HK1146400B - Cartons, blanks, a method of making a partially formed carton and a partially formed carton - Google Patents

Description

Box, blank, method for manufacturing a partially formed box and partially formed box

Technical Field

The present invention relates to a box with a carrying handle for packaging a plurality of articles; a partially formed box in flat form; a blank for forming such a carton or partially formed carton; and a method for their manufacture. More particularly, but not exclusively, the invention relates to a carton, partially formed carton and blank having a reinforced handle and an easily graspable handle.

Background

It is convenient in some retail settings to provide consumers with pre-packaged groups of articles known as multipacks. These multi-pack packages vary in shape and size from packages containing six cans of soft drinks to larger bottled beer packages. All packages need to be easy to lift, strong to ensure safe transport of the packaged goods, and in many cases printed with advertising logos of the packaged goods. It is known to provide cartons for packaging such groups of articles and to provide carrying handles for such cartons to facilitate transportation.

When larger packages containing heavy fragile goods, such as 12, 24 or 48 filled glass bottles, are employed, it is important for dispensing, shelving and consumer safety that the package not tear or fail. Careful attention must be given to the construction of the carrying handle for such cases. The carrying handle must be strong and comfortable in use and must be rigorously tested before any product can enter the market. It is also important that the tank properly protects its contents and is made in a way that is efficient in the use of materials. Environmentally conscious manufacturers need to produce the highest strength tanks using the least amount of material.

It is therefore desirable to provide a bin that can safely support large loads and is safe and easy to carry. It would also be desirable to provide a case having a carrying handle that is comfortable to use and minimizes or prevents chafing of the consumer's hands during use.

Furthermore, it is desirable that such a tank is easy to manufacture, ensuring high productivity, high yield and high quality levels.

The present invention seeks to avoid or at least reduce these and other problems of the prior art by providing a case that includes a carrying handle structure with a reinforcement and that is easy to construct.

Disclosure of Invention

According to a first aspect of the present invention there is provided a carton having a reinforced carrying handle, the carton comprising a series of carton walls including a composite end wall hinged to a top wall, the composite end wall comprising a top end closure panel having first hand gripping means and a first handle reinforcing panel having second hand gripping means, and the second hand gripping means being arranged in alignment with the first hand gripping means, the first handle reinforcing panel being hinged to the top end closure panel by a fold line disposed opposite and at an acute angle to the hinged connection between the top end closure panel and the top wall.

Preferably, the top end closure panel and the first handle reinforcing panel are secured together in face contacting relationship with an adhesive applied to the top end closure panel in the vicinity of the first hand gripping means. Preferably, the adhesive is applied in a linear arrangement on one or both sides of the first hand gripping means and/or in a contoured arrangement similar to the contoured shape of the superimposed first handle reinforcing panel.

Preferably, the linear arrangement comprises a series of strips of glue applied substantially perpendicularly relative to the hinged connection between the top end closure panel and the top wall, and wherein the strip of glue disposed closest to the inclined fold line connecting the first handle reinforcing panel to the top end closure panel is longer than the strip of glue disposed furthest from the inclined fold line connecting the first handle reinforcing panel to the top end closure panel.

According to a second aspect, the present invention provides a carton having a carrying handle, the carton comprising a series of carton walls including a composite end wall connected to a top wall, the carrying handle comprising a first gripping location formed in the composite end wall and a second gripping location formed in the top wall, the first and second gripping locations being formed at least in part by apertures and being arranged relative to each other such that they can be gripped simultaneously by the same hand of a user to facilitate carrying of the carton.

Preferably, a first reinforcing panel is secured in face contacting relation to a portion of said composite end wall juxtaposed said first gripping location and to a portion of said top wall juxtaposed said second gripping location, thereby reinforcing said carrying handle between said first and second gripping locations.

Further, the composite end wall may comprise a top end closure panel hinged to the top wall, wherein the top end closure panel comprises a first gripping aperture formed therein, the first reinforcing panel is hinged to the top end closure panel, is hinged to a first fastening panel and comprises a second gripping aperture, the first reinforcing panel is fastened in overlapping relationship with the top end closure panel such that the first and second gripping apertures are aligned thereby forming the first gripping location, and the first fastening panel is disposed in overlapping relationship with the top wall such that both the top end closure panel and a portion of the top wall are reinforced by the first reinforcing panel.

Preferably, a second reinforcing panel is disposed in face contacting relationship with the first reinforcing panel, and preferably the second reinforcing panel is hinged to the top end closure panel, is hinged to a second fastening panel and includes a third gripping aperture, the second reinforcing panel and second fastening panel being fastened in overlapping relationship to the first reinforcing panel and first fastening panel respectively, thereby reinforcing the carrying handle between the first and second gripping positions.

Preferably, the first fastening panel is hinged to the first reinforcing panel along a first connection and wherein the second fastening panel is hinged to the second reinforcing panel along a second connection, each of the first and second connections comprising a fold line interrupted by a series of elongate apertures, the series of elongate apertures of the first connection being offset from the elongate apertures of the second connection.

Preferably, the second gripping location in the top wall is formed by a finger gripping aperture constructed and arranged to receive a user's thumb, and the first gripping location in the composite end wall is formed by one or more hand gripping apertures each constructed and arranged to receive a portion of a user's hand. Optionally, the first reinforcing panel may be connected to the top end closure panel along a fold line that is at an acute angle to the connection between the top end closure panel and the end wall.

