Carton With Handle-Reinforcement Insert

Abstract

A carton includes a substantially tubular structure having an outer top panel. The carton also has an end wall structure including an outer top end flap foldably connected to the outer top panel along its end edge. The outer top end flap includes a handle opening having a weight-bearing region. The carton also has an insert including an inner top panel and an inner top end flap. The inner top panel is disposed in flat-face condition substantially in registry with the outer top panel. The inner top end flap is foldably connected to the inner top panel along an end edge of the inner top panel. The inner top end flap is substantially in registry with the outer top end flap and has a distal edge disposed adjacent the weight-bearing region of the handle opening. The insert further includes at least one auxiliary reinforcement flap disposed in flat-face condition with the inner top end flap so as to provide multiple-ply structure adjacent the handle opening weight-bearing region.

Description

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 11/232,309 filed on Sep. 21, 2005, the entirety of which is incorporated herein by reference. This application also claims the benefit of the filing date of U.S. Provisional Application Ser. No. 60/866,031, filed on Nov. 15, 2006, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

This invention relates to cartons. More specifically, the invention relates to a handle-reinforcement insert for a carton having end-wall or side-wall handles.

BACKGROUND OF THE INVENTION

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, 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.

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.

According to another approach, an additional layer of sheet material is used as an insert 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 region 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.

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

According to an embodiment of the invention, a carton having a substantially tubular structure is provided. The tubular structure includes an outer top panel. The carton also has an end wall structure for at least partially closing an end of the tubular structure. The end wall structure includes an outer top end flap foldably connected to the outer top panel along an end edge of the outer top panel. The outer top end flap includes a handle opening having a weight-bearing region. The carton also has an insert including an inner top panel and an inner top end flap. The inner top panel is disposed in flat-face condition substantially in registry with the outer top panel. The inner top end flap is foldably connected to the inner top panel along an end edge of the inner top panel. The inner top end flap is substantially in registry with the outer top end flap and has a distal edge disposed adjacent the weight-bearing region of the handle opening.

In a preferred embodiment, the insert may further include at least one auxiliary reinforcement flap disposed in flat-face condition with the inner top end flap so as to provide multiple-ply structure adjacent the handle opening weight-bearing region. In this embodiment, the at least one auxiliary reinforcement flap may be foldably adjoined to the inner top end flap. In this embodiment, the inner top end flap may extend downwardly from the inner top panel to its lower end edge, and the at least one auxiliary reinforcement flap may be foldably adjoined to the inner top end flap along the lower end edge. The at least one auxiliary reinforcement flap may extend upwardly to be disposed in flat-face condition with the inner surface of the inner top end flap opposite to the outer surface of the inner top end flap along which the end wall structure is disposed.

In another preferred embodiment, the outer top panel may include an outer access opening and the inner top panel may include an inner access opening in substantial registry with the outer access opening. In such an embodiment, at least one at least partially removable outer access opening panel may substantially fill the outer access opening and at least one at least partially removable inner access opening flap may substantially fill the inner access opening.

In a further preferred embodiment, the tubular structure may further include a pair of opposed side panels, the end wall structure may further include a pair of side end flaps foldably connected to the side panels respectively, and the side end flaps may be disposed at least in part along the top end flap. Each side end flap may include a handle cutout that is positioned in registry with a part of the handle opening. In this embodiment, the tubular structure may further include a bottom panel, the end wall structure may further includes a bottom end flap foldably connected to an end edge of the bottom panel, and the side end flaps may be disposed at least in part along the bottom end flap.

The foregoing has 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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates blanks for forming a carton of the first embodiment according to the present invention.

FIG. 2 is a longitudinal cross-section of an erected carton formed from the blanks of FIG. 1.

FIG. 3 is a perspective view of a carton of the second embodiment formed while using one or more insert blanks.

FIG. 4 is a plan view of a blank for forming a carton of the third embodiment according to the present invention.

FIG. 5 is a plan view of blanks for forming a carton of the fourth embodiment, according to the present invention.

FIG. 6 is a perspective view of a carton with a handle-reinforcement insert in accordance with the fifth embodiment of the present invention;

FIG. 7 is a plan view of a blank for forming the external tubular structure of the carton of FIG. 6;

FIG. 8 is a plan view of the handle-reinforcement insert placed inside the carton of FIG. 6; and

FIG. 9 is a view taken along line 9-9 of FIG. 6.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. 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 in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not limited but serve as a basis for the claims, and for teaching one skilled in the art to variously employ the present invention.

