WO1997036791A1

WO1997036791A1 - Thin-walled carton with reinforced handle attachment regions

Info

Publication number: WO1997036791A1
Application number: PCT/US1997/005009
Authority: WO
Inventors: Ronald Howard Wanless; Bill HJALMER; Claude E. Monsees; John Roberts; Marshall Hampton
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 1996-03-29
Filing date: 1997-03-28
Publication date: 1997-10-09
Anticipated expiration: 1998-09-29

Abstract

A plastic reinforcement patch (50) provided to strengthen carton side wall apertures which support a strap-type handle (13). The patch provides a tear-resistant handle attachment site, which enables increased package weight and further permits increased weight packages to be housed in thinner walled enclosures. The patch provides additional advantages with regard to handle insertion efficiency, greater versatility as to handle positions and handle designs.

Description

THIN-WALLED CARTON WITH REINFORCED HANDLE ATTACHMENT REGIONS

BACKGROUND OF THE INVENTION

This invention is directed towards packages with handles and more particularly packages for storing granular products and products with a high density.

In recent years there has been growing economic pressure to reduce the cost of packaging goods and materials. This goal is often achieved by reformulating products into a denser product configuration so that the product occupies a smaller package.

As container size is reduced with a corresponding increase in product weight, there is a need for suitable cartons and packaging to house the denser formulations. For large volume packages, handles are necessary to facilitate transport by the consumer. However, existing handles are often inadequate to meet the increased weight which results from dense products which are placed in the larger consumer packages. Recent advancements in container and handle combinations are seen in U.S. Patent # 4,986,420 to Gunn and Apke, and in U.S. Patent # 5,137,209 to Roberts et al. which are both incoφorated herein by reference. The above patents are directed towards a container and a bayonet handle for the container which maintain a smooth package profile during assembly and shipping. The bayonet handle employs a barbed head to engage package material surrounding an aperture through which the barbed head is inserted.

U.S. Patent 5,095,683 to Roberts et al., incoφorated herein by reference, describes an apparatus and process for inserting bayonet handles into apertured cartons. Both the insertion and engagement of the bayonet handle with the package require a certain minimum gauge package material be used.

SUMMARY OF THE INVENTION

In accordance with this invention, it has been found that substantially thinner carton stock material can be used with a barbed-style handle enabling a less expensive container package to be supplied. Further, the invention enables denser product formulations to be carried while still providing a thinner walled carton.

It is thus an object of this invention to provide a handle and package combination for granular consumer products which uses a thinner package wall material than that previously used.

It is still a further and more particular object of this invention to provide a plastic patch surrounding a carton aperture to facilitate the insertion and engagement of the handle with the carton. It is still a further and more particular object of this invention to provide a container which eliminates failure of the handle/aperture juncture.

It is still a further and more particular object of this invention to provide a container with better retention properties for maintaining an adjustable, rotatable handle in a first storage position. It is still a further and more particular object of this invention to provide a container with an improved geometry and greater versatility in the placement of the handle relative to the container.

It is still a further and more particular object of this invention to provide a carton blank which facilitates the insertion of a handle engaging member. It is still a further and more particular object of this invention to provide a carton blank with a reinforced handle insertion area to facilitate handle insertion into thin walled containers.

It is still a further and more particular object of this invention to provide a container with a handle aperture patch which reduces product spillage between the carton walls and inner liner of the carton.

These as well as other objects of this invention are provided by a carton formed from a cardboard sleeve having a material thickness of 0.038 inches or less; a first and second side wall, each side wall defining a respective sidewall aperture; a reinforcement patch positioned along an inner surface of each side wall and surrounding the respective aperture, the reinforcement patch being of a tear resistant material; a handle having an engagement member on each end, a first engagement member positioned adjacent the patch on an interior of the carton, the second engagement member positioned adjacent the patch on the interior of the carton, a strap portion of the handle passing through the respective apertures to an exterior of the carton; wherein, when the handle is used to lift the package, the engagement members engage a flat surface of the adjacent patch, the patch providing a tear resistant surface for receiving and distributing forces from the handle and thereby preventing the tearing of the carton about the apertures. BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a preferred embodiment of a container with certain additional details indicated in phantom.

Figure 2 is an enlarged view of figure 1 and in partial section. Figure 3 of the drawings is sectional view taken along line 3-3 of Figure 2.

DETAILED DESCRIPTION

In accordance with this invention, an improved carton and handle combination is provided which is ideally suited for packaging dense, granular material such as detergents. A preferred embodiment of the container uses a handle having barbed ends to engage sidewall apertures in the carton. Surrounding each aperture on the inner carton walls is a plastic patch which further defines an aperture, the patch aperture in alinement with the corresponding side wall aperture.

