| Carton with handle reinforcement structure -> Monitor Keywords |
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Carton with handle reinforcement structureRelated Patent Categories: Envelopes, Wrappers, And Paperboard Boxes, Paperboard Box, Lifting Or Suspending Element (e.g., Handle), One-piece With The Box, Box Includes Hand-receiving Aperture, Hand-receiving Aperture Extends Through A Box SidewallCarton with handle reinforcement structure description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070007325, Carton with handle reinforcement structure. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATION [0001] This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 60/696,792, entitled "Carton with Handle Reinforcement Structure," filed on Jul. 6, 2005 under 35 U.S.C. .sctn.111(b), the entirety of which is incorporated herein by reference. TECHNICAL FIELD [0002] This invention relates generally to a carton having a reinforced handle in an end wall, and particularly, to a carton having a handle opening reinforced by a handle structure panel that allows the carton to be used to carry heavier loads. BACKGROUND OF THE INVENTION [0003] Cartons for encasing and dispensing multiple articles such as beverage bottles or cans are useful for enabling consumers to transport, store, and access the articles for consumption. To facilitate carrying such cartons, carton it is desirable to include handles that are sufficiently strong to withstand the stress generated by the weight of articles enclosed. Handles are typically integral to or attached to a wall of the carton. The handles should also be ergonomic--distributing the weight of heavy articles if needed to minimize the user's fatigue, and preventing undue pressure or stress on any portion of the user's hand that engages the handle. [0004] Another challenge arises when the burst strength of the material comprising the adjacent wall is insufficient to avoid detaching the handle or tearing the wall itself. One potential solution is to construct the carton from a stronger material, such as corrugated board, or from sheet material having a relatively higher caliper. As fully enclosed cartons typically 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 expensive because it effectively amounts to reinforcing all six walls (top, sides, bottom, and ends) of the carton irrespective of the relative magnitude of the forces borne by each wall. [0005] According to another approach, an additional layer of sheet material is used as an insert that that reinforces the integrity of a handle as well as that of the end wall. For instance, a handle opening in an end flap of an end wall of a carton may be reinforced by overlaying an insert over the handle opening and securing the insert to the end flap. To avoid obstructing the handle opening, the insert must have a similar or somewhat larger opening that is aligned with the handle opening to reinforce its edges. Similarly, additional apertures or cutouts are often required in side flaps to prevent overlapping or obstructing the handle aperture. However, handle openings reinforced using this approach have exposed edges that are relatively keen, which may produce discomfort for the user who inserts fingers into the handle opening to lift the carton. Moreover, by overlaying an insert over an endless edged handle opening, the entire periphery is reinforced even though only the weight bearing portion of the handle opening needs such reinforcement. Furthermore, precise alignment of the apertures and cutouts in the side end flaps with the handle opening and the insert opening is difficult to accomplish on high-speed out plant equipment (OPE) such as at a bottling facility, as part of the process of erecting and loading the cartons. [0006] What is needed is a carton that has a reinforced end handle that accommodates heavier loads without failing and is ergonomic and comfortable to use, where the carton walls are efficiently constructed without wasting expensive material in carton walls that are less likely to fail or by reinforcing portions of the handle that do not bear weight. SUMMARY OF THE INVENTION [0007] The various embodiments of the present invention overcome the shortcomings of the prior art by providing a carton formed from a single sheet of paperboard or other foldable sheet material, the carton having a handle opening disposed in at least one end wall, wherein at least the weight bearing portion of the handle opening is reinforced by an insert that includes a handle structure panel formed from the same or an additional sheet of material as the carton. All or a portion of the insert including the handle structure panel is secured to the top and/or the end wall, and a reinforcing portion of the handle structure panel is aligned in reinforcing proximity to the weight-bearing edge of the handle opening. Advantageously, the handle structure panel can be assembled and secured within the carton in alignment with the weight-bearing portion of handle opening prior to the carton being loaded into a packaging machine to be erected and loaded. As another advantage, the configuration provides a multi-ply hand engaging surface that is more comfortable for the user, particularly in combination with a hand cushioning flap or a hollow core arrangement. [0008] More specifically, the exemplary carton incorporating the various aspects of the invention is formed from a carton blank that includes a bottom panel, a first side panel hingedly connected to the bottom panel, an outer top panel hingedly connected to the first side panel, a second side panel hingedly connected to the outer top panel. When the carton is erected, these panels become the top, bottom, and side walls of the carton. The carton blank also includes several end panels that form at least one end wall structure. Each end wall structure is formed from a bottom end panel hingedly connected to the bottom panel and a top end flap hingedly connected to the outer top panel. The top end flap includes a handle opening disposed therethrough. The handle opening is formed by partially detaching a handle punchout by tearing, cutting, punching out or otherwise partially excising a section of the carton blank along a handle severance line. The end wall structure also includes side end flaps hingedly connected to the first and second side panels respectively, each side end flap having dimensions tailored to avoid interfering with or overlapping the handle opening. [0009] In certain embodiments of the invention, the insert is formed from an insert blank that includes an inner top panel to which a handle structure panel is hingedly connected along each of its opposing end edges. The reinforcing portion of the handle structure panel includes an end edge that is aligned with and in reinforcing proximity to the weight bearing portion of the said handle opening. Each handle structure panel is foldable, preferably via in-plant equipment (IPE). The IPE also places the outside surface of the top inner panel in face contacting arrangement with the inside surface of the outer top panel, aligning the hinged connections between the inner top panel and each handle structure panel with the fold line that hingedly connects the outer top panel to the respective top end flap. The outside surface of the handle structure panel is secured to the inside surface of the top end flap in alignment with and proximity to the weight bearing portion of the handle opening in the top end flap. Alternatively, instead of a single inner top panel, dual inserts are positioned near either end of the carton, with each insert including a handle structure panel as described above. [0010] In addition, each side end flap