According to a third aspect, the present invention provides a carton having a corner formed by a folded connection between two carton walls, each carton wall being constructed at least in the vicinity of the corner from at least two overlapping layers of material, the folded connection between two carton walls comprising a first fold line interrupted by a first series of elongate apertures and a second fold line interrupted by a second series of elongate apertures, wherein the first series of elongate apertures are offset from the second series of elongate apertures.

According to a fourth aspect of the present invention there is provided a blank for forming a carton having a carrying handle structure, the blank comprising a series of main panels for forming the carton walls, the main panels comprising a top panel for forming a top wall, a top end closure panel for forming part of a composite end wall, and a first reinforcing panel, the top end closure panel being hinged to the top wall and having a first hand gripping means, the first reinforcing panel having a second hand gripping means and being hinged to the top end closure panel by a hinged connection, the hinged connection being provided between the first and second hand gripping means and being at an acute angle to the connection between the top panel and the top end closure panel.

According to a fifth aspect, the present invention provides a blank for forming a carton having a reinforced carrying handle structure, the blank comprising a series of panels for forming a main wall of the carton, the panels comprising a top panel and an end closure panel, the end closure panel comprising means for forming a first gripping location, the top panel comprising means for forming a second gripping location, the first and second gripping locations comprising gripping apertures and being arranged relative to one another such that: when the blank is formed into a carton, a user can simultaneously grasp the edges of the two grasping apertures with the same hand to carry the carton.

According to a sixth aspect, the present invention provides a blank for forming a box, the blank comprising at least two panels for forming a two ply corner of the box, each of the at least two panels comprising a fold line for forming the corner, wherein a first of the fold lines is interrupted by a first series of elongate apertures and a second of the fold lines is interrupted by a second series of elongate apertures, the at least two panels being arranged such that: the first series of elongated apertures are offset from the second series of elongated apertures when the panels overlap to form the two-ply corner.

According to a further aspect of the invention there is provided a method of forming a partially constructed carton from a blank, the blank comprising a series of main panels for forming the carton body, the main panels comprising a top panel, a top end closure panel for forming part of a composite end wall and a first handle reinforcing panel hinged to the top wall and having a first hand gripping means formed therein, the first handle reinforcing panel having a second hand gripping means formed therein and being hinged to the top end closure panel by a hinge connection disposed between the first and second hand gripping means and disposed at an acute angle to the connection between the top panel and the top end closure panel, the method comprising:

(i) applying a fastening means to the inside face of the top end closure panel;

(ii) folding the first handle reinforcing panel along the acute angled hinge connection into face contacting relationship with the top end closure panel to thereby secure the first handle reinforcing panel to the top end closure panel such that the first hand gripping device is aligned with the second hand gripping device in use; and

(iii) securing the main panels together to form the cabinet body.

Preferably, said fastening means is applied to said top end closure panel in the vicinity of said first hand gripping means. Preferably, the fastening means is an adhesive and is applied in a linear arrangement to either side of the first hand gripping means.

According to an optional feature of this aspect of the invention, the linear arrangement comprises a series of strips of glue applied substantially perpendicularly relative to the hinged connection between the top end closure panel and the top wall, and wherein the strip of glue disposed closest to the oblique fold line connecting the first handle reinforcing panel to the top end closure panel is longer than the strip of glue disposed furthest from the oblique fold line connecting the first handle reinforcing panel to the top end closure panel.

According to an optional feature of this aspect of the invention, the fastening means is applied in a profile arrangement similar to the profile shape of the superimposed first handle reinforcing panel.

According to a further aspect of the invention there is provided a partially formed flat form carton having a reinforced carrying handle, the partially formed flat form carton comprising a series of carton walls including a composite end wall hinged to a top wall, the composite end wall comprising a top end closure panel having first hand gripping means and a first handle reinforcing panel having second hand gripping means and the second hand gripping means being arranged in register with the first hand gripping means, the first handle reinforcing panel being hinged to the top end closure panel by a fold line disposed opposite and acutely angled to the hinged connection between the top end closure panel and the top wall.

Preferably, the top end closure panel and the first handle reinforcing panel are secured together in face contacting relationship with an adhesive applied to the top end closure panel in addition to the first hand gripping means.

Preferably, the adhesive is applied in a linear arrangement on one or both sides of the first hand gripping means.

Optionally, the linear arrangement comprises a series of strips of glue applied substantially perpendicularly relative to the hinged connection between the top end closure panel and the top wall, and wherein the strip of glue disposed closest to the oblique fold line connecting the first handle reinforcing panel to the top end closure panel is longer than the strip of glue disposed furthest from the oblique fold line connecting the first handle reinforcing panel to the top end closure panel.

Preferably, the adhesive is applied in a profile arrangement similar to the profile shape of the superimposed first handle reinforcing panel.

Drawings

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

figure 1 shows a plan view of a blank for forming a carton according to a first embodiment of the invention;

FIG. 2 shows an enlarged view of the top end closure panel of the blank of FIG. 1 for forming the first gripping portion of the carrying handle;

FIG. 3 illustrates a first step in constructing a carton having a carrying handle from the blank shown in FIGS. 1 and 2;

FIG. 4 illustrates a second step in constructing a carton having a carrying handle from the blank shown in FIGS. 1 and 2;

FIG. 5 illustrates a flattened tubular sleeve formed from the blank shown in FIGS. 1 and 2;

FIG. 6 shows a fully constructed carton formed from the blank of FIG. 1;

FIG. 7 shows a cross-sectional view of the carrying handle portion of the case shown in FIG. 6 taken along line x-x;

FIG. 8 shows a user lifting the case of FIG. 7 with the two gripping portions of the carrying handle;