With regard to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate several exemplary embodiments of a carton that is particularly useful for enclosing and carrying relatively heavy articles such as large glass bottles. Generally speaking, the exemplary cartons are formed from any foldable material, but preferably foldable sheet material such as paperboard, corrugated board, plastic, combinations or laminates of these materials, and the like. Each of the exemplary cartons includes an insert or other reinforcing panel including a handle panel structure that reinforces a handle opening formed in an end wall of the carton. The reinforcing portion of the handle panel structure aligns with the weight bearing portion of the handle opening.

Referring now to FIG. 1, there is shown an embodiment of a carton blank 100 and an insert blank 150, according to the present invention. The carton blank 100 includes at least four primary panels for forming the carton 200 shown in FIG. 2. The panels of the carton blank 100 include an edge panel 102, a bottom panel 104, a first side panel 106, an outer top panel 108, and a second side panel 110. The panels 102, 104, 106, 108, 110, inclusive, are hingedly connected one to the next. More specifically, the edge panel 102 is hingedly connected to the bottom panel 104 along fold line 112. The bottom panel 104 is hingedly connected to the first side panel 106 along fold line 114. The first side panel 106 is hingedly connected to the outer top panel 108 along fold line 116. And the outer top panel 108 is hingedly connected to the second side panel 110 along fold line 118. In FIG. 1 a unitary blank 100 is shown; those skilled in the art will understand that two or more blanks may be used to form the illustrated blank 100 as well as all the blanks taught and claimed herein.

Each of the panels 104, 106, 108, 110 is connected to opposing and preferably symmetric end panels, defined in part by fold lines that extend transversely—with respect to the orientation shown in the figure—along opposite transverse edges of the respective panel 104, 106, 108, 110. When erected, the end panels along each edge of the blank cooperate to form a respective end closure structure. In the embodiments illustrated throughout, each pair of end panels and end closure structures are sufficiently identical that like references have been used, with “a” or “b” affixed to distinguish the components of one end of the carton from the other. In other words, with regard to the illustrated embodiments, typically what applies to the elements designated with an “a” reference applies equally to those elements designated with a “b” reference. Accordingly, for the sake of clarity, the present teaching and description will refer to only those elements with the “a” reference unless a clear understanding of the illustrated embodiments requires a discussion of an element with a “b” reference.

The bottom panel 104 is hingedly connected to bottom end panel 120a along a fold line 130a. The first side panel 106 is hingedly connected to a first side end panel 122a along a fold line 132a. The outer top panel 108 is hingedly connected to an outer top end panel 124a along a fold line 134a. The second side panel 110 is hingedly connected to a second side end panel 126a along a fold line 136a.

The blank 100 further includes a tear line 140 and means for tear initiation 142. The tear line 140 may be a severance line or any other weakened line that facilitates access to the interior of a carton according to the present invention. It is contemplated that both the tear line 140 and means for tear initiation 142 include, but are not limited to, a line of perforations, a line of short slits, a line of half cuts, a single half cut, pull tape, rip cords, and any combination of perforations, slits, score lines, half cuts, tape, cord, or the equivalent. As understood by those skilled in the art, the tear line 140 and means for tear initiation 142 assist the user with opening the carton and accessing the articles therein. As further understood by one skilled in the art, here the curvature, shape, and/or orientation of the tear line 140 and means for tear initiation 142 are merely design choices. Hence, the tear line 140 and means for tear initiation 142 elements are merely illustrative and not limiting.

The outer top panel end flap 124a further includes elements that partially define a handle. These elements include a first handle edge fold line 144a adjacent to one side of a handle edge 145a, and second handle edge fold line 146a adjacent to a distal side of the handle edge 145a. Preferably, but not necessarily so, the fold lines 144a, 146a are substantially straight and parallel to each other. A handle cut line 148a defines the remainder of the handle. Here the handle is illustrated as a sinuous shape, believed to be comfortable to the user, but all handle shapes are contemplated and included in the scope of the claims. When folded along the fold lines 144a, 146a as described below with reference to the erection of the carton 200, handle punchout 149a rests within the erected carton.

