US20150144688A1

US20150144688A1 - Carton with handle and blank therefor

Info

Publication number: US20150144688A1
Application number: US14/414,361
Authority: US
Inventors: Aaron L. Bates; Bradford J. Walling; Matthew E. Zacherle
Original assignee: Meadwestvaco Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2012-07-11
Filing date: 2013-07-11
Publication date: 2015-05-28
Also published as: CL2015000087A1; KR20150032328A; CN104603014B; CA2878915A1; MX2015000451A; EP2872408A1; WO2014011868A1; AU2013290133A1; EP2872408B1; CN104603014A; BR112015000642A2

Abstract

Aspects of disclosure provide a carton (200) having a composite wall (24 a/ 24 b/ 26 b; 124 a/ 124 b/ 126 b; 224 a/ 224 b/ 226 b; 324 a/ 324 b/ 326 b; 424 a/ 424 b /426 b) comprising a handle (58; 158; 258; 358). The handle includes a load bearing structure configured to support a substantially vertical load and configured to support a substantially horizontal load. A first handle flap (68 b; 168 b; 268 b; 368 b; 468 b) is formed in an outer layer of the composite wall and hingedly connected thereto along a first hinge connection. Second and third handle flaps (52 a, 52 b; 152 a, 152 b; 252 a, 252 b; 352 a, 352 b; 452 b) are formed in an inner layer of the composite wall and hingedly connected thereto along second and third hinge connections. The second and third hinge connections are arranged such that they are substantially out of alignment with the first hinge connection and each comprise at least one arcuate fold line (54 b, 57 b; 154 b, 157 b; 254 b, 257 b; 354 b, 357 b).

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Nos. 61/670,377 and 61/702,544, filed Jul. 11, 2012 and Sep. 18, 2012 respectively, which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

This invention relates generally to cartons and, more specifically, to cartons with handles.

BACKGROUND

Cartons for packaging articles such as soft drink cans or bottles are useful to enable consumers to transport and store the articles. The cartons generally include one or more handles to facilitate gripping and carrying the carton to transport the articles. As groups of articles can be heavy, it is desired that the handles are sufficiently supportive for the weight of articles contained in the carton and are comfortable and easy to engage.
Certain known handle designs include a load-bearing edge that is uncomfortable. For example, load-bearing edges that are formed with a cut line can be uncomfortable when pressed against a user's hand. This problem is compounded when the article weight is high.
In WO2010/009293 a carton with reinforced end handles is disclosed in which a handle is configured to provide a load-bearing edge configured to compensate for both horizontal forces and vertical forces that can be applied by the handle or carton to a user's hand. For example, vertical forces may be due to the general weight of the articles and horizontal forces may be due to the weight of the carton when being carried at a slight angle or when swinging, pushing, pulling, or sliding the carton. The load-bearing edge includes top and side edges that the user can engage to move the carton or that can come into contact with a user's hand while engaging the handle. Generally described, the handle includes an aperture or opening defined in a wall of a carton that allows a user to insert fingers or another portion of a hand therethrough.
The handle disclosed in WO2010/009293 also includes an arrangement of handle flaps that are configured to provide cushioning along the load-bearing edge of the handle. A top handle flap is hingedly connected to a top edge of the handle and side handle flaps are hingedly connected to respective side edges of the handle. The top handle flap and the side handle flap are folded toward the interior of the carton when the handle is engaged and hinged connections of the folded handle flaps cushion the load-bearing edge of the handle.
However, for some applications the cushioning provided by the handle and/or the load bearing capability of the handle disclosed in WO2010/009293 is not necessarily as desired. For example, with heavy loads there is a risk that the side handle flaps and/or the top handle flap can tear off from the carton or that insufficient cushioning is provided. The present invention therefore provides a further improvement in the field of package handles.