FIG. 9 shows an interior view of the utilized carrying handle shown in FIG. 8;

FIG. 10 shows a plan view of a blank for forming a carton according to a second embodiment of the invention;

FIG. 11 shows a plan view of a blank for forming a carton with a carrying handle according to a third embodiment of the invention;

FIG. 12 shows a plan view of a portion of the blank shown in FIG. 11;

FIG. 13 shows an enlarged view of the blank of FIG. 11, focusing on the top end closure panel and the handle reinforcement panel, and showing a first step in the gluing and structuring process;

FIG. 14 illustrates a second step in the gluing and structuring process of the blank of FIG. 11, showing the portion configured as a flat-form carton sleeve;

FIG. 15 illustrates a third step in the gluing and structuring process of the blank of FIG. 11 and showing the tubular sleeve in a flattened form;

FIG. 16 shows an end view of the box after the tubular sleeve of FIG. 15 has been opened and loaded with vials;

FIG. 17 shows the final gluing step of the construction process of the cabinet of the third embodiment; and

fig. 18 shows a fully constructed case according to the third embodiment.

Detailed Description

Fig. 1 shows a blank 10 that can be folded to form a carton 30 (shown in fig. 7). In this embodiment, the blank 10 is formed from cardboard and is arranged such that the carton 30 formed from the blank 10 is a tubular end-loaded carton adapted to hold 48 carafes arranged in six rows of 8 carafes. In other embodiments, the blank 10 is modified based on the illustration to form a carton for containing other types of articles, including various configurations. Moreover, in other embodiments, blank 10, and thus carton 30, is formed from other suitable foldable sheet materials, and/or from more than one type of material. Further, in other embodiments, the blank 10 may be provided in more than one piece.

Blank 10 comprises a plurality of main panels for forming the tubular structure of carton 30. The main panels and structure of the exemplary case 30 will be briefly described. The structure of the carrying handle provided by the present invention will then be described in greater detail with the understanding that the carrying handle is applicable to a wide range of cases and in some embodiments as an insert in the case.

Referring to fig. 1, the blank includes a first side panel 20, a top panel 18, a second side panel 16, a bottom panel 14, and a glue flap 12 connected in a linear series along fold lines 28, 26, 24, and 22. The first and second side panels 20, 16 include fold lines 88, 86 and 84, 82, the fold lines 88, 86 and 84, 82 enabling the first and second side panels 20, 16 to be folded to form a tapered configuration when the blank 10 is formed into the carton 30.

This enables bottles with tapered necks to be securely packed. The fold lines 88, 86 and 84, 82 are entirely optional and may be omitted in embodiments where non-bottle items are packaged. In such an embodiment, the top and bottom panels 18, 14 may be of similar size, while in the present embodiment, the top panel 18 has an area that is smaller than the area of the bottom panel 14. In some embodiments, optional fold lines are used to conform the first and second side panels 20, 16 to the contours of an article having a non-tapered shape.

The blank 10 further comprises a series of end closure panels: first side end closure panels 36a, 36 b; top end closure panels 34a, 34 b; second side end closure panels 32a, 32b and bottom end closure panels 30a, 30 b. The end closure panels 36a, 36b, 34a, 34b, 32a, 32b, 30a, 30b are hinged to adjacent main panels 20, 18, 16, 14 along fold lines 72a, 72b, 70a, 70b, 68a, 68b, 66a, 66b, respectively. Fold lines 86, 88 and 84, 82 continue to the first and second side end closure panels 36a, 36b and 32a, 32b to enable the end closure structure of carton 30 to conform to the tapered shape of the tubular structure. These fold lines are optional.

The bottom end closure panels 30a, 30b include hand gripping apertures 60a, 60b, respectively. The bottom end closure panels 30a, 30b each provide an outer or outer sheet of composite end walls when the blank 10 is assembled into the carton 30. The hand gripping apertures 60a, 60b are provided with handle flaps 62a, 62b that are hinged to the bottom end closure panels 30a, 30b along fold lines 64a, 64 b. These handle flaps 62a, 62b provide cushioning to the user's hands when the edges of the hand gripping apertures 60a, 60b are gripped by the user to carry the carton 30. As with the provision of the cushioned handle flaps 62a, 62b, the arrangement, shape and placement of the hand gripping apertures 60a, 60b is also optional.

The blank 10 is symmetrical about its centre and similar features on both sides of the blank 10 are indicated with the same reference numerals, however the symbol "a" is used to indicate features on the left hand side of the blank 10 and the symbol "b" is used to indicate features on the right hand side of the blank 10.

An exemplary carrying handle of the present invention will now be described with particular reference only to the left hand side of the blank 10, it being understood that a similar carrying handle is provided on the right hand side of the blank 10. In other embodiments, a second carrying handle is not provided. In a further embodiment, carrying handle structures are also provided in the side walls of the cabinet, and a total of four carrying handle structures are provided.

Figure 2 shows an enlarged view of the carrying handle taken from the left hand side of the blank 10. Top end closure panel 34a includes a first hand gripping aperture 58a and is hinged to adjacent first and second handle reinforcing panels 38a and 40a by bifurcated fold lines 50a and 52a, respectively. The first and second handle reinforcing panels 38a and 40a include hand gripping apertures 54a, 56a, respectively, and the hand gripping apertures 54a and 56a overlap the hand gripping aperture 58a when the first and second handle reinforcing panels 38a and 40a are sequentially folded onto the top end closure panel 34 a. Fastening panels 42a, 46a are connected to first and second handle reinforcing panels 38a and 40a along perforated fold lines 44a, 48a, respectively. The hand gripping apertures 60a, 60b, 58a, 56a, 54a are sized to accommodate three or four fingers of a typical user's hand. In other embodiments, the hand gripping apertures may alternatively be sized to receive more or fewer fingers of a user's hand.