Continuing with reference to FIG. 1, there is shown an embodiment of a carton insert blank 150 according to the present invention. The illustrated insert blank 150 includes three panels for forming, together with the carton blank 100, the carton 200. The panels of the insert blank 150 include an inner top panel 151, and two handle panel structures 152a, 152b. Similar to the carton blank 100 explained herein, the illustrated insert blank 150 is symmetric and the opposite sides are substantially identical. Accordingly, substantially identical elements are designated “a” or “b” and the present discussion will be with reference only to the elements designated “a” unless otherwise required.

Each handle panel structure 152a further includes four panels for reinforcing the improved handle structure. The illustrated four panels are a first handle structure section 154a, a handle edge 156a, a second handle structure section 158a, and a handle structure attachment 160a. The first handle structure section 154a is hingedly connected to the handle edge 156a along fold line 162a. The handle edge 156a is hingedly connected to the second handle structure section 158a along fold line 164a. And the second handle structure section 158a is hingedly connected to the handle structure attachment 160a along fold line 166a.

The insert blank 150 further includes several preferable but alternatively optional elements, namely, fold apertures 170a and fold lines 172a. Inner panel 151 is hingedly connected to handle panel structure 152a along fold apertures 170a. As understood by those skilled in the art, fold apertures 170a reduce the bulk along a folded carton edge as well as the resistance of layered panels to folding. Similarly, fold lines 172a positioned between or in lieu of the fold apertures 170a may increase the ease of folding. The insert blank 150 further includes an optional means for carton access 174. Means for carton access 174 includes at least one tear line and an optional means for tear initiation, as described above with regard to the carton blank 100.

With reference now to FIGS. 1 and 2, one method of erecting the illustrated carton 200 includes folding and then connecting or otherwise securing the edge panel 102 to the second side panel 110. To form a partially erected open ended tubular carton, the edge panel 102 is secured to the second side 110; preferably such that the fold line 112 is immediately adjacent to the free edge of the second side panel 110. The insert blank 150 is then inserted through the tubular carton and positioned adjacent to the top panel 108. In the illustrated embodiments, the inner top panel 151 is connected or otherwise secured to the top panel 108, but such attachment is not required. For the purpose of positioning the insert 150, the optional fold apertures 170a or optional fold line 172a may be aligned with and placed immediately adjacent to the top panel fold line 134a. Next, the handle panel structure 152a is folded to create a hollow core handle by folding the handle structure section 154a inwardly along the fold apertures 170a and/or fold lines 172a, the handle edge 156a inwardly along the fold line 162a, the second handle edge 158a inwardly along the fold line 164a, and the handle structure attachment 160a outwardly along the fold line 166a before connecting or otherwise securing the attachment 160a to the inner panel 151. Fold line 162a is aligned substantially with fold line 144a so as to reinforce the weight bearing edge of the handle opening. Thus, the reinforcing portion of the handle panel structure 152a includes fold line 162a and handle edge 156a. As used herein, hollow is defined broadly beyond having a space or cavity inside to include not being attached so that a space or cavity could exist if adjacent structure sections were parted.

Alternatively, the insert blank 150 may be attached to the top panel 108 at different times during a sequence of erecting the tubular carton. In an alternative method of erecting, the handle panel structure 152a is folded to create the hollow core handle described herein before being attached to the top panel 108. Thereafter, the insert blank 150 with erected handle may be connected or secured to the top panel 108 before or after the edge panel 102 is connected or secured to the second side panel 110 to form the tubular carton.

As best shown in FIG. 2, the handle panel structure 152a is folded and attached to the inner panel 151 to form a hollow core handle of substantially parallel sides which, in cross-section, resembles the shape of a box beam. Alternative hollow core handle shapes are contemplated herein, including those with an angled cross-section and those with a curved cross-section. In addition, alternative handle edges are contemplated herein, including those comprising only the edge of a single fold line such as 162a or 164a, and those comprising a curved surface.

Upon erecting the handle panel structure 152a and positioning the top inner panel 151 adjacent to the top outer panel 108 of the tubular carton, the handle panel structure 152a and top end panel 124a may resemble the partially folded carton end wall configuration represented by the dashed lines of FIG. 2. There the handle panel structure 152a, which may or may not be connected or otherwise secured to the top end panel 124a, is poised to allow loading of the articles 202. Here, the articles to be loaded are beverage containers such as glass bottles. After the articles are grouped and loaded through either or both of the open ends of the carton 200, the side end panels 122a and 126a, the bottom end panel 120a, the handle panel structure 152a, and the top end panel 124a are fully folded and secured together to form the end wall structure. Thereafter, handle punchout 149a may be pushed inwardly and upwardly to partially wrap the erected handle panel structure along the first handle section 154a, the handle edge 156a, and second handle section 158a. When fully erected, the illustrated handle structure comprises a hollow core defined by handle panel sections 154a, 158a and a handle edge 156a, which provides a carton handle of improved performance and structure integrity. As understood by those skilled in the art, the hollow core handle structure is created by the configuration of the material rather than the composition of the material.