Figure 1 sets forth a preferred embodiment of this invention seen as a package 1 which includes a carton 3. Carton 3 is of a general box-like configuration having a rectangular top 5 opposite a similar shaped bottom, a first side 7 opposite a second side 8, and a broad front side 9 opposite a similar shaped back 10. Top 5 further defines a hinge along the back side, access to the carton product provided by a perforated tear-tape seam 1 1. A handle 13 is provided by a flat bayonet strap of plastic and defines a terminal barbed head 45 on a first end and a second barbed head 47 on a second handle end. Handle 13 is best seen and described in reference to U.S. Patent # 5,137,209 which is incoφorated herein by reference. Handle 13 is retained by the carton by the engagement of barbed heads 45 and 47 with carton side apertures 21. As seen in reference to figure 2, a thin plastic patch 50 defining a patch aperture 52 is secured to the inner carton side walls 7 and 8. Patch 50 is positioned with aperture 52 in register with adjacent sidewall aperture 21. It is preferred that the patch 50 be secured to the carton sidewall followed by the aperture formation of both the patch and carton side walls as a single step. The handle barbed ends 45 and 47 are then inserted through the respective aperture pairs. The patch serves the securing and retention functions which would otherwise be provided by the corresponding carton sideboard area adjacent aperture 21 as described in U.S. Patent # 5,137,209.

As seen in Figures 1-3, the handle is illustrated in an upright carrying position. Once engaged, the hook portions of the barbed ends are pulled tight to grasp the flat patch surface (not illustrated). While the illustrated patch 50 is seen as a rectangular plastic tab, dimensions and shape of the patch are not critical. It is preferred that the patch have sufficient dimensions so that the inserted handle engaging members (barbed ends) do not extend beyond the patch surface as the handle slides and rotates relative to the container. This will prevent the handle ends from engaging an edge or margin of the patch.

The incoφoration of the plastic patch 50 offers multiple advantages. One such advantage is the ability to increase the product weight carried in the container. By way of a first example, a first preferred embodiment of a 10 liter carton can be constructed from a sleeve of carton stock material having a thickness of 0.038 inches. Until the present invention, similar size cartons for housing dense, granular materials were constructed of similar thickness stock. The gross weight of such packages was limited to avoid the handle tearing the carton wall surrounding the aperture. The incoφoration of the present patch 50 permits denser product formulations to be housed in the containers. It has been found that increasing the package weight without a reinforcement patch results in a high handle failure rate as characterized by tearing of the carton sidewall adjacent the apertures 21 and a resulting separation of the handle from the carton and/or loss of product from the container.

Using fiberboard patches to reinforce the aperture area improved the container strength somewhat, but still permitted too high a handle failure rate. Further, the process of dispensing cardboard patches hindered carton production by slowing the overall carton assembly speed. Further inefficiencies resulted from the increased number of defective cartons having improper or missing patch placement.

The increased handle strength which results from a container using a plastic reinforcement patch is substantial. The increased strength enables heavier loads to be carried in thinner walled, less costly enclosures. As a second example, a similar volume

10 liter package to that described in example one can be constructed of 0.028 point carton stock. The same dense product formulation can be packaged in the thinner walled carton without any loss in the handle tear strength characteristics. As a result, a 26% decrease in the amount of carton material is achieved which lowers the carton cost and reduces the amount of post consumer waste.

Drop tests have confirmed that the thin-walled carton retains sufficient strength and integrity to withstand commercial shipping and handling practices. Additionally, handle failure rates of installed handles are virtually eliminated.

Carton integrity of the containers described in examples one and two above, was measured using an Instron Model 101 1 instrument to determine top load characteristics of the thinner walled outer carton material. Ten liter detergent filled cartons constructed of 28 and 38 point outer carton stock with an interior plastic patch of 0.035 inches thickness, a strap bayonet handle, and a standard inner liner had loads applied until a 0.50" deflection was achieved in the package. Peak resistance values were determined and the deflection was maintained for two minutes and the sustained load value determined. Both carton thicknesses had sufficient strength and maintained the carton integrity to permit the carton's use in commercial retail channels.

Drop load test were also carried out by taking filled ten liter cartons of 28 pt and 38 pt outer carton stock having plastic aperture patches of 0.035", strap bayonet handles and a standard thickness inner liner. The average gross weight of the cartons was 20.7 pounds. The cartons were repeatedly dropped a distance of 3 inches at which time the handle was abruptly engaged. Both the 28 pt and 38 pt cartons with plastic patches suffered no tearing of the carton wall or handle failure during 50 repetitions of the drop test. By contrast, 38 pt cartons using a 38 pt fiber patch in place of a plastic patch, experienced tearing of the outer carton wall after 10 drops, with complete handle failure typically occurring between the 16th and 20th drop. Omitting the fiberboard patch resulted in a more rapid handle failure.

The plastic patch provides a protective surface which engages the handle and redistributes the stress to a larger area of the carton. As a result, a thinner walled carton for dense products is provided which enables packages in excess of 20 pounds to be carried by a strap bayonet handle. In essence, it has been found that the limiting factor for carton strength of the type described is no longer the handle engagement site. As a result, increased loads and thinner carton stock can be used which permit a lower net cost of the packaging and product delivery.

Thinner carton stock also allows a greater number of carton blanks to be shipped and handled for any given volume or weight of carton blanks. If desired, the inner carton wall surrounding the apertures may be embossed prior to receiving the patch to provide a thinner profile for stacking carton blanks carrying the patch. Additional advantages result from the use of the aperture patch. All else being equal, use of the patch with existing carton stock dimensions would raise the container price. However, net savings are achieved by using thinner, less expensive stock along with corresponding savings in transportation and handling costs.