SUMMARY

The present invention seeks to provide an improvement in handle arrangements for packages over those already known.
According to a first aspect of the invention, for which protection is sought, there is provided a carton having a composite wall comprising a handle that includes a load bearing structure, the load bearing structure is configured to support a substantially vertical load and is configured to support a substantially horizontal load. A first handle flap is formed in an outer layer of the composite wall and is hingedly connected thereto along a first hinge connection. A second handle flap is formed in an inner layer of the composite wall and is hingedly connected thereto along a second hinge connection that is substantially out of alignment with the at least one first arcuate fold line and that comprises at least one arcuate fold line.
The first hinge connection may be defined by a first arcuate fold line; by a first pair of arcuate fold lines disposed proximate to and positioned oppositely to one another; by a first linear fold line; or by a first pair of linear fold lines disposed proximate to and positioned oppositely to one another.
Optionally, the first hinge connection comprises a first pair of linear fold lines. The linear fold lines of the first pair of linear fold lines may be in part parallel to one another and may define therebetween a first shaped panel. The first shaped panel is in some arrangements an approximately hexagonally-shaped panel. The first approximately hexagonally-shaped panel of the load bearing structure may provide a cushion for a user's hand when supporting a substantially vertical load.
Alternatively, the first hinge connection may comprise a first pair of arcuate fold lines. The arcuate fold lines of the first pair of arcuate fold lines may be disposed proximate to and positioned oppositely to each other to define a first substantially leaf-shaped panel therebetween. The first leaf-shaped panel of the load bearing structure may provide a cushion for a user's hand when supporting a substantially vertical load.
Optionally, the second hinge connection comprises a second pair of arcuate fold lines.
Optionally, the arcuate fold lines of the second pair of arcuate fold lines are disposed proximate to and positioned oppositely to each other to define a second substantially leaf-shaped panel therebetween. The second leaf-shaped panel of the load bearing structure may provide a cushion for a user's hand when supporting a substantially horizontal load.
A third handle flap may be formed in the inner layer of the composite wall and may be hingedly connected thereto along a third hinge connection that is substantially out of alignment with the first hinge connection. When provided, the third hinge connection may comprise at least one third arcuate fold line and wherein the at least one third arcuate fold line is substantially out of alignment with the first hinge connection.
Further optionally, the third hinge connection comprises a third pair of arcuate fold lines. The arcuate fold lines of the third pair of arcuate fold lines may be disposed proximate to and positioned oppositely to each other to define a third substantially leaf-shaped panel therebetween. The third leaf-shaped panel of the load bearing structure may provide a cushion for a user's hand when supporting a substantially horizontal load.
In some arrangements, the first hinge connection of the carton may comprise a first pair of linear fold lines. The linear fold lines of the first pair of linear fold lines define a first substantially hexagonally-shaped panel therebetween and the second hinge connection may comprise a second pair of arcuate fold lines and the arcuate fold lines of the second pair of arcuate fold lines may define a second substantially leaf-shaped panel therebetween and converge at either end of the second leaf-shaped panel. A third handle flap may be formed in the inner layer of the composite wall and may be hingedly connected thereto along a third hinge connection. The third hinge connection may comprise a third pair of arcuate fold lines. The arcuate fold lines of the third pair of arcuate fold lines may define a third substantially leaf-shaped panel therebetween and may converge at either end of the third leaf-shaped panel. A notional axis through the first hexagonally-shaped panel may be disposed at an acute angle relative to a notional axis through the converged ends of the second leaf-shaped panel and may be disposed at an acute angle relative to a notional axis through the converged ends of the third leaf-shaped panel.
In other arrangements, the first hinge connection may comprise a first pair of arcuate fold lines. The arcuate fold lines of the first pair of arcuate fold lines may define a first substantially leaf-shaped panel therebetween and may converge at either end of the first leaf-shaped panel. The second hinge connection may comprise a second pair of arcuate fold lines and the arcuate fold lines of the second pair of arcuate fold lines may define a second substantially leaf-shaped panel therebetween and may converge at either end of the second leaf-shaped panel. A third handle flap may be formed in the inner layer of the composite wall and may be hingedly connected thereto along a third hinge connection. The third hinge connection may comprise a third pair of arcuate fold lines and the arcuate fold lines of the third pair of arcuate fold lines may define a third substantially leaf-shaped panel therebetween and may converge at either end of the third leaf-shaped panel. A notional axis through the converged ends of the first leaf-shaped panel is optionally disposed at an acute angle relative to a notional axis through the converged ends of the second leaf-shaped panel and is disposed at an acute angle relative to a notional axis through the converged ends of the third leaf-shaped panel.
The first handle flap is optionally defined in part by the first hexagonally-shaped panel and at least in part by a line of separation that arches upwardly away from each of two ends of the first hexagonally-shaped panel, then downwardly away from the first hexagonally-shaped panel and along a substantially straight line.
Alternatively, the first handle flap is defined in part by the first leaf-shaped panel and at least in part by a line of separation that arches upwardly away from each end of the first leaf-shaped panel, then downwardly away from the first leaf-shaped panel and along a substantially straight line.
The first handle panel may be substantially-crown-shaped.
Optionally, the line of separation that arches upwardly away from each end of the first leaf-shaped panel is shaped to form an edge at each end of the first substantially leaf-shaped panel, the edges at the ends of the first leaf-shaped panel being shaped to abut the adjacently disposed second substantially leaf-shaped and third substantially leaf-shaped panels when the handle is used and the first, second and third handle panels are displaced inwardly of the carton. Said edges may be shaped to fit against the second and third substantially leaf-shaped panels, when those second and third substantially leaf-shaped panels are disposed at an acutely inwardly folded angle.
The first handle flap, second handle flap and the third handle flap are preferably configured to fold as a unit and to retain one another in a folded condition and together provide a substantially continuous hand support structure when folded.
Said edges of the first handle flap may at least partially define a portion of the first handle flap that is configured to be substantially in flat face contact with the second handle flap and third handle flap respectively in the folded condition.
The first handle flap, second handle flap and third handle flap may provide a substantially concave structure in the folded condition.
Optionally, the first handle flap comprises a handle initiating section defined by a substantially trapezoidal weakened arrangement and the second and third handle flaps are shaped and sized such that the substantially trapezoidal weakened arrangement of the first handle flap does not overlap the second and third handle flaps before the handle is folded and deployed.
Optionally, the carton comprises a series of main panels including a top panel and a bottom panel interconnected by first and second side panels to form a substantially tubular structure, at least one of the ends of the tubular structure being at least partially closed by said composite wall and wherein the inner layer of the composite wall comprises first and second side end closure panels hinged to the first and second side panels respectively and disposed side by side in substantially the same plane, the second handle flap being formed from the first side end closure panel and the third handle flap being formed from the second side end closure panel and wherein the outer layer of the composite wall comprises a top end closure panel hinged to the top panel, the first handle flap being formed from the top end closure panel.
Optionally, the second handle flap terminates short of an edge of the inner layer in which the second handle flap is formed.
Optionally, the second and third handle flaps terminate short of an edge of the side end closure panel in which they are formed, wherein
According to another aspect of the disclosure for which protection is sought, there is provided a blank for forming a carton. The blank may comprise an inner and an outer layer for forming a composite wall of the carton. The inner and outer layers may comprise components for forming a handle that includes a load bearing structure, the load bearing structure configured to support a substantially vertical load and configured to support a substantially horizontal load. A first handle flap may be formed in an outer layer of the composite wall and may be hingedly connected thereto along a first hinge connection. A second handle flap may be formed in the inner layer of the composite wall and may be hingedly connected thereto along a second hinge connection that is substantially out of alignment with the first hinge connection and that comprises at least one arcuate fold line.
Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1A is a plan view of a blank for forming a carton, according to a first exemplary embodiment of the disclosure;

FIG. 1B is an enlarged view of a portion of the plan view of FIG. 1A;

FIG. 2A is a plan view of a blank for forming a carton according to a second exemplary embodiment of the disclosure;

FIG. 2B is an enlarged view of a portion of the plan view of FIG. 2A;

FIGS. 2C and 2D are plan views of a composite end wall of a carton formed from the blank of FIG. 2A wherein the overlapping outer top and bottom panels are only shown in dotted outline to illustrate the overlaid arrangement of the various elements of the handle;

FIG. 3 is a perspective partial end view of a carton formed from a blank according to a third embodiment of the invention that is similar but not identical to the blank of FIG. 2A;

FIG. 4 is a partial perspective end view of the exterior of the handle of FIG. 3, the handle being pushed into a folded condition;

FIG. 5 is a partial perspective end view of the exterior of the handle of FIG. 4 in a deployed condition;

FIG. 6 is a partial perspective end view of the interior of the handle of FIG. 5 in an at least partially deployed condition;

FIG. 7 is a plan view of a blank for forming a carton having a handle structure according to a fourth exemplary embodiment of the disclosure;

FIGS. 8 and 9 are plan views of a composite end wall of a carton formed from the blank of FIG. 7 wherein the overlapping outer top and bottom panels are only shown in dotted outline to illustrate the overlaid arrangement of the various elements of the handle; and

FIG. 10 is a plan view of a blank for forming a carton having a handle structure according to a fifth exemplary embodiment of the disclosure.