As shown in FIG. 2, the handle panel structure 152a is erected as the top end panel 124a is fully folded and secured to form the end wall structure. In the exemplary embodiment, cutouts C (shown in FIG. 1) in the side end panels 122a, 126a remove material such that the at least partially formed handle panel structure 152a is not obstructed by the side end panels 122a, 126a as the top end panel 124a is fully folded and secured to form the end wall structure. The shape and dimensions of the cutouts C are otherwise merely design choices. For example, the cutouts C may be made such that a pointed section remains in the side end panels 122a, 126a as shown in FIG. 1 or, alternatively, the cutouts C may be made such that the pointed section does not remain as in shown in FIG. 4 for the side end panels 322a, 325a. An additional example of a cutout C is shown in FIG. 6.

FIG. 3 introduces an alternative erected carton 210 that includes one or more insert blanks 212. Here, the insert blank 212 comprises the same handle panel structure 152a as the insert blank 150 described in FIGS. 1 and 2. Further, the assembly and erection of the carton 210 is substantially identical to the assembly and erection of the carton 200 so it is not necessary to teach again the erecting or assembling of this carton 210, except to point out that the notable difference between the respective cartons 200, 210 is that the insert blank 212 only partially spans the top panel 108. Accordingly, alternative inserts may be of different lengths or widths, and may or may not include elements described with reference to the insert blank 150, best shown in FIG. 1. For example, the insert 212 does not include means for carton access. In addition, the insert 212 may or may not be connected or secured to the top panel 108 or the top end panel 124a. Further, an insert 212 may be located at each end wall structure or, alternatively, only one insert 212 may be positioned at any location of the carton for purposes of providing an improved handle.

Referring now to FIG. 4, there is shown an alternative embodiment of a unitary carton blank according to the present invention. This blank 300 includes four primary panels for forming the walls of a carton including an outer top panel 304, a first side panel 306, a bottom panel 308, a second side panel 310, as well as an inner top panel 311 for reinforcing the outer top panel 304. The panels 304, 306, 308, 310, 311, inclusive, are hingedly connected one to the next. More specifically, the outside top panel 304 is hingedly connected to the first side panel 306 along fold line 312. The first side panel 306 is hingedly connected to the bottom panel 308 along fold line 314. The bottom panel 308 is hingedly connected to the second side panel 310 along fold line 316. The second side panel 310 is hingedly connected to the inner top panel 311 along fold line 318. In FIG. 4, a unitary blank 300 is shown; those skilled in the art will understand that two or more blanks may be used to form the illustrated blank 300.

Each of the panels 304, 306, 308, 310, 311, inclusive, in hingedly connected to opposing preferably symmetric end panels defined in part by transverse fold lines disposed along opposite transverse edges of the respective 304, 306, 308, 310, 311. When erected, the end panels along each edge of the blank 300 cooperate to form a respective end closure structure. Similar to the carton blank 100 taught above, the present illustrated blank 300 is symmetric and the opposite sides are substantially identical. Accordingly, substantially identical elements are designated “a” or “b” and the present discussion will continue with reference to the elements designated “a” unless otherwise required.

The outer top panel 304 is hingedly connected to outer top end panel 320a along fold line 330a. The first side panel 306 is hingedly connected to a first side end panel 322a along fold line 332a. The bottom panel 308 is hingedly connected to a bottom end panel 324a along fold line 334a. The second side panel 310 is hingedly connected to a second side end panel 325a along fold line 336a. The inner top panel 311 is hingedly connected to a handle structure section 326a. The handle structure section 326a further comprises a handle edge 327a, a second handle section 328a, and a handle structure 329a. The handle structure section 326a is hingedly connected to the handle edge 327a along a fold line 337a. The handle edge 327a is hingedly connected to the second handle section 328a along fold line 338a. The second handle section 328a is hingedly connected to the handle structure attachment 329a along fold line 339a.