The improved handle tear strength provides a longer lasting container. With the recent introduction of paper bound and plastic refill packs for detergents and similar products, the present invention provides a useful container for use with the refill packs.

Additional cost savings are achieved by increases in handle insertion efficiency. The patch provides additional stiffness surrounding the carton apertures 21 which facilitates the insertion of the barbed handle ends. Data from test runs indicates insertion reliability increases at least 4-5% and can be maintained at an efficiency well over 97%. The substantially rigid and inflexible nature of the plastic patch provides additional thickness and support and compensates for the thinner walled material which would, without additional support, be expected to have a lower handle insertion rate. The patch also reduces the amount of product loss associated with carton liners.

The patch minimizes the carton distortion and displacement the engaged handle imparts upon the sidewalls. As a result, less granular product is lost between the liner and carton interface.

The aperture patch also provides a more secure retention for the strap handle when the handle is in the stored shipping position. The circumferential wall defined by the patch aperture provides a more rigid, less variable passage through which the handle resides and interacts. The patch permits a more precise mating of the handle dimensions to the aperture diameter. Accordingly, the amount of force needed to engage (withdraw) the handle from the storage position to an overhead carrying position is more easily and reliably controlled. As a result, inadvertent handle displacement during shipping and retail handling can be substantially reduced and thereby improve the aesthetics of the product display.

Other improvements include an improved package geometry. The patch enables the carton apertures to be positioned closer to the carton tear strip. Without the patch, the carton aperture had to be spaced a certain distance below the tear strip to avoid handle stress being applied to the tear strip area. The patch provides enough protection that rupture of the tear strip by handle stress is not a concern. As a result, the carton apertures can be positioned closer to the carton lid. This improved arrangement allows for a larger, uninterrupted surface for better carton graphics presentation. In addition, a shorter, less expensive handle can be used since less clearance is needed for handles located nearer the container's top.

Since the patch receives and distributes the stress of the handle engagement, the patch enables variation in the package structure. For example, a variety of different shaped handle engagement members are possible which heretofore may have been unsuitable for direct engagement with fiberboard. The improved handle insertion qualities the patch provides may favor other handle designs with improved insertion features. These variations may permit a reduced size barbed head or other engagement member, a thinner thickness handle, and/or a narrower width handle. Such handles would be less expensive to manufacture and would permit smaller carton apertures. Smaller apertures are easier to seal and minimize product loss and contamination problems.

While particular embodiments and examples of the present invention have been shown and described, modifications may be made to the packages and processes without departing from the teachings of the present invention. Accordingly, the present invention comprises all embodiments within the scope of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A package for housing products characterized by: a) an outer enclosure having a first side wall and a second side wall, each of said side walls having an inner surface and a side wall aperture therein, said enclosure further having a front wall and a top wall; b) a patch made of a tear resistant material substantially stronger than said side walls attached to said inner surface of each of said side walls adjacent to said side wall aperture, said patch having a patch aperture in alignment with said side wall aperture, thereby providing a reinforced side wall region; c) a strap handle having a first end and a second end and at least one barb member at said first and second ends, said first end being inserted through said side wall aperture in said first side wall and through said patch aperture, said second end being inserted through said side wall aperture in said second side wall and through said patch aperture, so that said first and second ends are movable within said package but are not removable therefrom.

2. The package according to Claim 1 further characterized by an inner enclosure liner located adjacent said inner surface of said first and second side walls, said liner being unattached to each of said first and second side walls at said reinforced side wall region, said liner preventing loss of contents within said package through said patch aperture and said side wall aperture.

3. The package according to Claim 2 wherein said first an second ends of said handle are movable in a space between said liner and said reinforced side wall region.

4. The package according to Claims 1, 2, or 3 wherein said patch is made of rigid plastic.

5. The package according to Claims 1, 2, 3, or 4 wherein said contents of said package has a weight exceeding a tear strength of said first and second side walls when said package is supported by said handle.

6. The package according to claims 1, 2, 3, 4, or 5 wherein said outer enclosure is made of carton board. 7 A method of reinforcing carton side walls of a package for receiving a handle, said method characterized by the steps of a) providing a carton board outer enclosure having a first side wall and a second side wall, said first and second side walls each having an inner surface, b) securing a reinforcement patch made of rigid plastic to said inner surface of each of said first and second side walls, thereby forming reinforced side wall regions, c) creating an aperture through each of said reinforced side wall regions, and d) inserting engaging ends of a handle through said aperture in each of said reinforced side wall regions so that said engaging ends of said handle are movable within said package but are not removable therefrom

8 The method according to Claim 7 wherein contents of said package has a weight exceeding a tear strength of said carton board enclosure when said package is supported by said handle

9 The method according to Claim 7 and Claim 8 further characterized by the step of installing an inner liner in said outer enclosure adjacent said reinforced side wall regions to provide a space for said engaging ends of said handle to be movable, said liner preventing loss of contents within said package through said aperture in each of said reinforced side wall regions.