Fold lines 50a and 52a diverge from the central top of top end closure panel 34a toward fold line 70a and are each disposed at an acute angle relative to fold line 70 a. In this embodiment modeIn which the acute angle is about 45 deg., as shown by alpha in fig. 2₁And alpha₂As shown. In other embodiments, assuming that the first and second handle reinforcing panels 38a and 40a and the hand gripping apertures 54a, 56a are configured such that the hand gripping apertures 54a, 56a and 58a are disposed in aligned overlapping relationship when folded along the fold lines 50a, 52a, the acute angle α is acute₁And alpha₂Other dimensions are possible and preferably less than 90 deg.. Fold lines 50a and 52a each optionally terminate at a location spaced apart from fold line 70 a. The provision of the sharp-angled fold lines facilitates the use of paperboard adjacent the top end closure panel 34a as a reinforcing panel for the combined end and top panels 18 in a manner that is efficient in the use of material. In other embodiments, it is contemplated that fold lines 50a and 52a converge at a point; in yet another embodiment, it is contemplated that the upper termination of fold lines 50a and 52a are spaced more than in the present embodiment, such that top end closure panel 34a has an upper portion with a trapezoidal shape.

An optional portion of the carrying handle structure is provided in the top panel 18. A finger grip aperture, generally indicated at 74a, is provided. The finger grip aperture includes an opening 80a and a finger relief flap 78a hingedly connected to the top panel by fold line 76 a. The finger grip hole 74a is provided such that: when the case 30 is assembled, the user can grasp the edges of the overlapping hand grasping holes 56a, 54a, 58a, 60a provided in the combined end walls with four fingers and grasp the edges of the finger grasping holes 74a with the thumbs of the same hand. This is shown in fig. 8 and 9. Preferably, the finger grip apertures 74a are positioned between the items such that there is space for the user to insert his thumb. The construction of the carrying handle structure will be described in more detail by describing an exemplary method of assembling a carton from the blank 10.

Preferably, the blank 10 will be provided to a converting mill in a partially assembled form in which the top end closure panels 34a, 34b and the first and second handle reinforcing panels 38a, 40a, 38b, 42b and the fastening panels 42a, 46a, 42b, 46b have been fastened together and the bottom end flap 14 is fastened to the first side wall 20.

The steps for constructing the partially assembled case 30 are shown in fig. 2-5. Glue (G) (or other fastening means) is applied to the first handle reinforcing panel 38a and to the fastening panel 42a, the first handle reinforcing panel 38a and the fastening panel 42a are folded together along the fold line 50a until the first handle reinforcing panel 38a is fastened in face contacting relationship to the top end closure panel 34 a. Thus, the hand gripping holes 54a and 58a become aligned. The fastening panel 42a is thereby adhered or fastened in overlapping face contacting relationship to the portion of the interior face of the top panel 18 between the fold line 70a and the finger grip aperture 74a (see fig. 3). The aperture fold line 44a is thereby disposed in alignment with a portion of the fold line 70 a.

Similarly, glue is applied to the second handle reinforcing panel 40a and the fastening panel 46a, and the second handle reinforcing panel 40a and the fastening panel 46a are then folded together along fold line 52a until the second handle reinforcing panel 40a and the fastening panel 46a are disposed and fastened in overlapping face contacting relationship with the first handle reinforcing panel 38a and the fastening panel 42 a. This configuration is shown in fig. 4, where a three-ply handle structure is formed and the aperture-containing fold line 48a is disposed in alignment with the aperture-containing fold line 44 a.

In this embodiment, the aperture-containing fold lines 44a and 48a are constructed and arranged to have a series of elongated apertures to reduce or limit the amount of paperboard overlap in the vicinity of the connection between the top wall 18 and the top end closure panel 34 a. The series of elongated apertures of the aperture-containing fold line 44a are slightly longitudinally offset relative to the series of elongated apertures of the aperture-containing fold line 48 a. In this embodiment, the aperture-containing fold line 44a includes five similarly sized generally evenly spaced elongated apertures, while the aperture-containing fold line 48a includes four larger elongated apertures and two apertures of approximately one-half size. When the aperture-containing fold lines 44a and 46a overlap such that they are at least partially coextensive, the elongated aperture of fold line 44a is offset from the elongated aperture of fold line 48a in the fold line direction. This allows the apertures, and thus the folded or folded cardboard, to be maximally overlapped in the vicinity of the connection between the top wall 18 and the top end closure panel 34 a. In this manner, the three material layers 34a/18, 38a/44a, and 40a/46a may be folded to form approximately 90 corners when the case 30 is fully constructed. The carrying handle between the two gripping positions (i.e., the hand gripping apertures 58a/56a/54a and the finger gripping apertures 74a) is thereby enhanced. The joint between the top panel 18 and the top end closure panel 34a is also reinforced and strengthened without being hindered by the three overlapping material layers that would otherwise interfere with the reinforcement and strengthening of the joint when the hole-containing fold lines 44a, 48a are not provided. The use of perforated fold lines having staggered perforation arrangements to enable folding of multiple material layers may be applied in other material folding applications than the case carrying handle applications described herein.