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. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. 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 components, systems, 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 to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton. In the embodiments detailed herein, the term carton refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for grouping, carrying, and dispensing articles, such as beverage cans or bottles. However, it is contemplated that the teachings of the disclosure can be applied to other containers. Generally described, the illustrated embodiments depict “fully-enclosed end-loading-style” cartons.
A first exemplary embodiment is illustrated in FIGS. 1A and 1B; a second illustrative embodiment is shown in FIGS. 2A-2C; a third illustrative embodiment is shown in FIGS. 3 to 6; a fourth illustrative embodiment is shown in FIGS. 7, 8 and 9; and a fifth arrangement is illustrated in FIG. 10. The blanks 10, 110, 310 of Figures 1A, 1B; 2A, 2B; 8 and 9 respectively are similar to each other and to a blank (not shown) used to form the carton 200 illustrated in FIGS. 3 to 6. The blanks 10, 110, 310 are each suitable for forming a “fully-enclosed end-loading-style” carton 200, such as that shown in FIG. 3. As referred to already, the focus of the invention is a composite handle structure that is formed in at least two overlapping layers of material. The handle structures shown in the Figures vary only in minor ways and therefore the Figures will be referred to collectively in a general description of the invention. The handles shown may be employed in other carton structures, for example tray-style cartons. Additionally, the handles may be utilized in fully-enclosed cartons of the “gable-top” style. A fifth embodiment of the disclosure is shown in FIG. 10, wherein a blank 410 is provided for forming such a gable-topped carton for housing bottles. The differences in this embodiment are described further below.
The blanks 10, 110, 310, 410 are each substantially symmetric such that opposed ends thereof are substantially similar. For clarity, like references have been used with a suffix “a” or “b” affixed to distinguish one end of the blank 10, 110, 310, 410 from the other. The description of an element or group of elements having a suffix “a” is generally suitable for a like-numbered element or group of elements having a suffix “b” and vice versa. In certain instances, only one of like elements may be described unless a description of other or all of the like elements is useful for understanding the invention. The end closure structures in this optionally illustrated embodiment are identical and therefore only one of the composite end closure structures will be described in detail, it being understood that the other end closure structure, and more specifically the handle arrangement therein, is identical. It will be understood that a carton may comprise only one or more than two such handles even though two handle structures are illustrated.
The illustrated blanks 10, 110, 310, 410 and carton 200 are formed of a single sheet of suitable substrate. As used herein, the term “suitable substrate” includes all manner of foldable sheet material including paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. In the illustrated embodiments, a unitary blank is used to form a carton, although it should be recognized that two or more blanks may be used to form a carton. The illustrated blanks are each configured to form a carton for packaging an exemplary arrangement of exemplary articles. It is envisaged that the blanks can be alternatively configured to form a carton for packaging other articles and/or different arrangements of articles.
As used herein, the term “fold line” refers to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line may be a scored line, an embossed line, or a debossed line.
As used herein, the term “severance line” refers to all manner of lines that facilitate separating portions of the substrate from one another or that indicate optimal separation locations. A severance line may be a frangible or weakened line, a cut line, or a slit.
It should be understood that severance lines and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-depth-cuts, a single half-cut, a cut line, an interrupted cut line, an alternating line of fold and half-depth cuts, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can have different degrees of weakness such that the line of perforations can be a fold line and/or a severance line. In other words, the line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.
Referring to FIGS. 1A, 2A and 7, the blanks 10, 110, 310 comprise a series of main panels comprising: a base panel 14, 114, 314 first and second side panels 12, 112, 312, 16, 116, 316 hingedly connected to foldable side edges 36, 38, 136, 138, 336, 338 of the base panel 14, 114, 314; and a top panel 18, 118, 318 hingedly connected to the second side panel 16, 116, 316 along fold line 40, 140, 340. A glue panel 44, 144, 344 is hingedly connected along fold line 42, 142, 342 to the other side edge of the top panel 18, 118, 318. The glue panel 44, 144, 344 is provided for connecting the top panel 18, 118, 318 to the first side panel 12, 112, 312 in forming a part formed carton which can be erected into an open-ended tubular structure.
End closure panels 20 a, 20 b, 22 a, 22 b, 24 a, 24 b, 26 a, 26 b; 120 a, 120 b, 122 a, 122 b, 124 a, 124 b, 126 a, 126 b; 226 b, 222 b, 224 b, 220 b; 320 a, 320 b, 322 a, 322 b, 324 a, 324 b, 326 a, 326 b; are hingedly connected to foldable end edges 31 a, 31 b, 33 a, 33 b, 35 a, 35 b, 37 a, 37 b; 131 a, 131 b, 133 a, 133 b, 135 a, 135 b, 137 a, 137 b; 331 a, 331 b, 333 a, 333 b, 335 a, 335 b, 337 a, 337 b; of the first side panel 12, 112, 212, 312, base panel 14, 114, 214, 314, second side panel 16, 116, 216, 316, and top panel 18, 118, 218, 318 respectively. The end closure panels 20 a, 22 a, 24 a, 26 a; 120 a, 122 a, 124 a, 126 a; 320 a, 322 a, 324 a, 326 a co-operate together to form a composite end closure structure for the tubular carton formed from the main panels 12, 14, 16, 18; 112, 114, 116, 118; 212, 214, 216, 218; 312, 314, 316, 318. The end closure panels 20 b, 22 b, 24 b, 26 b; 120 b, 122 b, 124 b, 126 b; 220 b, 222 b, 224 b, 226 b; 320 b, 322 b, 324 b, 326 b co-operate together to form another composite end closure structure for the tubular carton.
