Carton with reinforced handle

• US 9,636,882 B2
• Filed: 08/18/2015
• Issued: 05/02/2017
• Est. Priority Date: 08/19/2014
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Holley, Jr., John Murdick
• Primary Examiner(s): DEMEREE, CHRISTOPHER R
• Application Number:
  US14/828,791
• Publication Number:
  US 20160052676A1
• Time in Patent Office: 623 Days
• Field of Search: 22911716, 229244, 22911713, 22911717, 229240, 2291032, 229200, 206427, 220676, 493162, 493 88, 493405, 493 89, 53456, 53458
• CPC Class Codes: B31B 2100/002 characterised by the shape of the blank from which they are formed
• CPC Class Codes: B31B 50/262 involving folding, leading, or trailing flaps of blanks
• CPC Class Codes: B31B 50/86 Forming integral handles; Attaching separate handles
• CPC Class Codes: B65D 2571/00141 glued
• CPC Class Codes: B65D 2571/00265 extending from the upper or lower wall
• CPC Class Codes: B65D 2571/00302 consisting of an inward deformation of at least a wall, e.g. embossed, keels
• CPC Class Codes: B65D 2571/0045 for hands
• CPC Class Codes: B65D 2571/00524 integral
• CPC Class Codes: B65D 2571/00574 whereby contents can still be carried after the line has been torn
• CPC Class Codes: B65D 2571/0066 formed from one single sheet
• CPC Class Codes: B65D 2571/00728 the end walls being closed by gluing
• CPC Class Codes: B65D 2571/00814 for reinforcing
• CPC Class Codes: B65D 71/36 having a tubular shape, e.g. tubular wrappers, with end walls

Abstract

A carton for holding a plurality of articles. The carton can comprise a plurality of panels comprising at least a top panel and a side panel. A plurality of end flaps can be respectively foldably connected to respective panels of the plurality of panels, can be at least partially overlapped to at least partially form a closed end of the carton, and can comprise at least a side end flap foldably connected to the side panel along a first fold line. A handle can be formed in the closed end of the carton for grasping and carrying the carton. The handle can extend in at least the side end flap. A reinforcing flap can be foldably connected to the side end flap along a second fold line, and the reinforcing flap can at least partially overlap the side end flap for reinforcing the handle.

Claims

1. A carton for holding a plurality of articles, the carton comprising:

a plurality of panels that extends at least partially around an interior of the carton, the plurality of panels comprising at least a top panel and a side panel;

a plurality of end flaps respectively foldably connected to respective panels of the plurality of panels, the plurality of end flaps being at least partially overlapped with respect to one another to thereby at least partially form a closed end of the carton, the plurality of end flaps comprising at least a side end flap foldably connected to the side panel along a first fold line;

a handle in the closed end of the carton for grasping and carrying the carton, the handle extending in at least the side end flap; and

a reinforcing flap foldably connected to the side end flap along a second fold line, the reinforcing flap at least partially overlapping the side end flap for reinforcing the handle, a portion of the side end flap having a free edge that is collinear with the second fold line,

the handle comprises a first opening in the side end flap and a second opening in the reinforcing flap, and the first opening and the second opening are generally aligned with one another in the closed end, and

the side end flap comprises an upper edge and a lower edge opposite the upper edge and the second fold line extends from the upper edge and the lower edge, and the second fold line is interrupted by the first opening and the second opening so that the second fold line extends generally upwardly and downwardly from the first opening and the second opening.

2. The carton of claim 1, wherein the reinforcing flap is at least partially in face-to-face contact with the side end flap above the first opening and the second opening.

3. The carton of claim 1, wherein the second fold line extends from an edge of the first opening and the second opening.

4. The carton of claim 1, wherein a first upper portion of the side end flap is foldably connected to a second upper portion of the reinforcing flap, and the first upper portion is at least partially in face-to-face contact with the second upper portion above the first opening and the second opening.

5. The carton of claim 4, wherein the reinforcing flap is foldably connected to and at least partially in face-to-face contact with the side end flap below the first opening and the second opening.

6. The carton of claim 1, wherein the side end flap comprises an upper flap and a lower flap, and the reinforcing flap is foldably connected to the upper flap along the second fold line.

7. The carton of claim 6, wherein the upper flap is connected to the lower flap by at least a connector panel.

8. The carton of claim 6, further comprising a corner flap foldably connected to the lower flap of the side end flap, the corner flap being folded with respect to the side end flap to extend adjacent a corner of the carton.

9. The carton of claim 1, further comprising an article protection feature in the closed end of the carton, the article protection feature comprising at least a deformation extending in at least the reinforcing flap.

10. The carton of claim 9, wherein the deformation further extends in the side end flap and the second fold line extends at least partially across the deformation.

11. The carton of claim 9, wherein the article protection feature further comprises an aperture in the side end flap adjacent the deformation in the reinforcing flap, the aperture interrupting the second fold line.