Finally, the glue flap 12 is fastened to the inner face of the first side wall 20 using glue or other fastening means, thereby forming a tubular structure of flat form. This is illustrated in fig. 5, which shows two carrying handle configurations.

The partially formed box sleeve is then constructed as an open ended tubular structure and bottles or other articles are loaded from one or both ends. Once the tubular sleeve is fully loaded, the end is closed by constructing a composite end wall. The composite end wall is formed by: folding each top end closure panel 34a, 34b downwardly along fold lines 70a, 70 b; folding each bottom end flap 30a, 30b upwardly along fold lines 66a, 66 b; and securing each bottom end flap 30a, 30b to the outside of the respective top end closure panel 34a, 34 b. In this manner, four layers of reinforced carrying handle structures are formed in each composite end wall, with the outer hand gripping apertures 60a, 60b overlapping the inner hand gripping apertures 54a/56a/58a, 54b/56b/58 b. In other embodiments, the folding order may be changed. In other embodiments, the bottom end flaps 30a, 30b may not include the aperture and may have an edge shaped like one side of the handle apertures 58a, 56a, 54 a. The completed cassette 30 is illustrated in perspective view in fig. 6 and in cross-section through line X-X in fig. 7.

An exemplary manner of using the carrying handle structure is shown in FIG. 8, wherein the user places three or four fingers into and grasps the edge of the hand gripping aperture 60a/58a/56a/54a by pushing the handle flap into the carton 30. The user's fingers/hands are cushioned by the handle flap 62 a. The user also inserts a thumb into the finger grip hole 74a by pushing the finger flap 78a inward of the case 30 (see fig. 9). By providing two gripping locations in adjacent walls (combined end and top walls), respectively, bin 30 is easier to grip than prior art handle arrangements that provide only one gripping location. By reinforcing the corners of the bin 30 between the two gripping positions, a secure arrangement is formed that will not crush or crumple during normal use, and provides a strong and comfortable four-ply handle arrangement when in use.

In other embodiments, the gripping location provided in the top wall 18 is sized to accommodate more than just one finger of a user's hand. In further embodiments, the gripping locations provided in the composite end wall are sized to accommodate less than three or four fingers of a user's hand. In yet another embodiment, the top panel 18 is reinforced in the vicinity of the finger grip hole 74 a. In some embodiments, this reinforcement is provided by the fastening panels 42a, 46 a. The use of finger grip apertures 74a is optional.

A second embodiment of the invention is illustrated by a blank 110 shown in figure 10. Since many of the features of the first embodiment are also present in the second embodiment, these similar features are denoted using the same reference numerals, but increased by a factor of "100" to distinguish between the two embodiments. Since there are many similarities between these two embodiments, only the differences will be described in detail. Since the blank 100 is symmetrical about its centre, the carrying handle of the second embodiment will be described only in relation to the left hand side of the blank 100.

In fig. 10, the blank 110 is shown with panels for forming a carrying handle structure. In this embodiment, three handle reinforcement panels 192a, 138a, 140a are provided. Each handle reinforcing panel 192a, 138a, 140a includes a hand gripping aperture 190a, 154a, 156 a. A fastening panel 196a, 142a, 146a is attached to each handle reinforcing panel 192a, 138a, 140a along a perforated fold line 198a, 144a, 148 a. In this arrangement, the first and second handle reinforcement panels 138a, 140a are connected to the top end closure panel 134a with bifurcated fold lines 152a, 150a, respectively, wherein the bifurcated fold lines 152a, 150a are disposed at an acute angle relative to the fold line 170a connecting the top end closure panel 134a to the top panel 118. The acutely angled fold lines 152a, 150a do not terminate at a common center point, but are separated by a fold line 194a, wherein the fold line 194a connects the third handle reinforcing panel 192a to the top end closure panel 134 a. The construction shown in the second embodiment is advantageous for providing the third reinforcing layer 192 a. When the carton is partially or fully constructed from the blank 110, the third handle reinforcement panel may overlap directly on top of the top end closure panel 134a or be clipped on top of at least one or all of the first and second handle reinforcement panels 138a, 140 a. In this manner, a five-ply carrying handle structure is formed, with four ply handle panels being provided by the top end closure panel and the three handle reinforcing panels 192a, 138a, 140a, and an optional fifth ply handle panel being provided by the bottom end closure panel 130 a.

As described with reference to the first embodiment, the aperture fold lines 144a, 148a, 198a are provided with offset elongate apertures so that the amount of overlapping material in the vicinity of the connection between the top panel 118 and the top end closure panel 134a is minimised. A carrying handle is provided having two grip portions in adjacent walls of the box that can be gripped simultaneously by one hand of a user. The fastening panels 142a, 146a, 196a and the handle reinforcing panels 192a, 138a, 140a reinforce and strengthen the corner portions of the carton between the two gripping portions to provide a secure and comfortable carrying handle suitable for cartons arranged to accommodate loads of up to or greater than 48 bottles.

A third embodiment of the present invention is illustrated in fig. 11 to 18. In these figures, reference numerals beginning with "3" are used to distinguish these features from those of the first embodiment.

Fig. 11 shows a blank 310 that can be folded to form a partially formed carton sleeve 390 (as shown in fig. 15) and a carton 330 (as shown in fig. 18). In this embodiment, the blank 310 is formed from paperboard and is arranged such that: the carton 330 formed from the blank 310 is a tubular end-loading carton adapted to hold 20 carafes arranged in four rows of 5 carafes. In other embodiments, the blank 310 is modified based on the illustration so that it forms a carton 330 containing other types of articles, including various configurations. Further, in other embodiments, the blank 310, and thus the partially formed box sleeve 390 and the box 330, are formed from other suitable foldable sheet materials, such as, by way of non-limiting example, plastic materials, paper or cardboard. In yet another embodiment, the blank 310 may be formed from more than one type of material. Further, in other embodiments, the blank 310 may be provided having more than one piece of material, including a two-piece blank in one embodiment.