The blanks 10, 110, 310 and carton 200 further include elements that combine to provide handles 58, 158, 258, 358 (also referred to as handle arrangements 58, 158, 258, 358 and handle structures 58, 158, 258, 358) in the end closure structures at opposed ends of a carton formed from a blank 10, 110, 310. The top- end closure panel 26 b, 126 b, 226 b, 326 b includes a first outer handle flap 68 b, 168 b, 268 b, 368 b (best viewed in FIGS. 1 B, 2B and 3). The first handle flap 68 b, 168 b, 268 b, 368 b is movable out of the plane of the top end closure panel 26 b, 126 b, 226 b, 326 b to form a handle aperture, through which a user may insert part of their hand (H) (see FIG. 4) for grasping a carton 200 by a handle structure 258.
The first outer handle flap 68 b, 168 b, 268 b, 368 b comprises an arrangement of fold lines, weakened lines and cut lines. The first outer handle flap 68 b, 168 b, 368 b (also referred to as top handle flap 68 b, 168 b) is hingedly connected to the top end closure panel 26 b, 126 b, 226 b, 326 b proximate an upper portion of the handle aperture by virtue of a first hinge connection. Optionally, in some embodiments, the first hinge connection is formed as or may comprise an arcuate fold line 60 b, 160 b, 260 b, 360 b. The first hinge connection may also include a further optional arcuate fold line 61 b, 161 b, 261 b, 361 b that is disposed proximate to and opposite to the arcuate fold line 60 b, 160 b, 260 b, 360 b. Between the arcuate fold lines 60 b, 61 b; 160 b, 161 b; 260 b, 261 b; and 360 b, 361 b a first, at least substantially or approximately, elliptically-shaped panel 62 b, 162 b, 362 b is thereby defined. The elliptically shaped panel 62 b, 162 b; 362 b may also be described as being a leaf-shaped panel having two converging arc-shaped sides. Preferably, the arcuate fold lines 60 b, 61 b; 160 b, 161 b; 260 b, 261 b; and 360 b, 361 b converge such that the, at least substantially or approximately, elliptically-shaped panel 62 b, 162 b, 362 b (or leaf-shaped panel 62 b, 162 b, 362 b) has pointed rather ends. In other envisaged embodiments, the converging arcuate fold lines 60 b, 61 b; 160 b, 161 b; 260 b, 261 b; and 360 b, 361 b may converge at a point or may not quite meet one another and may converge at a rounded portion or straightened edge portion. It is preferred that the further fold line 61 b, 161 b, 261 b, 361 b is provided to pre-determine where the first handle panel 68 b, 168 b, 268 b, 368 b will crease when in use. However, the further fold line 61 b, 161 b, 261 b, 361 b is optional. The first arcuate fold line 60 b, 160 b, 260 b, 360 b and further fold line 61 b, 161 b, 261 b, 361 b when provided, together form a first pair of fold lines.
The first handle flap 68 b, 168 b, 368 b is defined in part by the first substantially-elliptically shaped panel 62 b, 162 b, 362 b and in part by a line of separation 81 b, 181 b, 281 b, 381 b. The line of separation 81 b, 181 b, 281 b, 381 b may be a continuous cut line (as in FIG. 2A); a continuous perforate line; or a cut-line or perforate line interrupted by one or more connecting nick portions 73 b, 273 b, 373 b as in FIGS. 1B, 3 and 7). Optionally, the line of separation 81 b, 181 b, 281 b, 381 b extends from inwardly curved terminations 66 b, 64 b; 166 b, 164 b; 364 b, 366 b; disposed below and proximate to ends of the first substantially-elliptically shaped panel 62 b, 162 b, 362 b. The ends of the first substantially-elliptically shaped panel 62 b, 162 b, 362 b are in some arrangements defined by the points at which the weakened lines 60 b, 61 b; 160 b, 161 b; 260 b, 261 b, 360 b, 361 b converge. From the terminations 66 b, 64 b; 166 b, 164 b; 366 b, 364 b the line of separation 81 b, 181 b, 281 b, 381 b curves upwardly and arcuately.
In the first illustrated embodiment, the line of separation 81 b does not extend above the first fold line 60 b. It extends along a curvilinear section with the line of separation extending away from each end of the first substantially-elliptically shaped panel 62 b. It then curves back inwardly (proximate to a connecting nick 73 b) and toward a linear section. The line of separation 81 b is preferably, but nevertheless optionally, symmetrical. The first handle panel 68 b optionally comprises three or more linked bulbous curved sections.
In the second, third and fourth illustrated embodiments, the lines of separation 181 b, 281 b, 381 b again do not extend above the first fold line 160 b, 260 b, 360 b. The lines 181 b, 281 b, 381 b then follow a curvilinear section wherein the lines of separation 181 b, 281 b extend toward each end of the first substantially-elliptically shaped panel 162 b, 262 b, 362 b and curve more substantially inwardly (proximate a connecting nick 273 b, 373 b in the third and fourth embodiments) toward a linear section. The lines of separation 181 b, 281 b, 381 b are each symmetrical. The first handle panel 168 b, 268 b, 368 b again optionally comprises three or more linked bulbous curved sections.
An optional weakened arrangement is provided: in part to assist in initiating the separation of the first handle flap 68 b, 168 b, 268 b, 368 b from the top end closure panel 26 b, 126 b, 226 b, 326 b; and in part to assist with the inward folding of the first handle flap 68 b, 168 b, 268 b, 368 b when the handle 58, 158, 258, 358 is deployed.
The optional weakened arrangement comprises a linear fold line 76 b, 176 b, 376 b disposed above and substantially parallel to the linear section of line of separation 81 b, 181 b, 281 b, 381 b. The optional weakened arrangement of the first, second and third embodiments optionally comprise a substantially trapezoidal weakened arrangement of: fold line 80 b, 180 b; and angled cut lines 75 b, 175 b which define portions 78 b, 72 b, 74 b and 70 b (see FIG. 1B); and 178 b, 172 b, 174 b and 170 b (see FIG. 2B). The cut lines 75 b, 175 b and fold line 80 b, 180 b may be omitted. Indeed, in the fourth embodiment only horizontal fold line 376 b is provided for assisting with the inward folding of the first handle flap 368 b. In yet further envisaged embodiments horizontal fold line 76 b, 176 b, 376 b is not provided.
The first handle flap 68 b, 168 b, 368 b is foldable about the first hinge connection including the first arcuate fold line 60 b, 160 b, 260 b, 360 b, inwardly of the top end closure panel 26 b, 126 b, 226 b, 326 b. The first substantially elliptically-shaped panel 62 b, 162 b, 362 b provides a cushioned edge of a three-dimensional load-bearing structure. The three-dimensional load-bearing structure is further formed and supported by inner elements namely second and third handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 362 b which will now be described with reference to FIGS. 1A, 2A, 2B, 2C, 7, 8 and 9.
