carton 90.

The main panel 12 forms the base panel 12 when the handle structure H is in use as a carrying handle by a user. The main panel 12 may also form the base panel 12 when the articles are being dispensed from the carton 90 or when the carton 90 is at rest upon a surface such as a shelf. As such, it will be understood that descriptive terms “top”, “base”, and “side” do not necessarily limit the carton 90 to adopting a particular orientation but serve to distinguish those panels from one another. In other embodiments the cylindrical axis of the articles may be orientated differently with respect to the top wall 16 of the carton 90. For example, but not limited to, the cylindrical axis of the articles be may orientated substantially perpendicularly to the plane of the top wall 16 of the carton 90.

Turning to the construction of the carton 90, blank 10 with the reinforcing member affixed thereto (as shown in FIG. 1) is folded about the fold line 17 such that the second side panel 18 is disposed in overlying relationship with the top panel 16 and such that the securing panel 20 is disposed in face contacting relationship with the first side panel 14.

Glue G or other adhesive treatment is applied to an outer surface of the securing panel 20. Alternatively, glue G or other adhesive treatment may be applied to a corresponding edge portion of an inner surface of the base panel 12.

The blank 10 is folded about the fold line 13 such that the base panel 12 is disposed in overlying relationship with the securing panel 20 and part of the first side panel 14. The base panel 12 is thereby secured to the securing panel 20.

The blank 10 is thus formed into a flat collapsed tubular structure which can be readily shipped or distributed to a convertor plant, at which the flat collapsed tubular structure may be erected into an open ended tubular structure and loaded with articles through one or both of its open ends.

The flat collapsed tubular structure may be erected to form an open ended tubular structure by unfolding the first side panel 14 with respect to the base panel 12 such that the first side panel 14 is disposed substantially perpendicularly with respect to the base panel 12.

The carton 90, in its open ended tubular form, may be loaded with articles through one or both open ends thereof. It will be appreciated that in some embodiments one of the open ends of the carton 90 may be closed before loading the interior with articles through the remaining open end.

Once the carton 90 has been loaded with articles the open ends of the carton 90 are closed.

The method for closing each of the open ends of the carton 90 is substantially the same and will be described by reference to closing the first open end.

A first end of the tubular structure is closed by folding the first end closure panel 22a about fold line 23a and by folding the third end closure panel 26a about fold line 27a.

Glue or other adhesive treatment may be applied to a first portion of an inner surface of the second end closure panel 24a. In alternative embodiments glue or other adhesive treatment may be applied to a corresponding portion of an outer surface of first end closure panel 22a.

Glue or other adhesive treatment may be applied to a second portion of an inner surface of the second end closure panel 24a. In alternative embodiments glue or other adhesive treatment may be applied to a corresponding portion of an outer surface of third end closure panel 26a.

The second end closure panel 24a is then folded about the fold line 25a to be brought into contact with the first and third end closure panels 22a, 26a. The second end closure panel 24a may be secured to each of the first and third end closure panels 22a, 26a.

Glue or other adhesive treatment is applied to a portion of an inner surface of the fourth end closure panel 28a. In alternative embodiments glue or other adhesive treatment may be applied to a portion of an outer surface of the second end closure panel 24a.

The fourth end closure panel 28a is then folded about the fold line 29a to be brought into contact with the second end closure panel 24a and optionally into contact with the first and third end closure panels 22a, 26a.

The fourth end closure panel 28a is secured to the second end closure panel 24a. The fourth end closure panel 28a may be secured to the first and third end closure panels 22a, 26a, for example by glue or other adhesive treatment.

In alternative embodiments the second end closure panel 24a may be folded about fold line 25a after folding the fourth end closure panel 28a about fold line 29a. It will be appreciated that in such embodiments the second end closure panel 24a is disposed outermost.

In other embodiments alternative securing means may be employed to secure the end closure panels 22a, 24a, 26a, 28a, 22b, 24b, 26b, 28b for example, but not limited to, mechanical locking devices such as staples or punch locks integrally formed within the end closure panels 22a, 24a, 26a, 28a; 22b, 24b, 26b, 28b.

The process described above in relation to the first end is replicated to close the second end of the carton 90 and is not further described.

