Abstract:
A reinforced carton handle structure includes a carton wall panel ( 16 ) hinged along a first fold line ( 40 ) to a linear series of at least two reinforcing panels ( 26, 32, 34 ) hinged one to the next. Each of the carton wall panel ( 16 ) and reinforcing panels ( 26, 32, 34 ) includes an aperture or recess ( 54, 56 ) for forming a handle opening. One of the reinforcing panels ( 26 ) in the linear series is hinged to a next reinforcing panel ( 32 ) of the linear series about a second fold line ( 87   a,    87   b ) that is closer to the first fold line ( 40 ) than an edge of the one reinforcing panel ( 26 ) which edge is furthest from the first fold line ( 40 ).

Description:
FIELD OF INVENTION  
       [0001]    The present invention relates to handle structures and more particularly, though not exclusively, to reinforced carton handle structures. 
       BACKGROUND OF THE INVENTION  
       [0002]    An inherent technical challenge in the field of packaging design, is that of providing handle structures, by which the user may grasp the package, that are sufficiently strong to support the full weight of the articles contained therein, whilst not unduly adding to the production costs of the packaging. 
         [0003]    U.S. Pat. No. 4,037,777 discloses a means by which material may be struck from portions of a composite top panel to act as reinforcement of a handle structure. Such a method of reinforcement requires the presence of a suitable composite top panel in the packaging and also serves to weaken the structural integrity of the composite top panel. Furthermore, this method allows only for the provision of a second layer of material to serve as reinforcement around the handle structure and cannot provide for a third and subsequent layers. 
         [0004]    In many cases, the weight of the articles is such that one or two thicknesses of the packaging material may be insufficient to provide the necessary structural integrity for transporting the article. For example, WO 2004 002 837 discloses a carton wherein the only means by which reinforcement of the handle structures may be achieved is through the provision of dedicated reinforcement panels. However, should additional layers of reinforcement be desired, the invention of WO 2004 002 837 would require the amount of material required for the reinforcement panels to increase proportionately. 
         [0005]    Both GB 2325459 and FR 8711249 illustrate, by way of technological background, reinforced handles applied to cartons. 
         [0006]    The present invention seeks to overcome or at least mitigate the problems of the prior art. It is desirable to provide a reinforced carton handle structure that may provide additional layers of reinforcement around the handle edges, without requiring a proportional increase in material for the reinforcing panels. 
       SUMMARY  
       [0007]    A first aspect of the present invention provides a reinforced carton handle structure comprising a carton wall panel hinged to a linear series of at least two reinforcing panels hinged one to the next. Each of the carton wall panel and reinforcing panels comprise some portion of an aperture. At least one reinforcing panel in the linear series is hinged to a next reinforcing panel of the linear series about a fold line that is closer to the carton wall panel than an edge of the at least one reinforcing panel that is furthest from the carton wall panel. 
         [0008]    A second aspect of the present invention provides a reinforced carton handle structure wherein the at least one reinforcing panel is hinged upon each side to first reinforcing flaps and the next reinforcing panel is hinged upon each side to second reinforcing flaps, and wherein each of the first reinforcing flaps are hinged to those second reinforcing flaps located on the same side of the linear series of reinforcing panels. The fold line about which the reinforcing flaps are hinged, is closer to the carton wall panel than the edge of the preceding reinforcing panel that is furthest from the carton wall panel. 
         [0009]    Preferably, wherein at least one reinforcing panel is hinged to the next reinforcing panel as a result of the first reinforcing flaps being hinged to the second reinforcing flaps. 
         [0010]    Preferably, wherein the linear series comprises three reinforcing panels resulting in a 4-ply thickness of material in the reinforced carton handle structure. 
         [0011]    Preferably, wherein the reinforcing panels comprise apertures and recesses that are in registry with the hand aperture defined within the carton wall panel, when the reinforced carton handle structure is set up. 
         [0012]    In one embodiment of the present invention, a reinforced carton handle structure is provided at both ends of a carton formed from two blanks wherein a tray portion including the reinforced carton handle structures is formed from a first blank and a cover portion is formed from a second blank. 
         [0013]    A further aspect of the invention provides a blank for forming a reinforced carton handle structure comprising a wall panel hinged to a linear series of at least two reinforcing panels hinged one to the next. At least one reinforcing panel in the linear series is hinged to a next reinforcing panel of the linear series about a fold line that is closer to the carton wall panel than an edge of the at least one reinforcing panel that is furthest from the carton wall panel. 
         [0014]    Preferably, wherein at least one reinforcing panel of the blank is hinged upon each side to first reinforcing flaps and the next reinforcing panel is hinged upon each side to second reinforcing flaps, and wherein each of the first reinforcing flaps are hinged to those second reinforcing flaps located on the same side of the linear series of reinforcing panels, and wherein the fold line about which the reinforcing flaps are hinged, is closer to the carton wall panel than the edge of the at least one reinforcing panel that is furthest from the carton wall panel. 