includes a cutout having dimensions that are complementary to the dimensions of at least part of the handle opening. The bottom panel is secured to the second side panel to place the partially erected carton into a collapsed tubular configuration. [0011] When the carton is erected, preferably via out-plant equipment such as a packaging machine, the walls of the collapsed tubular carton are pulled apart and the side end flaps are folded toward the interior of the carton. The bottom and top end flaps are folded toward the interior of the carton as well. The top end flap forms the outermost ply of the reinforced composite handle. [0012] In a certain alternative embodiments, the handle structure panel includes a first handle structure section that is defined from the inner top panel by a hinged connection and is made easily foldable, with respect to the inner top panel, by a succession of spaced fold apertures or fold lines, or a combination of spaced apertures and fold lines. A handle edge is hingedly connected along a fold line to the first handle structure section. The handle edge is hingedly connected along a fold line to second handle structure section, which is hingedly connected along a fold line to a handle structure attachment. Each handle structure panel is foldable, preferably via in-plant equipment (IPE), into a collapsed hollow core structure which can be held in place by securing the inside surface of handle structure attachment to the inside surface of inner top panel. The IPE also places the outside surface of the top inner panel in face contacting arrangement with the inside surface of the outer top panel, aligning the hinged connections between the inner top panel and each first handle structure with the fold line that hingedly connects the outer top panel to the respective top end flap. The outside surface of the first handle structure is secured to the inside surface of the top end flap in alignment with and proximity to the weight bearing portion of the handle opening in the top end flap. The bottom panel is secured to the second side panel to place the partially erected carton into a collapsed tubular configuration. [0013] When the carton is erected, preferably via out-plant equipment such as a packaging machine, the walls of the collapsed tubular carton are pulled apart and the side end flaps are folded toward the interior of the carton. The bottom end flaps are folded toward the interior of the carton as well. When the top end flaps are folded toward the interior of the carton, the collapsed hollow core structure is forced into the shape of a box beam, with the handle edge forming the lower edge of the box beam shape, and the first and second handle structure sections forming the sides of the box beam shape. The first and second handle structures are substantially parallel to the top end panel, creating the intermediate plies of the reinforced composite handle. The top end flap forms the outermost ply of the reinforced composite handle. [0014] The box beam shape provides additional structural integrity to the weight bearing portion of the handle opening in addition to the additional layers of sheet material. However, other hollow core configurations are contemplated as well, including but not limited to, a beam having semicircular or triangular cross section with one surface of the beam being secured to the top end flap in alignment with the weight bearing portion of the handle opening. [0015] According to one aspect of the invention, the handle structure panel may be just long enough to reinforce the weight bearing portion of the handle opening, or may extend along the top end flap as long as the entire width of the outer panel, which may be co-extensive with the width of the end wall of the carton. [0016] According to another aspect of the invention, the handle punchout that is partially detached to form the handle opening is foldable into the interior of the carton to wrap around the reinforcing portion of the handle panel structure, forming the innermost ply of the reinforced composite handle. A handle edge portion of the handle punchout further reinforces and cushions the hand-engaging portion as it is placed in registry with the reinforcing portion of the handle structure panel. [0017] According to yet another aspect of the invention, the insert blank may be integral to the carton blank. More to the point, the outer top panel is hingedly connected along a fold line to the first side panel, which is hingedly connected along a fold line to the bottom panel, which is hingedly connected along a fold line to the second side panel, which is hingedly connected along a fold line to the insert blank. The handle structure panel is assembled as described with respect to the embodiments described above, and the carton is configured in a collapsed tubular state by securing the insert blank to the outer top panel in a face contacting arrangement as described above. [0018] In another alternative embodiment, the insert blank is substituted for the outer top panel, with the handle structure panels replacing the top end flaps, and the handle openings being disposed through bottom end flaps, which are extended in length. Thus, the first side panel is hingedly connected along a fold line to the top panel, which comprises the insert blank. The top panel is hingedly connected along a fold line to the second side panel, which is hingedly connected along a fold line to the bottom panel. The handle structure panel is assembled and secured as described above, and the carton is configured in a collapsed tubular state by securing the bottom panel to the first side panel. To erect the carton, each collapsed hollow core structure is erected as it is folded toward the interior of the carton, and the corresponding bottom end flap is folded and secured thereto in overlapping relationship. The handle edge of the hollow core structure is aligned with and in reinforcing proximity to the weight bearing portion of the handle opening. [0019] Certain of the embodiments include a dispenser formed at least in part from the top wall of the carton, which may extend onto the side walls as well. The dispenser is formed by at least partially removing a detachable portion that is defined by a tear line that can be easily broken by tear initiation means, such as push tabs, tear tabs, or tear strips, or any combination thereof. The carton is opened by breaking the tear lines and removing the detachable portion to access the articles within the carton. In embodiments having an inner top panel, a means for carton access is formed in the inner top panel, which may be defined by at least a second tear line and a second detachable portion or portions that are fully or partially detachable from the carton. In these embodiments, the carton is opened by removing the first detachable portion and then by breaking the second set of tear lines to gain access to the articles within. [0020] 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. Continue reading about Carton with handle reinforcement structure... Full patent description for Carton with handle reinforcement structure Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Carton with handle reinforcement structure patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Carton with handle reinforcement structure or other areas of interest. ### Previous Patent Application: Gift wrap kit, methods and apparatus Next Patent Application: Miranda two-way window envelope Industry Class: Envelopes, wrappers, and paperboard boxes ### FreshPatents.com Support Thank you for viewing the Carton with handle reinforcement structure patent info. 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