Carton with handle reinforcement structure

Abstract

A carton with a handle opening formed in an end wall includes one or more inserts—each being hingedly connected to a handle panel structure for reinforcing and improving the ergonomics of the handle opening. Each handle panel structure includes a reinforcing portion that reinforces the weight-bearing edge of the handle opening. In certain embodiments, this reinforcing portion is formed by folding the multiple panels of the handle panel structure into a hollow box beam shape with a handle edge that reinforcingly aligns with the weight-bearing edge of the handle opening to provide structural integrity. In certain other embodiments, the reinforcing portion is the outermost edge of the handle panel structure, which similarly aligns to support the integrity of the handle opening. The handle opening is further cushioned and reinforced by a punchout flap that folds inward through the handle opening and wraps around the handle panel structure.

Description

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. §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 attache...

AI Technical Summary

Benefits of technology

[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.

[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.

Problems solved by technology

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.

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.

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.

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.

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