         [0015]    A further embodiment of the present invention being that of a reinforced carton handle structure comprising a carton wall hinged to a linear series of three reinforcing panels hinged one to the next. A first reinforcing panel of the linear series and a second reinforcing panel in the linear series are each hinged upon both sides to corresponding reinforcing flaps, and wherein a reinforcing flap hinged to one side of the second reinforcing panel is hinged, about a fold line offset from the proximal edge of the first reinforcing panel of the linear series, to the reinforcing flap that is hinged to the corresponding side of said first reinforcing panel. 
         [0016]    Preferably wherein the above reinforced carton handle structure is provided at both ends of a carton formed from two blanks wherein a tray portion including the reinforced carton handle structures is formed from the first blank and a cover portion is formed from the second blank. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0017]    Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which; 
           [0018]      FIG. 1  illustrates a plan view of a blank for forming a carton that includes a reinforced carton handle structure according to a preferred embodiment of the of the present invention, 
           [0019]      FIG. 2  illustrates the locations on the blank of  FIG. 1  at which glue should be applied, 
           [0020]      FIG. 3  illustrates the blank of  FIG. 1 , at the first stage in the folding process, 
           [0021]      FIG. 4  illustrates the blank of  FIG. 1 , at the second stage in the folding process, 
           [0022]      FIG. 5  illustrates the partially set up tray component of a carton that includes a reinforced carton handle structure according to a preferred embodiment of the of the present invention, 
           [0023]      FIG. 6  illustrates the partially set up tray component of  FIG. 5  with the partially set up cover component of a carton that includes the reinforced carton handle structure according to a preferred embodiment of the of the present invention; and 
           [0024]      FIG. 7  illustrates a set up carton that includes the reinforced carton handle structure according to a preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0025]    The present invention relates to a reinforced carton handle structure.  FIG. 1  shows a carton blank incorporating a reinforced handle structure according to a preferred embodiment of the present invention. Carton blank  10  includes a base panel  24 , to opposing ends of which, are hinged end wall panels  16  and  18  by fold lines  44  and  48  respectively. Side flaps  74   a  and  74   b  are hinged to opposing sides of the base panel  24  by fold lines  94   a  and  94   b  respectively. 
         [0026]    Bevel panels  66   a  and  66   b  are hinged, on opposing sides, to end wall panel  16  about is fold lines  96   a  and  96   b  respectively. Each bevel panel  66   a  and  66   b  is then hinged, in turn, to a side support panel  76   a  and  76   b  about respective fold lines  86   a  and  86   b.    
         [0027]    A reinforcing structure is provided, comprising, in this embodiment, a first reinforcing panel  26  hinged to an edge of the end wall panel  16  furthest from the base panel  24 , about fold line  40 . 
         [0028]    Defined within end wall panel  16  is hand aperture  54  defined within which are a number of finger flaps  60  each of which being hinged to end wall panel  16  by a respective one of fold lines  61 . 
         [0029]    First reinforcing flaps  70   a  and  70   b  are hinged, about fold line  82   a  and  82   b,  to opposing sides of first reinforcing panel  26 . Fold lines  87   a  and  87   b  each define an edge of each respective first reinforcing flap  70   a  and  70   b,  fold lines  87   a  and  87   b  are adjacent fold lines  82   a  and  82   b  respectively. 
         [0030]    Second reinforcing flaps  73   a  and  73   b  are hinged to the first reinforcing flaps  70   a  and  70   b,  about the fold lines  87   a  and  87   b  respectively. Second reinforcing flaps  73   a  and  73   b  are hinged, about fold lines  89   a  and  89   b,  to opposing sides of a second reinforcing panel  32 . 
         [0031]    First reinforcing panel  26  and second reinforcing panel  32  are in effect hinged to one another via first reinforcing flaps  70   a  and  70   b  and second reinforcing flaps  73   a  and  73   b.    
         [0032]    In the embodiment illustrated in  FIG. 1 , second reinforcing panel  32  is disposed between the first reinforcing panel  26  and a third reinforcing panel  34 . 
         [0033]    The third reinforcing panel  34  is hinged to an edge of the second reinforcing panel  32  that is furthest from the base panel  24 , by  52 . 
         [0034]    Preferably, a recess  56  is provided in the free edges of the second and third reinforcing panel  56 . 
         [0035]      FIGS. 1 to 4  illustrate a reinforced carton handle structure, according to a preferred embodiment of the present invention, the preferred embodiment being a tray for a two part carton. The blank of  FIGS. 1 to 4  is symmetrical about the transverse axis and therefore details of the features of the opposite end of the blank are summarised as follows. 
         [0036]    Bevel panels  68   a  and  68   b  are hinged, on opposing sides, to end wall panel  18  about fold lines  98   a  and  98   b  respectively. Each bevel panel  68   a  and  68   b  is then hinged, in turn, to a side support panel  78   a  and  78   b  about respective fold lines  88   a  and  88   b.    
         [0037]    First reinforcing panel  28  is hinged to an edge of the end wall panel  18  furthest from the base panel  24 , about fold line  50 . 