Each second and third handle flap 46 b, 52 b; 146 b, 152 b; 346 b, 352 b (also referred to as inner handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 352 b) is hinged to an inner ply of material of the carton (in this arrangement side end closure panels 20 b, 24 b; 120 b, 124 b; 220 b, 224 b; 320 b, 324 b) by a second hinge connection and by a third hinge connection. The second hinge connection may include a second fold line 48 b, 148 b, 348 b and the third hinge connection may include a third fold line 54 b, 154 b, 354 b. Optionally, the second and third fold lines 48 b, 148 b; 54 b, 154 b; 348 b, 354 b are arcuate. In other embodiments, the second and third fold lines 48 b, 148 b, 54 b, 154 b; 348 b, 354 b are at least substantially linear or straight.
Preferably, however the second and third fold lines 48 b, 148 b, 54 b, 154 b, 348 b, 354 b are arcuate and the second and third hinge connections further respectively include additional arcuate fold lines 47 b, 147 b, 57 b, 157 b, 347 b 357 b disposed proximate to and opposite to the second and third arcuate fold lines 48 b, 148 b, 54 b, 154 b, 348 b, 354 b. At least substantially-elliptically-shaped panels 50 b, 150 b, 350 b are formed between the second arcuate fold line 48 b, 148 b, 348 b and the further arcuate fold line 47 b, 147 b, 347 b (also referred to as a second pair of fold lines). At least substantially-elliptically-shaped panels 56 b, 156 b, 356 b are formed between the third arcuate fold line 54 b, 154 b, 354 b and the further arcuate fold line 57 b, 157 b, 357 b. The panels 50 b, 150 b, 350 b 56 b, 156 b, 356 b may also be described as being leaf-shaped panels.
Preferably, the arcuate fold lines 47 b, 147 b, 347 b, 57 b, 157 b, 357 b converge such that the at least substantially or approximately elliptically-shaped panels 50 b, 150 b, 350 b, 56 b, 156 b, 356 b (or leaf-shaped panels 50 b, 150 b, 350 b, 56 b, 156 b, 356 b) have pointed (rather than rounded) ends. In other envisaged embodiments, the converging arcuate fold lines 48 b/47 b, 148 b/147 b, 348 b/347 b may converge at a point or may not quite meet one another and may converge toward a rounded portion or straightened edge portion. Otherwise the second and third handle flaps 46 b, 52 b; 146 b, 152 b are free of connection from the adjacent side end closure panels 20 b, 24 b; 120 b, 124 b; 220 b, 224 b, 320 b, 324 b or at least separable therefrom (by separation of a perforation or connecting nick) so that the second and third handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 352 b can be folded out of the plane of the adjacent side end closure panels 20 b, 24 b; 120 b, 124 b; 220 b, 224 b, 320 b, 324 b and inwardly of the carton, in co-operation with the folding of the partially overlapping first handle flap 68 b, 168 d, 368 d.
Advantageously, in the fourth embodiment (FIGS. 7, 8 and 9), the second and third handle flaps 346 b, 352 b optionally terminate short of (in other words in-set from) the outer edge of the side end closure panel 320 b, 324 b in which they are formed. Additionally or alternatively, the second and third handle flaps 346 b, 352 b are separated by a shaped aperture from an edge 351 b, 353 b of the adjacent side end closure panel 320 b, 326 b. These features may enable the second and third handle flaps 346 b, 352 b to be more easily folded, inwardly, of said side end closure panels 320 b, 324 b whilst at the same time ensuring that the blank 310 can be handled by processing machinery.
In the first and second embodiments weakened line 51 b, 53 b, 151 b, 153 b is substantially a cut line having an optional connecting nick portion (not readily visible in FIGS. 1A and 2A). This connecting nick portion maintains the second and third handle panels 46 b, 52 b, 146 b, 152 b connected to and in the same plane as the side end closure panels 20 b, 24 b, 120 b, 124 b so that those panels 20 b, 24 b, 120 b, 124 b, 46 b, 52 b, 146 b, 152 b are maintained, together, in co-planar alignment. As such the panels 20 b, 24 b, 120 b, 124 b, 46 b, 52 b, 146 b, 152 b retain a degree of stiffness so that manipulation and handling of the blanks 10, 110 through high-speed processing lines is not hindered. For example the processing may be hindered if the second or third handle flap 46 b, 52 b, 146 b, 152 b, became disconnected from the side end closure panels 20 b, 24 b, 120 b, 124 b (by breaking of the nick portion along weakened line 51 b, 53 b, 151 b, 153 b).
However, as is discussed below, upon operation of the handle it is required that the second and third handle flaps 46 b, 52 b, 146 b, 152 b, 346 b, 352 b fold inwardly of the carton and fold about the pre-defined folding lines 48 b, 54 b, 148 b, 154 b, 348 b, 354 b. Depending upon the thickness and density of the substrate used to form the blank 10, 110 and the size (strength) of the connecting nick portion that maintains a connection between the second and third handle flaps 46 b, 52 b, 146 b, 152 b and the side end closure panel 20 b, 24 b, 120 b, 124 b, the force required to break the connection (and allow the second and third handle flaps 46 b, 52 b, 146 b, 152 b to fold as required) may in some arrangements cause instead, the second and third handle flaps 46 b, 52 b, 146 b, 152 b to fold in a different place. In such an event, the second and third handle flaps 46 b, 52 b, 146 b, 152 b may not provide the requisite load bearing and cushioning.
Therefore, in the fourth embodiment, the second and third handle flaps 346 b, 352 b are entirely detached from edge 351 b, 353 b of the side end closure panels 320 b, 324 b. To ensure that the second and third handle panels 346 b, 352 b do not impede the automated processing of the blank 310, the second and third handle flaps 346 b, 352 b are (proportionally) smaller in size than the second and third handle flaps 46 b, 52 b, 146 b, 152 b of the first and second embodiments of the disclosure and/or are optionally inset from a notional boundary or edge of side end closure panel 320 b, 324 b.
The second and third handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 352 b are optionally sized and shaped so that their substantially elliptically-shaped panels 50 b, 56 b, 150 b, 156 b, 350 b, 356 b are disposed at an acute angle relative to the first substantially elliptically-shaped panel 62 a, 162 a, 362 a. See FIGS. 2C, 2D, 8 and 9. In particular see the notional axes A1, A2, A3 shown through each of the first, second and third at least substantially elliptically-shaped panels 162 a, 150 a and 156 b in FIGS. 2C and 2D. The axis A2 is disposed at an optional acute angle of about 45° relative to axis A1; the axis A3 is disposed at an optional acute angle of about 45° relative to axis A1.
The second and third handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 352 b are optionally sized and shaped so that a portion of the second and third handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 352 b is disposed in underlying relationship with the first handle flap 68 b, 168 b, 368 b.