The blank 300 further includes two tear lines 340a, 340b and means for tear initiation 342, similar to the tear line 140 and means for tear initiation 142, respectively, taught above with regard to the blank 100. As the respective tear lines 140, 340a, 340b and means for tear initiation 142, 342 are substantially similar; no new discussion is required here. The inner top panel 311 further includes several preferable but alternatively optional elements, namely, fold apertures 346a and fold lines 348a. Finally, the illustrated handle structure section 326a is hingedly connected to the top inner panel 311 along the fold apertures 346a and fold lines 348a.

The outer top panel end flap 320a further includes elements that partially define a handle. These elements include a first handle edge fold line 350a adjacent to one side of a handle edge 352a, and a second handle edge fold line 354a adjacent to a distal side of the handle edge 352a. Preferably, but not necessarily, the fold lines 350a, 354a are substantially straight and parallel to each other. A handle cut line 356a defines the remainder of the handle. Here the handle is illustrated as a sinuous shape, believed to be comfortable to the user, but all handle shapes are contemplated and included in the scope of the claims. When folded along the fold lines 350a, 354a as taught above with reference to the erection of the carton 200, handle punchout 358a rests within the erected carton.

One method of erecting an open ended tubular carton formed from the blank 300, includes folding and then connecting or otherwise securing the inner top panel 311 to the inner side of the outer top panel 304, preferably such that the free edge of the inner top panel is immediately adjacent to the top panel fold line 312. The remainder of the present method will be easily understood by those skilled in the art who read the method taught herein with regard to the erection of the cartons 200, 210, shown in FIGS. 2 and 3.

Referring now to FIG. 5, there is shown another alternative embodiment of carton blanks according to the present invention. The carton blank 600 and the carton insert blank 650 are somewhat similar to the carton blank 100 and the carton insert blank 150, respectively, as described above. Accordingly, certain differences between the carton blanks 100, 600 and between the carton insert blanks 150, 650 will be described. The handle reinforcing portion of the carton insert blank 650 include the outermost edges E of handle panel structures 654a, 654b. The carton blank 600 is erected to form a carton (not shown) substantially as described above for the carton blank 100 and carton insert blank 650 is folded and secured inside the carton in a similar manner as described with respect to the carton blank insert 150. More specifically, the carton insert blank 650 is secured to the carton such that the top inner panel 651 is secured to the outer top panel 608 and the handle panel structures 654a, 654b are secured to or otherwise disposed in a face contacting arrangement with the area above the handle openings on the top end panels 624a, 624b. Outermost edges E of the handle panel structures 654a, 654b are reinforcingly aligned with the fold line 644a. The thickness or caliper of carton insert blank 650 may correspond to the distance between fold line 644a and 646a, such that when the carton is erected and the punchout 649a is folded inwardly into the carton, a cushioning surface is formed by handle edge 645a.

However, it is preferred that the thickness of each handle panel structure 654a, 654b is limited so that the handle panel structure 654a, 654b does not impede the respective top end panels 624a, 624b from overlapping or otherwise being secured to the inside or outside surface of a respective pair of side end panels 622a, 624a and 622b, 624b, in a face contacting arrangement. Rather than requiring the cutouts C to avoid the handle panel structures 654a, 654b, the side end panels 622a, 622b, 624a, 624b include cutouts C that are shaped and positioned to be complementary to the handle openings of the carton such that the side end panels 622a, 622b, 624a, 624b at least partially reinforce the thickness of the handle opening in respective side wall of the carton. Thus, the weight-bearing portion of each handle opening is reinforced at least in part by the reinforcing portion, edge E, of each handle panel structure 654a, 654b and by the cutouts C formed in the side end panels 622a, 622b, 624a, 624b.

Referring to FIG. 6, therein is illustrated a substantially tubular carton 10 with a handle-reinforcement insert in accordance with a further embodiment of the invention. The carton 10 is formed from a blank 412 that is illustrated in FIG. 7. Referring now simultaneously to FIGS. 6 and 7, but with particular attention directed to FIG. 7, a blank 412 and the carton 10 formed therefrom are suitably constructed of a single sheet of substrate. Suitable substrates include, but are not limited to, all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, or the like. The carton may include a water resistant coating on at least one surface. In the exemplary embodiment, the blank is particularly designed for packaging beverage bottles. It is envisaged that other articles and/or different arrangements of articles may be contained within the carton and that the blank may therefore be sized accordingly.