The blank 310 includes a plurality of main panels for forming a tubular structure of the carton 330. The main panel and structure of the exemplary case 330 will be briefly described. The two-ply reinforced carrying handle structure provided by the third embodiment of the present invention will then be described in greater detail with the understanding that the carrying handle is applicable to a wide range of cases and is designed in some conceivable embodiments as an insert in the case.

Referring to fig. 11, blank 310 includes first side panel 312, top panel 314, second side panel 316, bottom panel 318, and glue flap 320 connected in a linear series along fold lines 342, 344, 346, and 348. The top panel 314 is smaller in area than the bottom panel 318 and the first and second side panels 312, 316 have a tapered shape defined by fold lines 332a/332b and 336a/336b, respectively. Thus, the carton 330 formed from the blank 310 is shaped to be smaller at its top than at its bottom, thus holding firmly 20 bottles (B), each of which has a neck narrower than its base portion.

The blank 310 also includes a series of end closure panels for forming an end closure structure that closes the ends of the carton 330. The blank 310 is symmetrical about its centre, like features on both sides of the blank 310 being indicated with like reference numerals, however the reference "a" is used to indicate features on the right hand side of the blank 310 and "b" is used to indicate features on the left hand side of the blank 310. The end closure panel includes: first side end closure panels 322a, 322 b; top end closure panels 324a, 324 b; a second side end closure panel 326a, 326b and a bottom end closure panel 328a, 328 b. The end closure panels 322a, 322b, 324a, 324b, 326a, 326b, 328a and 328b are hinged to respective adjacent main panels 312, 314, 316, 318 along respective fold lines 332a, 332b, 334a, 334b, 336a, 336b and 338a, 338 b.

Carrying handles are provided in each end closure structure to facilitate carrying the box 330. The top end closure panels 324a, 324b each include a first handle aperture or hand gripping means 350a, 350 b. Optionally, the hand cushioning flap is hinged to the upper edge 362a, 362b of the first handle aperture 350a, 350 b. The hand cushioning flaps are provided to cushion the user's hands to minimize or prevent chafing of the user's hands when using the first handle apertures 350a, 350b to carry the case 330. In other embodiments, the first handle apertures 350a, 350b take on a variety of sizes and shapes, each enabling a user to insert a hand at least partially therein to grasp the upper edges 362a, 362b of the first handle apertures 350a, 350b to carry the case 330.

Referring now to fig. 12, handle reinforcement panels 354a, 354b are hingedly connected to respective top end closure panels 324a, 324b along fold lines 358a, 358 b. The fold lines 358a, 358b are at acute angles relative to the fold lines 334a, 334b between the top panel 314 and the top end closure structures 324a, 324 b. The angle alpha between fold lines 358a and 334a is shown in figure 11. The handle reinforcement panels 354a, 354b are shaped for stacking against the tapered side end closure panels 322a, 322b along cut lines 356a, 356b such that the material used to form the handle reinforcement panels 354a, 354b is taken within the outer boundaries of the blank 310. In this manner, the handle reinforcement panels 354a, 354b are formed from material that would otherwise be wasted.

A second handle hole 352a, 352b is formed in each handle reinforcing panel 354a, 354 b. The second handle apertures or hand gripping means 352a, 352b are arranged for alignment with the first handle apertures 350a, 350b when the handle reinforcing panels 354a, 354b are folded along the oblique fold line 358a and into overlapping relationship with the top end closure panels 324a, 324 b. Thus, the second handle apertures are oriented at a similar acute angle α relative to the fold lines 358a, 358 b. An example of the geometric arrangement of the second hand hole is shown in fig. 11, where the angle a between fold line 358a and fold line 334a is shown. A similar angle a is also shown between the upper edges 360a, 360b and the fold lines 358a, 358 b. (for ease of illustration, a virtual line 370 is drawn as an extension of the upper edges 60a, 60b of the second handle apertures 352a, 352 b. this virtual line 370 is added to the blank 310 to clearly illustrate the angle α between the second handle aperture 352a and the fold line 358a, but is not formed as part of the blank itself.)

The construction of the carrying handle of the third embodiment of the present invention will now be described with particular reference only to the left hand side of the blank 310, it being understood that a similar carrying handle is provided on the right hand side of the blank 310. Preferably, the blank 310 will be provided to a converting mill in a partially assembled form, with the carrying handle structure at least partially formed, and the first side panel 312 secured to the bottom panel 318 with glue flaps 320. The resulting tubular structure 390 in flat form is shown in fig. 15.

The steps of constructing the partially assembled case 390 are shown in fig. 13 and 14. Preferably, these steps are performed in a linear packaging machine to reduce the need for rotation of the blank 310 during construction. As shown in fig. 13, glues G1, G2, G3, G4, G5, G6, G7 are applied to top closure panel 324 b. Preferably, the glue and/or other adhesive and/or fastening means is applied in a linear arrangement, substantially perpendicular to the fold line 334b and substantially parallel to the direction of travel (X) of the blank 310. In other embodiments of the invention, suitable fastening means other than glue are used to affect the secure attachment of the top end closure panel 324b to the reinforcement panel 354 b. Non-limiting examples of such suitable fastening means include: mechanical fittings, such as nails; pressure or heat activates the adhesive and the adhesive tape.