The second and third handle flaps 46 b, 52 b; 146 b, 152 b are optionally sized and shaped so that their elliptical portions 50 b, 56 b, 150 b, 156 b, 350 b, 356 b are not disposed in underlying relationship with the first elliptical portion 162 b of the first handle flap 168 b (see FIGS. 2C, 8 and 9 for an illustration of this albeit of the other end of the carton labeled with suffix ‘a’).
The second and third handle flaps 46 b, 52 b; 146 b, 152 b are optionally sized and shaped so that the trapezoidal shaped weakened arrangement 80 b, 180 b, 75 b, 175 b, 80 a, 180 a, 75 a, 175 a, provided to assist in initiating the displacement of the first handle flap 68 a, 68 b, 168 a, 168 b, is not in overlaying superposition with the second and third handle flaps 46 b, 52 b; 146 b, 152 b.
The second and third handle flaps are optionally sized and shaped so that a curved outer edge thereof, 90 b, 91 b, 190 a, 190 b, 390 a, 390 b (see FIGS. 1A, 2A, 2C and 7) is in alignment with a portion of the line of separation 81 b, 181 b, 281 b, 381 b of the first handle flap 68 b, 168 b, 268 b, 368 b or at least proximate or closely positioned relative thereto. As such, in the first illustrated embodiment where the curved portion of the line of separation 81 a curves towards the nick portion 73 a, so the corresponding part 90 b of the second and third handle flaps 46 b, 52 b are similarly shaped. In the second, third and fourth illustrated embodiments, where the curvilinear portion of line of separation 181 b, 281 b, 381 b straightens towards the bottom of the first handle flap 168 b, 268 b, 368 b so the corresponding part 190 a, 290 a, 390 a of the second and third handle flaps 146 b, 152 b, 246 b, 252 b, 346 b, 352 b are similarly shaped (see FIGS. 2B, 2C, 3, 6, 7, 8 and 9).
A carton 200 is constructed from a blank similar to blanks 10, 110, 310, optionally in a typical manner. A manufacturing glue seam is formed by affixing glue panel 44, 144, 344 to the inside face of first side panel 12, 112, 312 such that a part-formed flat-folded blank is formed. In this part formed condition the flat-form carton may be transported to a converting plant whereat it will be erected into an open-ended tubular structure and loaded with articles through one or both ends. The ends are then closed by forming the composite end wall structures by first folding the side end closure panels 20 b, 24 b, 120 b, 124 b, 220 b, 224 b, 320 b, 324 b and then the bottom end closure panel 22 b, 122 b, 222 b, 322 b and then finally the top end closure panel 26 b, 126 b, 226 b, 326 b (as can be seen from FIGS. 2C and 2D albeit from the other end of the carton).
To use the handle 58, 158, 258, 358, first of all, if connecting nick portions 73 b, 273 b, 373 b are provided, they must be broken by applying an inwardly directed force to the first handle flap 68 b, 368 b. Once these nicks (or other connections provided along line of separation 81 b, 281 b, 381 b) are broken, the first handle flap 68 b, 268 b, 368 b can be displaced out of the plane of the top end closure panel 26 b, 226 b, 326 b. By applying further inward force a user will cause the first handle flap 68 b, 168 b, 368 b to push the second and third handle flaps 46 b, 52 b, 146 b, 152 b, 246 b, 352 b, 346 b, 352 b inwardly of the carton 200. The three at least substantially elliptically-shaped panels 62 b, 50 b, 56 b; 162 b, 150 b, 156 b; 362 b, 350 b, 356 b all move inwardly relative to the plane of the top or side end closure panel 26 b, 20 b, 24 b; 126 b, 120 b, 124 b; 386 b, 320 b, 324 b from which they are formed until the shape of the arcuate fold lines 60 b, 48 b, 54 b; 160 b, 148 b, 154 b; 360 b, 348 b, 354 b and/or the shape of the panels 62 b, 50 b, 56 b; 162 b, 150 b, 156 b; 362 b, 350 b, 356 b resists further inward folding and together the three at least substantially elliptically-shaped panels 62 b, 50 b, 56 b; 162 b, 150 b, 156; 362 b, 350 b, 356 b form a supported three-dimensional load bearing structure which a user can comfortable and securely grasp for lifting and carrying the carton 200. Furthermore, the risk of failure through tearing of the inner second and third handle flaps 46 b, 52 b; 146 b, 152 b; 346 b, 352 b is reduced because of the use of one or more arcuate-shaped fold lines 60 b, 61 b, 48 b, 47 b, 54 b, 57 b; 160 b, 161 b, 148 b, 147 b, 154 b, 157 b; 360 b, 361 b, 348 b, 347 b, 354 b, 357 b. In the set-up handle structure a portion of the first handle flap 68 b, 168 b, 368 b below the elliptical panel 62 b, 162 b, 362 b is folded substantially convexly.
As referred to above, shaped edges 81 b, 181 b, 381 b (defining the bulbous portions curving from the terminations 64 b, 66 b; 164 b, 166 b; 364 b, 366 b) of the first handle flap 68 b, 168 b, 368 b allow the first substantially elliptical panel 62 b, 162 b, 362 b to rest and fit against the second and third substantially elliptical panels 50 b, 56 b, 150 b, 156 b, 350 b, 356 b whilst allowing at least some of the remainder of the first handle flap 68 b, 168 b, 368 b (below panel 62 b, 162 b, 362 b) to fold, substantially opposite to, (albeit somewhat convexly), the composite end closure structure 26 b, 24 b, 22 b, 20 b; 126 b, 124 b, 122 b, 120 b; 326 b, 324 b, 322 b, 320 b. The remainder of the first handle flap 68 b, 168 b, 368 b is spaced from the composite end closure structure by a distance that is at least approximately the width of the first elliptical panel 62 b, 162 b, 362 b. In FIG. 6 a view of the carton 200 from the interior is shown wherein the folded handle 258 is illustrated. It will be appreciated that in use, the handle 258 may be further folded, such that the handle flap 268 b may be folded further towards the top end closure panel 226 b.
Referring now to the handle structure shown in FIG. 10, the blank 410 is again substantially symmetric and opposed ends thereof are substantially similar. For clarity, like references have been used with a suffix “a” or “b” affixed to distinguish one end of the blank 410 from the other. The description of an element or group of elements having a suffix “a” is generally suitable for a like-numbered element or group of elements having a suffix “b” and vice versa. In certain instances, only one of like elements may be numbered and/or described. Specifically, to avoid obscuring the drawing, certain elements of the handle structure are numbered only on one end of the blank 410 and other elements of the handle structure are only numbered on the other end of the blank 410.