Referring further to FIGS. 6 and 7, the blank 412 includes a series of foldably interconnected panels that are erected to form a substantially tubular carton 10. A joinder flap 421 is foldably adjoined to bottom panel 420 along a first side edge thereof. A first side panel 422 is foldably adjoined to the bottom panel 420 along a second side edge opposite the joinder flap 421. In turn, the side panel 422 is foldably adjoined to a top panel 424. A second side panel 426 is also foldably adjoined to the top panel 424 along a side edge thereof. The two side panels 422, 426 are disposed on opposite sides of the top panel 424 along respective opposing side edges thereof. The top panel 424 is also referred to herein below as an “outer top panel” to distinguish its relationship with the exemplary embodiment of an insert that will be described below. The interconnected series of wall panels 420, 422, 424, 426 of the blank 412 have end flaps that form end closure in the erected carton 10. Bottom end flaps 430a, 430b are foldably adjoined to the bottom panel 420 along opposing end edges thereof. First side end flaps 432a, 432b are foldably adjoined to the first side panel 422 along opposing end edges thereof. Outer top end flaps 434a, 434b are foldably adjoined to the outer top panel 424 along opposing end edges thereof. Second side end flaps 436a, 436b are foldably adjoined to the second side panel 426 along opposing end edges thereof.

An access opening 440 for the erected carton 412 extends across the outer top panel 424 and into at least one of the side panels 422, 426. The access opening 440 is defined by a frangible line or other weakened line of severance. An at least partially removable outer access opening panel 443 substantially covers the outer access opening 440 to help create a substantially fully-enclosed carton 10. Partial and full handle openings 442a, 442b, 444a, 444b, 446a, 446b are defined in respective side end flaps 432a, 432b, outer top end flaps 434a, 434b, and side end flaps 436a, 436b to collectively form opposing handle openings in the erected carton 412. Handle flaps 445a, 445b that are at least partially removable may be disposed in the outermost full handle openings 444a, 444b to help provide a fully-enclosed erected carton 412.

The carton 10 is erected by folding the series of interconnected panels 420, 421, 422, 424, 426 with respect to one another and affixing the joinder flap 421 to the end most side panel 426. The joinder flap 421 and second side panel 426 may be adjoined by suitable means for affixing surfaces of a substrate to one another such as, but not limited to, application of an adhesive or the like. It is to be noted that the invention contemplates that different ones of the panels 420, 422, 424, 426 may occupy endmost positions without affecting the effectiveness or operation of the invention and without departing from the scope or spirit of the invention.

Referring now to FIG. 8, therein is shown in plan view an exemplary embodiment of a handle-reinforcement insert 500 for reinforcing the handle regions of the carton of FIG. 6. The insert 500 includes a central portion, which for convenience is referred to as an inner top panel 524. Inner top end flaps 534a, 534b are foldably adjoined to the inner top panel 524 along opposing end edges thereof. Relief elements are disposed along each region of joinder 560 of the end edge of the inner top panel and a respective inner top end flap 534a, 534b. Although the relief region of joinder 560 may consist of many different types and numbers of relief elements, a suitable combination of relief structures 562, 566 and relief apertures 564 are illustrated in FIG. 3. The exemplary embodiment includes flanking relief structures 562 and centrally disposed relief structures 566. Each relief structure 562, 566 includes at least one weakened line for promoting folding, such as an interrupted cut line. Other suitable weakened lines include but are not limited to scores and perforations. The parallel, spaced weakened lines of the relief members 562, 566 that are illustrated in the exemplary embodiment are particularly suitable for receiving, accommodating and promoting folding with respect to the crowns of bottles B. Although each relief structure 562, 566 in the exemplary embodiment includes three parallel weakened lines that promote folding, the invention may be effectively practiced with more than or less than three lines. The precise location of the relief apertures 564 and relief structures 562, 566 may be varied without departing from the spirit and scope of the invention. Auxiliary reinforcement flaps 544a, 544b are foldably adjoined to respective inner top end flaps 534a, 534b along respective fold lines 538a, 538b. Weakened lines of severance 540, 541, including but not limited to frangible lines or interrupted cut lines, define inner access panels 543a, 543b in the inner top panel 524. The inner access panels 543a, 543b are at least partially removable so as to create an inner access opening through the inner top panel 524 that is substantially in registry with the outer access opening 40 defined in the outer top panel 24. Lifting of the removable inner access panels 543a, 543b is easily initiated by insertion of a finger or other indexing article through the tear-initiation aperture 525 provided.