In other embodiments, the glue or adhesive may take various arrangements, for example, in one contemplated embodiment, only glue strips G1, G5, and G3 are provided. In a further embodiment, only strips of glue G2 and G5 are applied. In yet another embodiment, only strips of glue G1, G2, and G3 are provided. As will be apparent upon reading the above, glue may be provided in various arrangements to achieve a secure bond of the reinforcement panel 354b to the top end closure panel 324 b.

In an alternative embodiment, adhesive means, such as the adhesive arrangement previously described and/or shown in fig. 14, is applied to the reinforcement panel 354b, rather than to the top closure panel 324 b. Advantageously, however, glue is applied to top closure panel 324b to reduce or eliminate glue leaking or dripping on the packaging machine during folding of reinforcing panel 354b along fold line 358 b.

In the illustrated embodiment, the left hand "b" side of the blank 310 (as viewed in fig. 11) provides the leading edge of the carton blank 310 as the carton blank 310 travels through the carton forming machine. It should be understood that since the blank 310 is symmetrical, the right hand "b" side of the blank 310 may alternatively provide the front edge. By having the blanks 310 conveyed through the line in the direction "X", the single gluing device of the machine can be used to apply glue (G1, G2, G3, G4, G5, G6, as previously described) first to the front top end closure panel 324b and then to the rear top end closure panel 324 a. In this way, the gluing and folding equipment required to perform the gluing and folding operations necessary to construct the partially formed flattened tubular case 390 (see fig. 15) is simplified.

Further steps in constructing the partially formed flat tubular case 390 are illustrated in FIG. 14. The bottom panel 318 is folded along fold line 346 and overlaps the second side panel 316 and a portion of the top panel 314 in face contacting relationship. A further gluing operation is performed and a bead or strip of glue G7 is applied to the outside of glue flap 320. In other embodiments, other adhesives or fastening means may be used. Additionally or alternatively, the adhesive strip G7 may be an interrupted strip. The bottom panel 318 and the first side panel 312 are then secured together by folding the first side panel 312 along fold line 342 and folding the first side panel 312 into face contacting relationship with a portion of the top wall 314 and the glue flap 320, and an open-ended tubular structure is formed when the partially-formed case 390 is opened.

The partially constructed flat-form casing 390 can be supplied to a processing paper mill in a flat-form state. At the converting plant, the flat form carton 390 will be continuously fed into the packaging line. Here, the case 390, which is a partially formed flat form, is opened to take a tubular structure and loaded with articles from one or both ends. In this embodiment, the article is a bottle (B), as shown in fig. 16. In alternative embodiments, various types, shapes and sizes of articles are used, such as other primary packaging containers, such as cans (in embodiments where article (B) is not tapered, the first and second side walls 312, 316 will not be tapered, but rather their edges may be shaped to conform to the shape of the other types of articles to be contained within the case 330). To secure the article (B) within the case 330, each end of the case 330 is securely closed. In this embodiment, the top end closure panel 324a, side end closure panels 322a, 326a and bottom end closure panel 328a are folded and fastened together in the normal manner (as shown in FIG. 17). In other embodiments, the top end closure panel 324a, side closure panels 322a, 326a, and bottom end closure panel 328a may be sized and shaped to only partially close the ends of the carton 330, but closed enough to ensure that the articles (B) are securely held within the carton 330.

The completed box structure 330 is shown in fig. 18. The user may then carry the loaded case 330 using the two-ply enhanced carrying handle structure 350a/360a, 350b/360 b.

It will be appreciated that various changes may be made within the scope of the invention, for example, the size and shape of the panels may be adjusted to accommodate different sizes and/or shapes and/or numbers and/or configurations of articles. In other embodiments of the invention, it is contemplated that the size and/or shape of the handle aperture may be adjusted to accommodate fewer or more portions of the user's hand. In yet another embodiment, it is contemplated that the handle aperture may be initially covered by a dust flap to protect the contents of the case, the dust flap being movable to expose the hand gripping aperture or the hand gripping means. It is also contemplated that in another embodiment, two handle reinforcement panels may be provided, each hinged to and adjacent to the top end closure panel 324a along oblique fold lines 358a/358 b. It is also contemplated that various features of the illustrated embodiments may be used in combination with features of other embodiments. For example, the carrying handle of fig. 11-18 may additionally include the finger grip apertures of the first two embodiments in other embodiments.

It should be appreciated that directional references used herein, such as "top," "bottom," "front," "back," "end," "side," "inner," "outer," "upper," and "lower," do not limit the respective panels to such orientation, but are merely used to distinguish the panels from one another. Any such hinge connection or fold line should not be considered to necessarily be only a single fold line; rather, it is contemplated that the hinge connection or fold line may be formed by one or more of the following without departing from the scope of the present invention: short seams, loose lines, or interrupted fold lines.

Claims (20)

1. A carton having a reinforced carrying handle, the carton comprising a series of carton walls including a composite end wall, a top wall, a bottom wall, and a pair of side walls, the composite end wall comprising: a top end closure panel hinged to said top wall and having first hand gripping means; a first handle reinforcing panel having a second hand gripping device disposed in alignment with the first hand gripping device; and a bottom end closure panel hinged to the bottom wall and having third hand gripping means arranged in alignment with the first and second hand gripping means, the first handle reinforcing panel being hinged to the top end closure panel by a fold line disposed opposite the hinged connection between the top end closure panel and the top wall and at an acute angle.