In FIG. 10, there is shown a blank 410, wherein the top panel 418 is smaller in area than the bottom panel 414. The blank 410 forms a gable topped style carton and the side end closure flap 420 a, 424 a, 420 b, 424 b are configured to taper to provide a shaped carton (not shown) that more tightly encases a matrixed arrangement of bottles (not shown) or other articles having a top portion that is smaller than a bottom portion. As is known, a diamond-shaped fold arrangement 430 a/431 a, 435 a/437 a, 430 b/431 b, 435 b/437 b, is used to adjoin the tapering side end closure flaps 420 a, 424 a, 420 b, 424 b to the first and second side panels 412, 416 respectively. The aforedescribed features of blank 410 are entirely optional and are not significant to the operation of the handle structure shown therein. It will be recognized that application of the handle structure of the fifth embodiment illustrated in FIG. 10 is not limited to being in a blank for forming a gable-top style carton and it is explicitly envisaged that the handle structure illustrated in FIG. 10 may be utilized in a square-style fully enclosed carton as shown in earlier embodiments and in other styles of carton as well, for example tray-style cartons.
The handle structure of the fifth illustrated arrangement differs in that the first hinge connection for the first handle flap 468 a comprises a first pair of linear fold lines 460 b, 461 b. First and second linear fold lines 460 b, 461 b of the first pair of linear fold lines 460 b, 461 b are substantially parallel to one another and defined therebetween an approximately hexagonally-shaped panel 462 b.
Angled end portions 465 b, 463 b of the upper most, first fold line 460 b connect the first fold line 460 b to a line of separation. The line of separation is defined by a cut-line or perforate line interrupted by one or more connecting nick portions.
The line of separation does not extend above the first fold line 460 b. It extends along a curvilinear section with the line of separation extending away from each end of the first approximately hexagonal shaped panel 462 b. It then curves back inwardly (proximate to a connecting nick) and terminates a linear section. The line of separation is symmetrical. The first handle panel 468 b optionally comprises two bulbous curved sections connected by a flattish top. The second fold line 461 d terminates at each of its ends on a bulbous part of the line of separation and as such, the approximately hexagonally-shaped panel 462 b is defined by four fold lines and two cut edges. The approximately hexagonally-shaped panel 462 b can move inwardly relative to the end closure panel 426 b and provides a cushion for a user's hand.
Similar to the previous illustrated embodiments, an optional weakened arrangement is provided: in part to assist in initiating the separation of the first handle flap 468 b from the top end closure panel 426 b and in part to assist with the inward folding of the first handle flap 468 b when the handle 58, 158, 258, 358 is deployed.
In the fifth illustrated embodiment, the optional weakened arrangement comprises a linear fold line 476 b disposed above and substantially parallel to the linear section of line of separation. The linear fold line 476 b is interrupted by a substantially semi-circular or arcuate cut line which defines a substantially semi-circular or arcuate aperture or cut-out portion 472 b. The aperture or cut-out portion 472 b enables a user to grasp the handle flap 468 a, break the connecting nick portions and fold the handle flap 468 a about linear fold line 476 b, first linear fold line 460 b and about second linear fold line 461 b. The first approximately horizontally-shaped panel 462 b provides a cushioned edge of a three-dimensional load-bearing structure. The three-dimensional load-bearing structure is further formed and supported by inner elements namely second and third handle flaps 452 b, which are similar to those already described in respect of FIGS. 7, 8 and 9 and are not therefore described in greater detail.
To ensure that the second and third handle panels 452 b do not impede the automated processing of the blank 410, the second and third handle flaps 452 b are (proportionally) smaller in size than the second and third handle flaps 452 b of the first and second embodiments of the disclosure and/or are optionally inset from a notional boundary or edge of side end closure panel 420 b, 424 b.
The second and third handle flaps 452 b are optionally sized and shaped so that their substantially elliptically-shaped or leaf-shaped panels are disposed at an acute angle relative to the first substantially hexagonally-shaped panel 462 a. The second and third handle flaps 452 b are optionally sized and shaped so that a portion of them is disposed in underlying relationship with the first handle flap 468 b.
A carton (not shown) is constructed from a blank 410 in a known manner and using a similar sequence to that described above.
The handle is used in the same way as described above, albeit with the substantially hexagonally shaped panel 462 b and substantially elliptically-shaped panels of the inner handle flaps 452 b moving inwardly, together, relative to the plane of the top or side end closure panel 426 b, 420 b, 424 b from which they are formed until the shape of the first, second and third pairs of fold lines and/or the shape of the panels 462 b, 456 a, resists further inward folding and together the three shaped panels 462 b, 456 b form a supported three-dimensional load bearing structure which a user can comfortable and securely grasp for lifting and carrying the carton.
The present invention has been illustrated in relation to particular embodiments which are intended in all respects to be illustrative rather than restrictive. Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope of the invention. For example, as used herein, directional references such as “top”, “base”, “bottom”, “end”, “side”, “inner”, “outer”, “upper”, “middle”, “lower”, “front” and “rear” do not necessarily limit the respective walls of the carton to such orientation, but merely serve to distinguish these walls from one another. Any reference to hinged connection should not be construed as necessarily referring to a junction including a single hinge only; indeed, it is envisaged that hinged connection can be formed from one or more potentially disparate means for hingedly connecting materials.
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. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.
In other embodiments where the first hinge connection comprises one linear fold lines, it is envisaged that a shaped panel may be defined between that linear fold line and another fold line that may be linear or arcuate. It is envisaged therefore that the first shaped panel may be substantially rectangular or segment-shaped as further non-limiting examples.
It will be recognized that as used herein the term arcuate may mean curved, curvilinear, partially or approximately curved. A series of straight short fold lines arranged in a non-linear substantially curved manner can create an arcuate fold line. Arcuate may mean semi-circular, but may also mean non-circular, for example, partially elliptical, partially oval and otherwise curved or radiused.