The insert 500 is not illustrated in exact scale with respect to the exemplary embodiment of a carton 10 and the exemplary embodiment of a blank 412. The invention encompasses an insert 500 of various sizes and configurations. For example, the inner top panel 524 may be equal in width or lesser in width as compared to the width of the outer top panel 424. In addition, the inner top panel 524 may have both a size and configuration substantially equivalent to that of the outer top panel 424. Such equivalency of size and configuration helps facilitate placement of the insert 500 in the erected carton 412. An inner top panel 524 of substantially the same size and configuration as the outer top panel 424 may more easily be aligned in register with the outer top panel 424. The insert 500 may be suitably employed as taught by the invention by first folding the auxiliary reinforcement flaps 544a, 544b over into face contacting condition with the inner top end flaps 534a, 534b. The invention is more effective when the auxiliary reinforcement flaps 544a, 544b are adhered to the respective inner top end flaps 534a, 534b. Although the invention is effective if the auxiliary reinforcement flaps 544a, 544b are simply folded over and positioned in flat-face condition with the inner top end flaps 534a, 534b, without being affixed thereto, after placement of the inner top panel 524 of the insert 500 in flat-face condition with the outer top panel 424, the effectiveness of the invention is enhanced if the auxiliary reinforcement flaps 544a, 544b are adhered to the inner top end flaps 534a, 534b prior to alignment and placement of the inner top panel 524 in flat-face condition with the outer top panel 424.

The insert 500 may be positioned in the flat or the erected blank 412 in several ways contemplated by the invention. The inner top panel 524 of the insert 500 may or may not be affixed to the outer top panel 424 of the blank 412. If affixed, the inner top panel 524 may be affixed by various suitable methods of affixing surfaces of substrates to one another, such as by application of an adhesive or other suitable means. The inner top panel 524 may be placed or affixed either before or after erection of the blank 412.

Referring momentarily back to FIG. 6, a representative outline of the positioned insert 500 is shown in phantom illustration as seen looking through the outer surface of the carton 10.

Referring now to FIG. 9, the cross-sectional view of the erected carton 10 illustrates the relationship between the handle-reinforcement insert 500 and the erected carton 10. In particular, this view illustrates the manner in which each inner top end flap 534a, 534b cooperates with a respective auxiliary reinforcement panel 544a, 544b to form a multiple-ply (two-ply in this instance) reinforcement structure at a weight-bearing region of a composite handle opening 42a, 42b, 44a, 44b, 46a, 46b. Each handle is a composite structure formed from the multiple partial and full handle openings 42a, 42b, 44a, 44b, 46a, 46b. In general, the weight-bearing region of a handle opening is the region immediately above a handle opening. The stress placed upon the side wall structure of a carton is focused at this region when a packaged carton is lifted by the handles. As can be seen in FIG. 4, what is essentially a region of four-ply substrate thickness is formed just above each composite handle opening. The effectiveness of the invention is increased when all of the plies of the substrate at the reinforced region are affixed to one another. As previously discussed herein, suitable means of affixation of layers of substrate include application of an adhesive. In the exemplary embodiment illustrated, the fold line 538a, 538b of the insert 500 about which respective top end flaps 534a, 534b and auxiliary reinforcement flaps 544a, 544b are foldably adjoined to one another helps define an edge (a distal edge) 538a, 538b of the two-ply reinforcement that is disposed adjacent the upper perimeter of the composite handle opening.

The carton 10 with reinforced handle insert 500 illustrated and described herein provide a means for reinforcing the weight-bearing region of handle openings without unduly increasing the amount of substrate used to form a package. In addition, the insert 500 taught by the present invention provides a means for easily positioning the reinforcement structure of the invention for use.

As used herein, the terms “fold line” and “severance line” refer to all manner of lines indicating optimal respective fold or cut locations. A fold line is typically a scored line, an embossed line or a debossed line. Severance lines, and sometimes fold lines, may be frangible or otherwise weakened lines, perforations, a line of perforations, a line of short slits, a line of half-cuts, or a single half-cut. A severance line may also be a cut line or slit. Fold lines and severance lines may also be some combination of the above lines, and the like.