2. The carton of claim 1, wherein a first handle reinforcing panel is secured to an inner face of the top end closure panel and the bottom end closure panel is secured to an outer face of the top end closure panel.

3. The carton of claim 1, wherein a first gripping location is formed in the composite end wall and a second gripping location is formed in the top wall, the first and second gripping locations being formed at least in part by apertures and being disposed relative to each other such that they can be simultaneously gripped by the same hand of a user to facilitate carrying the carton.

4. A carton according to claim 3 wherein a first handle reinforcing panel is secured in face contacting relationship to a portion of the composite end wall juxtaposed the first gripping location and is secured in face contacting relationship to a portion of the top wall juxtaposed the second gripping location.

5. A carton according to claim 4 wherein the first hand gripping means comprises a first gripping aperture formed in the top end closure panel, the first handle reinforcing panel is hinged to a first fastening panel, the second hand gripping means comprises a second gripping aperture formed in the first handle reinforcing panel, the first handle reinforcing panel is fastened in overlapping relationship with the top end closure panel such that the first and second gripping apertures are aligned thereby forming the first gripping location, and the first fastening panel is disposed in overlapping relationship with the top wall such that both the top end closure panel and a portion of the top wall are reinforced by the first handle reinforcing panel.

6. The cabinet as claimed in claim 4 or 5, wherein the combination end wall further includes: a second handle reinforcing panel disposed in face contacting relationship with the first handle reinforcing panel, wherein the second handle reinforcing panel is hinged to the top end closure panel, is hinged to a second fastening panel, and includes an additional gripping aperture, the second handle reinforcing panel and second fastening panel being fastened in overlapping relationship to the first handle reinforcing panel and first fastening panel, respectively.

7. A carton according to claim 6 wherein the first fastening panel is hinged to the first handle reinforcing panel along a first connection and wherein the second fastening panel is hinged to the second handle reinforcing panel along a second connection, each of the first and second connections comprising a fold line interrupted by a series of apertures, the series of apertures of the first connection being offset from the apertures of the second connection.

8. The carton of claim 3 wherein the second gripping location in the top wall is formed by a finger gripping aperture constructed and arranged to receive a thumb of a user and the first gripping location in the composite end wall is formed by one or more hand gripping apertures each constructed and arranged to receive a portion of a hand of a user.

9. A carton according to claim 1 wherein the top wall and the composite end wall define a corner therebetween, the corner comprising a folded connection, each of the top wall and the composite end wall being constructed from at least two overlapping layers of material at least in the vicinity of the corner, the folded connection comprising first and second fold lines, the first and second fold lines being at least partially coextensive with each other, the first fold line being interrupted by a first series of apertures, the second fold line being interrupted by a second series of apertures, wherein the first series of apertures are offset from the second series of apertures.

10. A carton according to claim 9 wherein each aperture of at least one of the first and second series of apertures is of elongate shape and is arranged such that each aperture extends in the direction of the first and second fold lines.

11. A carton according to claim 9 or 10 wherein the first and second series of apertures are constructed and arranged for maximising the overlap of the apertures and thereby minimising the overlap of the folded or collapsed carton in the vicinity of the connection between the two carton walls.

12. The cabinet as claimed in claim 10, wherein the first series of holes are longitudinally offset from the second series of holes.

13. A blank for forming a carton having a carrying handle structure, the blank comprising a series of main panels for forming the walls of the carton, the main panels comprising a top panel for forming a top wall, first and second side panels for forming opposed side walls, a top end closure panel for forming part of a composite end wall, the first and second side panels being hinged respectively to opposed side edges of the top panel, the top end closure panel being hinged to an end edge of the top panel and having first hand gripping means, and a first reinforcing panel having second hand gripping means and being hinged to the top end closure panel by a hinged connection disposed between the first and second hand gripping means and at an acute angle to the connection between the top panel and top end closure panel, each of the first and second side panels has an end edge extending from and continuous with an end edge of the top panel, the first reinforcing panel extending from the hinged connection and lying along the end edge of one of the first and second side panels.

14. The blank of claim 13, comprising: a second reinforcing panel having a third hand gripping means and being hinged to the top end closure panel by a hinge connection provided between the first and third hand gripping means and at an acute angle to the connection between the top panel and top end closure panel.

15. The blank of claim 13, the top end closure panel comprising means for forming a first gripping location, the top panel comprising means for forming a second gripping location, the first and second gripping locations comprising gripping apertures and being arranged relative to each other such that: when the blank is formed into a carton, a user can simultaneously grasp the edges of the two grasping apertures with the same hand to carry the carton.

16. The carton of claim 2, wherein the composite end wall further comprises a pair of side end closure panels, the first handle reinforcing panel being separate from either of the side end closure panels when the carton is in the form of a flat blank.

17. A carton according to claim 16 wherein the first handle reinforcing panel is hinged to a reinforcing panel disposed in face contacting relationship with the inner face of the top wall.

18. The blank of claim 13 wherein the first reinforcing panel extends from the hinged connection to a free side edge of the first reinforcing panel, the first reinforcing panel having a pair of inner and outer end edges each extending between the hinged connection and the free side edge, the inner end edge of the first reinforcing panel extending along the end edge of one of the first and second side panels.

19. The blank of claim 18, wherein the side end closure panel is hinged to an end edge of one of the first and second side panels and extends therefrom to a free end edge disposed along an inner end edge of the first reinforcing panel.

20. The blank of claim 19 wherein the free end edge of the side end closure panel is at least partially collinear with the inner end edge of the first reinforcing panel.