12. The carton of claim 11, wherein:

the side panel is a first side panel, the side end flap is a first side end flap, the reinforcing flap is a first reinforcing flap, and the deformation is a first deformation;

the plurality of panels comprises a second side panel, the plurality of end flaps comprises a second side end flap foldably connected to the second side panel, and a second reinforcing flap is foldably connected to the second side flap; and

the article protection feature comprises a second deformation extending in the second reinforcing flap and the second side end flap, the first side end flap and the first reinforcing flap at least partially overlapping the second side end flap and the second reinforcing flap so that the first deformation, the second deformation, and the aperture are generally aligned in the closed end of the carton.

13. The carton of claim 1, wherein:

the side panel is a first side panel, the side end flap is a first side end flap, and the reinforcing flap is a first reinforcing flap;

the plurality of panels comprises a second side panel, the plurality of end flaps comprises a second side end flap foldably connected to the second side panel, and a second reinforcing flap is foldably connected to the second side flap along a third fold line; and

the handle further extends in the second side end flap and the second reinforcing flap, the second reinforcing flap at least partially overlapping the second side end flap for reinforcing the handle.

14. The carton of claim 13, wherein the handle comprises a handle opening extending in the first side end flap, the second side end flap, the first reinforcing flap, and the second reinforcing flap.

15. The carton of claim 14, wherein the plurality of end flaps further comprises a top end flap foldably connected to the top panel, the handle further comprises a handle flap foldably connected to the top end flap, the top end flap at least partially overlaps the first side end flap and the second side end flap, and the handle flap is generally aligned with the handle opening.

16. The carton of claim 14, wherein a first upper portion of each of the first side end flap and the second side end flap is foldably connected to a second upper portion of the respective first reinforcing flap and second reinforcing flap, and the first upper portion of each of the first side end flap and the second side end flap is at least partially in face-to-face contact with the second upper portion of the respective first reinforcing flap and second reinforcing flap above the handle opening.

17. The carton of claim 14, wherein the second fold line and the third fold line are interrupted by the handle opening so that the second fold line and the third fold line extend generally upwardly and downwardly from the handle opening.

18. The carton of claim 14, wherein the first side end flap and the second side end flap at least partially overlap the respective first reinforcing flap and second reinforcing flap in the closed end of the carton.

19. The carton of claim 13, wherein the second reinforcing flap has a free edge that is parallel to the third fold line.

20. The carton of claim 19, wherein the free edge of the second reinforcing flap is offset from the third fold line.

21. The carton of claim 1, wherein the free edge of the side flap extends below the lower edge of the reinforcing flap and is parallel to the second fold line.

22. A blank for forming a carton for holding a plurality of articles, the blank comprising:

a plurality of panels comprising at least a top panel and a side panel;

a plurality of end flaps respectively foldably connected to respective panels of the plurality of panels, wherein the plurality of end flaps are for being at least partially overlapped with respect to one another to thereby at least partially form a closed end of the carton formed from the blank, the plurality of end flaps comprising at least a side end flap foldably connected to the side panel along a first fold line;

handle features for forming a handle in the closed end of the carton formed from the blank, the handle features extending in at least the side end flap; and

a reinforcing flap foldably connected to the side end flap along a second fold line, wherein the reinforcing flap is for at least partially overlapping the side end flap for reinforcing the handle when the carton is formed from the blank, a portion of the side end flap having a free edge that is collinear with the second fold line,

the handle comprises a first opening in the side end flap and a second opening in the reinforcing flap, and the first opening and the second opening are for being generally aligned with one another in the closed end when the carton is formed from the blank, and

the side end flap comprises an upper edge and a lower edge opposite the upper edge and the second fold line extends from the upper edge and the lower edge, and the second fold line is interrupted by the first opening and the second opening so that the second fold line extends generally upwardly and downwardly from the first opening and the second opening when the carton is formed from the blank.

23. The blank of claim 22, wherein the second fold line extends from an edge of the first opening and the second opening.

24. The blank of claim 22, wherein a first upper portion of the side end flap is foldably connected to a second upper portion of the reinforcing flap, and the first upper portion is for being disposed at least partially in face-to-face contact with the second upper portion above the first opening and the second opening when the carton is formed from the blank.

25. The blank of claim 24, wherein the reinforcing flap is foldably connected to the side end flap on an opposite side of the first opening and the second opening from the first upper portion and the second upper portion.

26. The blank of claim 22, wherein the side end flap comprises an upper flap connected to a lower flap by at least a connector panel, and the reinforcing flap is foldably connected to the upper flap along the second fold line.

27. The blank of claim 26, further comprising a corner flap foldably connected to the lower flap of the side end flap, and the corner flap is for being folded with respect to the side end flap to extend adjacent a corner of the carton formed from the blank.

28. The blank of claim 22, further comprising an article protection feature in the closed end of the carton, the article protection feature comprising at least a deformation extending in at least the reinforcing flap.