The above-described embodiments are merely exemplary illustrations of implementations set that forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims. For example, multiple auxiliary reinforcement panels may be employed to create reinforcement plies greater than two-ply. In another variation of note, the insert 500 may have an inner top end flap 534a, 534b and associated auxiliary reinforcement flap 544a, 544b or flaps at only one end of the inner top panel 524 but still function effectively in accordance with the teachings of the invention.

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. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. For example, any of the embodiments described herein may be implemented with a single insert that extends the entire length of the top wall, or with an individual insert that is disposed at or near either or both ends of the carton, as shown in FIG. 3. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.

Claims

1. A carton comprising:

a substantially tubular structure including an outer top panel;

an end wall structure including an outer top end flap foldably connected to the outer top panel along an end edge thereof, the outer top end flap including a handle opening having a weight-bearing region; and

an insert including an inner top panel disposed in flat-face condition substantially in registry with the outer top panel and an inner top end flap foldably connected to the inner top panel along an end edge thereof, the inner top end flap being substantially in registry with the outer top end flap and having a distal edge disposed adjacent the weight-bearing region of the handle opening.

2. The carton of claim 1, wherein the insert further includes at least one auxiliary reinforcement flap disposed in flat-face condition with the inner top end flap so as to provide multiple-ply structure adjacent the weight-bearing region.

3. The carton of claim 2, wherein the at least one auxiliary reinforcement flap is foldably adjoined to the inner top end flap.

4. The carton of claim 1, wherein the outer top panel includes an outer access opening and the inner top panel includes an inner access opening in substantial registry with the outer access opening.

5. The carton of claim 4, wherein at least one at least partially removable outer access opening panel substantially fills the outer access opening and at least one at least partially removable inner access opening flap substantially fills the inner access opening.

6. The carton of claim 2, wherein the inner top end flap extends downwardly from the inner top panel to a lower end edge of the inner top end flap, and the at least one auxiliary reinforcement flap is foldably adjoined to the inner top end flap along the lower end edge and extends upwardly to be disposed in flat-face condition with an inner surface of the inner top end flap opposite to an outer surface of the inner top end flap along which the end wall structure is disposed.

7. The carton of claim 1, wherein the tubular structure further includes a pair of opposed side panels, the end wall structure further includes a pair of side end flaps foldably connected to the side panels respectively, and the side end flaps are disposed at least in part along the top end flap, each of the side end flaps including a handle cutout that is positioned in registry with a part of the handle opening.

8. The carton of claim 7, wherein the tubular structure further includes a bottom panel, the end wall structure further includes a bottom end flap foldably connected to an end edge of the bottom panel, and the side end flaps are disposed at least in part along the bottom end flap.

9. The carton of claim 1, wherein the tubular structure further includes a pair of opposed side panels, and the insert is hingedly connected to one of the side panels.

10. A carton, comprising:

an outer top panel;

first and second side panels hingedly connected the outer top panel;

a bottom panel hingedly connected to the first and second side panels;

an end wall including a top end flap hingedly connected to the outer top panel and having a handle opening with a weight bearing region; first and second side end flaps hingedly connected to the first and second side panels respectively; and a bottom end flap hingedly connected to the bottom panel; and an insert including an inner top panel defined by side edges and end edges, and a handle panel structure hingedly connected to the inner top panel along one of the end edges, wherein a reinforcing portion of the handle panel structure is placed in reinforcing proximity to the weight bearing region of the handle opening.

11. The carton of claim 10, wherein the reinforcing portion of the handle panel structure comprises an inner top end flap, and each side end flap comprises a cutout having dimensions complementary to the dimensions of at least part of the handle opening.

12. The carton claim 11, wherein the inner top end flap of the handle panel structure is disposed in substantial alignment with the weight bearing region of the handle opening.

13. The carton of claim 10, wherein the insert further includes at least one auxiliary reinforcement flap disposed in flat-face condition with the reinforcing portion of the handle panel structure so as to provide multiple-ply structure adjacent the weight-bearing region.

14. The carton of claim 13, wherein the at least one auxiliary reinforcement flap is foldably adjoined to the reinforcing portion of the handle panel structure.

15. The carton of claim 11, wherein the inner top panel extends entirely along the length of the carton.

16. The carton of claim 11 wherein the insert further includes a second handle panel structure hingedly connected to the inner top panel.