Claims

1. A carton having a composite wall comprising a handle that includes a first handle flap formed in an outer layer of the composite wall and is hingedly connected to the outer layer along a first hinge connection, and a second handle flap formed in an inner layer of the composite wall and hingedly connected to the inner layer along a second hinge connection, wherein the second hinge connection is substantially out of alignment with the first hinge connection and comprises a pair of inner arcuate fold lines.

2. The carton according to claim 1 wherein the first hinge connection comprises one selected from the group consisting of:

(i) an outer arcuate fold line;

(ii) a pair of outer arcuate fold lines disposed proximate to and positioned oppositely to each other;

(iii) a linear fold line; Grand

(iv) a pair of linear fold lines disposed proximate to and positioned oppositely to each other.

3. (canceled)

4. (canceled)

5. The carton according to claim 1 wherein the first hinge connection comprises a pair of outer arcuate fold lines, wherein the outer arcuate fold lines of the pair are disposed proximate to and positioned oppositely to each other to define a first substantially leaf-shaped panel therebetween, and wherein the first leaf-shaped panel provides at least part of a load bearing structure.

6. (canceled)

7. The carton according to claim 1 wherein the inner arcuate fold lines of the pair are disposed proximate to and positioned oppositely to each other to define a second substantially leaf-shaped panel therebetween, and wherein the second leaf-shaped panel provides at least part of the load bearing structure.

8. The carton according to claim 1 wherein the handle further includes a third handle flap which is formed in the inner layer of the composite wall the third handle flap is hingedly connected to the inner layer along a third hinge connection.

9. The carton according to claim 8 wherein the third hinge connection comprises at least one inner arcuate fold line and wherein the at least one inner arcuate fold line of the third hinge connection is substantially out of alignment with the first hinge connection.

10. (canceled)

11. (canceled)

12. The carton according to claim 1 wherein the inner arcuate fold lines of the pair define a second substantially leaf-shaped panel therebetween and converge at either end of the second leaf-shaped panel, wherein the handle further includes a third handle flap which is formed in the inner layer of the composite wall, and the third handle flap is hingedly connected to the inner layer along a third hinge connection, wherein the third hinge connection comprises a pair of inner arcuate fold lines, wherein the inner arcuate fold lines of the third hinge connection define a third substantially leaf-shaped panel therebetween and converge at either end of the third leaf-shaped panel.

13. (canceled)

14. The carton according to claim 12 wherein the first handle flap is defined in part by the first hinge connection and at least in part by a line of separation that extends downwardly away from the first hinge connection.

15. (canceled)

16. The carton according to claim 14 wherein the line of separation is shaped to form an edge at each end of the first hinge connection, the edges at the ends of the first hinge connection being shaped to abut the adjacently disposed second substantially leaf-shaped and third substantially leaf-shaped panels when the handle is used and the first, second and third handle panels are displaced inwardly of the carton.

17. The carton according to claim 16 wherein said edges are shaped to fit against the second and third substantially leaf-shaped panels, when those second and third substantially leaf-shaped panels are disposed at an acutely inwardly folded angle.

18. The carton according to claim 12 wherein the first handle flap, the second handle flap and the third handle flap are configured to fold as a unit and to retain one another in a folded condition and together provide a substantially continuous load bearing structure when folded.

19. The carton according to claim 16, wherein said edges of the first handle flap at least partially define a portion of the first handle flap that is configured to be substantially in flat face contact with the second handle flap and third handle flap respectively in the folded condition.

20. (canceled)

21. (canceled)

22. The carton according to claim 12, wherein the carton comprises a series of main panels including a top panel and a bottom panel interconnected by first and second side panels to form a substantially tubular structure, at least one of the ends of the tubular structure being at least partially closed by said composite wall and wherein the inner layer of the composite wall comprises first and second side end closure panels hinged to the first and second side panels respectively and disposed side by side in substantially the same plane, the second handle flap being formed from the first side end closure panel and the third handle flap being formed from the second side end closure panel and wherein the outer layer of the composite wall comprises a top end closure panel hinged to the top panel, the first handle flap being formed from the top end closure panel.

23. (canceled)

24. (canceled)

25. A blank for forming a carton, the blank comprising an inner and outer layer for forming a composite wall of the carton, the inner and outer layers comprising components for forming a handle that includes a first handle flap formed in the outer layer and hingedly connected to the outer layer along a first hinge connection, and a second handle flap formed in the inner layer and hingedly connected to the inner layer along a second hinge connection, wherein the second hinge connection is substantially out of alignment with the first hinge connection and comprises a pair of inner arcuate fold lines.

26. The blank according to claim 25 wherein the first hinge connection comprises one selected from the group consisting of:

(i) an outer arcuate fold line;

(iii) a linear fold line; and

(iv) a pair of linear fold lines.

27. The blank according to claim 25 comprising a series of main panels including a top panel, a bottom panel, first and second side panels, wherein two of said main panels are affixed together to form a flat-folded structure that when opened forms a substantially tubular structure, at least one of opposed ends of the tubular structure being at least partially closable by a composite end wall structures and wherein an inner layer of the composite end wall structure comprises first side end closure panels hinged to the first side panels, the second handle flap being formed from the first side end closure panel and wherein the outer layer is provided by a top end closure panel hinged to the top panel.

28. A carton having a composite wall comprising a handle that includes a first handle flap formed in an outer layer of the composite wall and hingedly connected to the outer layer along a first hinge connection, and a second handle flap formed in an inner layer of the composite wall and hingedly connected to the inner layer along a second hinge connection, wherein the second hinge connection is substantially out of alignment with the first hinge connection, and wherein the first hinge connection comprises at least one outer arcuate fold line.

29. The carton according to claim 28 wherein the second hinge connection comprises one selected from the group consisting of:

(i) an inner arcuate fold line;

(ii) a pair of inner arcuate fold lines disposed proximate to and positioned oppositely to each other;

(iii) a linear fold line; and

30. The carton according to claim 28 wherein the second hinge connection comprises a pair of inner arcuate fold lines, wherein the inner arcuate fold lines of the pair are disposed proximate to and positioned oppositely to each other to define a second substantially leaf-shaped panel therebetween, and wherein the second leaf-shaped panel provides at least part of a load bearing structure.

31. The carton according to claim 28 wherein the handle further includes a third handle flap which is formed in the inner layer of the composite wall, the third handle flap is hingedly connected to the inner layer along a third hinge connection.