29. The blank of claim 28, wherein the deformation further extends in the side end flap and the second fold line extends at least partially across the deformation.

30. The blank of claim 28, wherein the article protection feature further comprises an aperture in the side end flap adjacent the deformation in the reinforcing flap, the aperture interrupting the second fold line.

31. The blank of claim 30, wherein:

the side panel is a first side panel, the side end flap is a first side end flap, the reinforcing flap is a first reinforcing flap, and the deformation is a first deformation;

the plurality of panels comprises a second side panel, the plurality of end flaps comprises a second side end flap foldably connected to the second side panel, and a second reinforcing flap is foldably connected to the second side flap; and

the article protection feature comprises a second deformation extending in the second reinforcing flap and the second side end flap, wherein the first side end flap and the first reinforcing flap are for at least partially overlapping the second side end flap and the second reinforcing flap so that the first deformation, the second deformation, and the aperture are generally aligned in the closed end of the carton formed from the blank.

32. The blank of claim 22, wherein:

the side panel is a first side panel, the side end flap is a first side end flap, and the reinforcing flap is a first reinforcing flap;

the plurality of panels comprises a second side panel, the plurality of end flaps comprises a second side end flap foldably connected to the second side panel, a second reinforcing flap is foldably connected to the second side flap along a third fold line, the handle features further extend in the second side end flap, and the second reinforcing flap is for at least partially overlapping the second side end flap for reinforcing the handle when the carton is formed from the blank.

33. The blank of claim 32, wherein the second reinforcing flap has a free edge that is parallel to the third fold line.

34. The blank of claim 33, wherein the free edge of the second reinforcing flap is offset from the third fold line.

35. The blank of claim 22, wherein the free edge of the side flap extends below the lower edge of the reinforcing flap and is parallel to the second fold line.

36. A method of forming a carton for holding a plurality of articles, the method comprising:

obtaining a blank comprising a plurality of panels comprising at least a top panel and a side panel, a plurality of end flaps respectively foldably connected to respective panels of the plurality of panels, the plurality of end flaps comprising at least a side end flap foldably connected to the side panel along a first fold line, handle features extending in at least the side end flap, and a reinforcing flap foldably connected to the side end flap along a second fold line, a portion of the side end flap having a free edge that is collinear with the second fold line, the handle comprises a first opening in the side end flap and a second opening in the reinforcing flap, the side end flap comprises an upper edge and a lower edge opposite the upper edge and the second fold line extends from the upper edge and the lower edge, and the second fold line is interrupted by the first opening and the second opening;

positioning the reinforcing flap to at least partially overlap the side end flap;

at least partially forming an interior of the carton by positioning the plurality of panels to form a generally open-ended sleeve; and

at least partially overlapping the end flaps of the plurality of end flaps with respect to one another to at least partially form a closed end of the carton, the at least partially overlapping the end flaps at least partially forming a handle from the handle features in the closed end of the carton, the reinforcing flap at least partially reinforcing the handle and the first opening and the second opening being generally aligned in the closed end.

37. The method of claim 36, wherein a first upper portion of the side end flap is foldably connected to a second upper portion of the reinforcing flap, and the positioning the reinforcing flap comprises positioning the second upper portion to be at least partially in face-to-face contact with the first upper portion above the first opening and the second opening.

38. The method of claim 36, wherein:

the side panel is a first side panel, the side end flap is a first side end flap, and the reinforcing flap is a first reinforcing flap; and

the plurality of panels comprises a second side panel, the plurality of end flaps comprises a second side end flap foldably connected to the second side panel, and a second reinforcing flap is foldably connected to the second side flap along a third fold line, the handle further extending in the second side end flap and the second reinforcing flap;

the method further comprising positioning the second reinforcing flap to at least partially overlap the second side end flap for reinforcing the handle, and the at least partially overlapping the end flaps of the plurality of end flaps further comprises folding the first side end flap and the second side end flap to at least partially form the closed end of the carton.

39. The method of claim 38, wherein the at least partially forming the handle from the handle features comprises forming a handle opening extending in the first side end flap, the second side end flap, the first reinforcing flap, and the second reinforcing flap.

40. The method of claim 39, wherein the plurality of end flaps further comprises a top end flap foldably connected to the top panel, the handle features further comprise a handle flap foldably connected to the top end flap, the at least partially overlapping the end flaps of the plurality of end flaps further comprises folding the top end flap to at least partially overlap the first side end flap and the second side end flap so that the handle flap is generally aligned with the handle opening.

41. The method of claim 38, wherein the second reinforcing flap has a free edge that is parallel to the third fold line.

42. The blank of claim 41, wherein the free edge of the second reinforcing flap is offset from the third fold line.

43. The method of claim 36, wherein the free edge of the side flap extends below the lower edge of the reinforcing flap and is parallel to the second fold line.