FIG. 2 illustrates the assembled carton 90 forming a package with a plurality of articles (not shown). When the handle structure H is deployed, cushioning flaps 44, 46 are folded inwardly, and the gripping portion 50 and part of the reinforcing member 60 affixed thereto are raised above the plane of the top panel 16. The high tensile strength of the BOPP can mitigate against or even prevent complete failure of the handle structure H even if the carton 90 contains a weight sufficient to cause a shear tear to propagate from the edge of either aperture 40, 42. In one particular non-limiting theory the reinforcing member 60 (which may also be referred to as a “patch”) does not act “as one” with the paperboard material from which the blank 10 and race-track style handle are formed. Rather, the paperboard blank 10 is permitted to have a shear failure in a way that allows the tensile strength of the BOPP patch 60 to reinforce the handle H, particularly in the gripping portion 50. This may be accomplished by separating the position of the stress point of failure of the paperboard handle and the position of the stress point of failure of the patch 60. The stress point of failure of the paperboard handle may be along a curved edge of the arcuate slot 45, 47 proximate to an end of a cushioning flap fold line 51, 49. The stress point of failure of the reinforcing member 60 may be along the curved section between points P1 and P2 (see FIG. 4). By spacing the stress points in a longitudinal and/or transverse direction relative to the stress point of the paperboard handle it is possible to provide adequate reinforcement of the race-track style handle using non-shear resistant, but higher tensile strength material. In various embodiments, the curved section of the reinforcing member 60 is spaced longitudinally from said curved edge of the arcuate slot 40, 42 by a distance “X” of between about 1 cm and about 1.4 cm. As can be seen in FIGS. 1, 3 and 4, the curved section of the reinforcing member 60 has a radius of curvature that is greater than the radius of curvature of said curved edge. In this way the stress point associated with the reinforcing member 60 is also spaced laterally from a stress point associated with the curved edge of the arcuate slot. In other words, the profile of the reinforcing member 60 includes at least one curved section that is not aligned with a perimeter or curved edge of part of one of the two arcuate slots 40, 42.

Factors affecting the performance of the patch 60 may include, but are not limited to: the strength of the adhesive bond between the patch 60 and the blank 10; the relative position of the stress points as described above; the tensile and shear characteristics of the materials from which the blank 10 and patch 60 are formed; and/or the radius of corners on the patch (see for example the radius of the corner of the patch 60 proximate to point P2 in FIG. 4).

Referring now to FIGS. 5 and 6 there are shown alternative embodiments of the present invention. In the alternative illustrated embodiments, like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “100” or “200” and so on to indicate that these features belong to the alternative illustrated embodiments. The alternative embodiments share many common features with the embodiment of FIGS. 1 to 4 and therefore only the differences from the embodiment illustrated in FIGS. 1 to 4 will be described.

In FIGS. 5 and 6, the reinforcing members 160, 260 are each formed from a material having a high shear resistance (and not necessarily having a greater tensile strength compared to the tensile strength of the material from which the blanks are formed). In the examples of FIGS. 5 and 6, the reinforcing members are formed from PET, a shear-resistant material. In one particular, non-limiting theory, the reinforcing material is profiled and positioned in order to strengthen the area of the paperboard that is vulnerable to failure. In a sense, the paperboard handle and reinforcing member are acting together, as one, to increase the shear-resistance of the handle structure H. In such arrangements, dimension “X” may be lower compared to embodiments utilising a high-tensile strength reinforcing member and the radius of curvature “R” of the patch 160, 260, may be closer to the radius of curvature of the edge of the arcuate slots 140, 142, 240, 242 at the end of the cushioning flap fold line 149, 151, 249, 251. In other words, the profile of the inner edge 157, 159, 257, 259 of the reinforcing member 160, 260 may more closely follow or match the profile of the (upper) edge of the handle slots 140, 142, 240, 242. In FIGS. 5 and 6, the stress point of failure of the paperboard handle may be along the aperture edge 145, 147, 245, 247 and proximate to an end of a cushioning flap fold line 151, 149, 251, 249. The stress point of failure of the reinforcing member 160, 260 may still be along the curved edge as before, but by keeping the stress point close to the stress point of the paperboard handle it is possible to provide adequate reinforcement of the race-track style handle using shear resistant material.

It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels, apertures and reinforcing members may be adjusted to accommodate articles of differing size, shape and weight. It will be appreciated that in some arrangements the reinforcing member may extend to the edges of the panel containing the handle that the reinforcing member serves to reinforce.

It will be recognised that as used herein, directional references such as “top”, “base”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that a hinged connection can be formed from one or more of the following: a short slit, a frangible line or a fold line, without departing from the scope of the invention. It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape.

As used herein, the terms “hinged connection” and “fold line” each refers to all manner of lines that define hinge features of the blank or substrate of sheet material, facilitate folding portions of the blank or substrate of sheet material with respect to one another, or otherwise indicate optimal panel folding locations for the blank or substrate of sheet material. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed a hinged connection can be formed from one or more fold lines.

As used herein, the term “fold line” may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cut line, aligned slits, a line of short scores and any combination of the aforesaid options, without departing from the scope of the invention.

As used herein, the term “severance line” may refer to all manner of lines formed in the blank or substrate of sheet material that facilitate separating portions of the blank or substrate of sheet material from one another, or otherwise that indicate optimal separation locations on the blank or substrate. As used herein, the term “severance line” may refer to one of the following: a single cut line, a single partial-depth cut line (e.g., a single half-cut line), an interrupted cut line, a score line, an interrupted score line, a line of perforations, a line of short cuts, a line of short slits, a line of short partial-depth cuts (e.g., a line of short half cuts), and any combination of the aforementioned options.

It should be understood that hinged connections, fold lines and severance lines can each include elements that are formed in the blank or substrate of sheet material, 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 be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking to provide a fold line, to facilitate folding and facilitate breaking with more effort to provide a frangible fold line, or to facilitate breaking with little effort to provide a severance line.

Claims

1. A carton comprising a two part handle structure, the two part handle structure comprising: a first integrally formed part comprising two arcuate slots spaced by a gripping portion; and a second reinforcing part comprising a reinforcing member attached to at least the gripping portion of the first integrally formed part of the handle, the reinforcing member has a profile that includes at least one curved section that is not aligned with a perimeter of at least one of said two arcuate slots and the reinforcing member is formed from material that is separate from the material from which the first integrally formed part of the handle is formed.

2. A carton according to claim 1, wherein the reinforcing member is formed from material that is different to the material from which the first integrally formed part of the handle is formed.

3. A carton according to claim 2, wherein the reinforcing member is formed from a material having a higher tensile strength compared to the material from which the first integrally formed part of the handle is formed.

4. A carton according to claim 2, wherein the reinforcing member is formed from a material having a higher shear resistance compared to the material from which the first integrally formed part of the handle is formed.

5. A carton according to claim 2, wherein the reinforcing member is formed from biaxially oriented polypropylene and the carton and first integrally formed part of the handle is formed from paperboard.

6. A carton according to claim 2, wherein the reinforcing member is formed from polyethylene terephthalate and the carton and first integrally formed part of the handle is formed from paperboard.

7. A carton according to any one of claim 1, wherein the perimeter of the at least one of said two arcuate slots comprises a curved edge and a stress point is associated with said curved edge, and wherein the at least one curved section of the reinforcing member is spaced laterally and/or longitudinally from said curved edge.

8. A carton according to claim 7, wherein the at least one curved section of the reinforcing member is spaced longitudinally from said curved edge by a distance (X) of between about 1 cm and about 1.4 cm.

9. A carton according to any one of claim 1, wherein the perimeter of the at least one of said two arcuate slots comprises a curved edge and a stress point is associated with said curved edge, and wherein the at least one curved section of the reinforcing member has a radius of curvature that is greater than the radius of curvature of said curved edge.

10. A carton according to any one of claim 1, wherein the reinforcing part comprises a reinforcing member having a pressure sensitive adhesive applied thereto and a removable backing sheet covering said pressure sensitive adhesive.

11. A blank for forming a carton comprising a two part handle structure, the blank comprising a top panel and a series of other panels for forming the walls of the carton, the top panel comprising a first integrally formed part of the handle structure comprising two arcuate slots spaced by a gripping portion and having affixed thereto a second reinforcing part comprising a reinforcing member attached to at least the gripping portion of the first integrally formed part of the handle, the reinforcing member being pre-cut such that a profile of the reinforcing member includes at least one curved section that is not aligned with a perimeter of at least one of the arcuate slots, the reinforcing member being formed from material that is separate from the material from which the first integrally formed part of the handle is formed.

12. A blank according to claim 11 wherein the perimeter of the at least one of said two arcuate slots comprises a curved edge and a stress point is associated with the curved edge, and wherein the at least one curved section of the reinforcing member is spaced laterally and/or longitudinally from the curved edge.

13. A blank according to claim 12 wherein the at least one curved section of the reinforcing member is spaced longitudinally from said curved edge by a distance (X) of between about 1 cm and about 1.4 cm.

14. A blank according to claim 11 wherein the perimeter of the at least one of said two arcuate slots comprises a curved edge and a stress point is associated with said curved edge, and wherein the at least one curved section of the reinforcing member has a radius of curvature that is greater than the radius of curvature of said curved edge.

15. A blank according to claim 11, wherein the reinforcing part comprises a reinforcing member having a pressure sensitive adhesive applied thereto and a removable backing sheet covering said pressure sensitive adhesive.

16. A blank according to claim 11 wherein the reinforcing member is formed from material that is different to the material from which the first integrally formed part of the handle is formed.

17. A blank according to claim 16 wherein the reinforcing member is formed from a material having a higher tensile strength compared to the material from which the first integrally formed part of the handle is formed.

18. A blank according to claim 16, wherein the reinforcing member is formed from a material having a higher shear resistance compared to the material from which the first integrally formed part of the handle is formed.