         [0038]    Defined within end wall panel  18  is hand aperture  54  defined within which are a number of finger flaps  60  each of which being hinged to end wall panel  18  by a respective one of fold lines  61 . 
         [0039]    First reinforcing flaps  72   a  and  72   b  are hinged, about fold line  84   a  and  84   b,  to opposing sides of first reinforcing panel  28 . Fold lines  83   a  and  83   b  each define an edge of each respective first reinforcing flap  72   a  and  72   b,  fold lines  83   a  and  83   b  are adjacent fold lines  84   a  and  84   b  respectively. 
         [0040]    Second reinforcing flaps  75   a  and  75   b  are hinged to the first reinforcing flaps  70   a  and  70   b,  about the fold lines  83   a  and  83   b  respectively. Second reinforcing flaps  75   a  and  75   b  are hinged, about fold lines  85   a  and  85   b,  to opposing sides of a second reinforcing panel  36 . 
         [0041]    First reinforcing panel  28  and second reinforcing panel  36  are in effect hinged to one another via first reinforcing flaps  72   a  and  72   b  and second reinforcing flaps  75   a  and  75   b.    
         [0042]    Second reinforcing panel  36  is disposed between the first reinforcing panel  28  and a third reinforcing panel  38 . 
         [0043]    The third reinforcing panel  38  is hinged to an edge of the second reinforcing panel  36  that is furthest from the base panel  24 , by  51 . 
         [0044]    Each of panels  16 ,  26 ,  18  and  28  have defined within them, hand apertures  54  and finger flaps  60 . Each finger flap  60  is hinged to a respective one of panels  16 , 18 ,  26  or  28  by a respective one of fold lines  61 . The larger of the finger flaps  60  within each of panels  16 ,  18 ,  26  and  28  have defined with them, a further fold line  62  parallel and offset from fold line  61 . 
         [0045]    Likewise, recesses  58  are provided in the second and third reinforcing panels  36 ,  38 . 
         [0046]    Turning now to the process by which the reinforced carton handle structure is set up,  FIGS. 2 to 4  illustrate a sequence by which the preferred embodiment of the present invention may be partially set up.  FIG. 2  illustrates the areas, G 1  and G 2 , to which glue is initially applied. Of course, it is envisaged that other means of securing panels together can be employed without departing from the scope of the invention. 
         [0047]    Second reinforcing flaps  73   a/   75   a  and  73   b/   75   b  are then folded, about fold lines  87   a/   83   a  and  87   b/   83   b,  so as to bring the uppermost surface of second reinforcing panel  32 / 36  and third reinforcing panel  34 / 38  into face contacting relation with G 1  and G 2  respectively. 
         [0048]      FIG. 3  illustrates the reinforced carton handle structure in a partially set up state. Glue point G 3  is illustrated as being located upon the upper-most surface of third reinforcing panel  34 / 38 .  FIG. 3  also illustrates the way in which third reinforcing panel  34 / 38  has a shaped edge (or recess)  56 / 58  such that it is in registry with the edge of the hand aperture  54  defined within end wall panel  16 / 18  and first reinforcing panel  26 / 28 . 
         [0049]      FIG. 4  shows the reinforced carton handle structure in fully set up condition resulting from the folding of the first reinforcing panel  26 / 28  about fold line  40 / 50  such that third reinforcing panel  34 / 38  comes into substantially face contacting relationship with end wall panel  16 / 18  at glue point G 3 . Also illustrated is the fact that hand aperture  54 , defined within first reinforcing panel  26 / 28  is positioned such that it is in registry with hand aperture  54  defined within end wall panel  16 / 18  when the first reinforcing panel is folded about fold line  40 / 50 . 
         [0050]      FIGS. 5 to 7  illustrate the steps of setting up a carton according to a preferred embodiment of the present invention.  FIG. 5  shows the use of the reinforced carton handle structure according to a preferred embodiment of the present invention in the end wall panels  16  and  18  of a carton tray structure. The end wall panels  16  and  18  have been folded at right angles to the base panel  24 , about fold lines  44  and  48  respectively. 
         [0051]      FIG. 6  shows one possible cover portion  11  that it is envisaged may be applied to a tray structure of  FIG. 5 . 
         [0052]      FIG. 7  shows the set up carton of  FIGS. 5 and 6 . Bevel panels  66   a,    66   b,    68   a  and  68   b  have been folded out of the planes of end wall panels  16  and  18  about fold lines  96   a,    96   b,    98   a  and  98   b  respectively. Side support panels  76   a,    76   b,    78   a  and  78   b  have been folded about fold lines  86   a,    86   b,    88   a  and  88   b  respectively. Side flaps  74   a  and  74   b  have been folded at right angles to the base panel  24 , about fold lines  94   a  and  94   b.  Beam panels  114   a  and  112   a  of the cover  11  have been folded upwards at right angles to the top panel  122  and the side wall panels  112  and  114  have been folded such that they are in substantially face contacting relationship with beam panels  112   a  and  114   a.  Side wall panels  112  and  114  are then attached to side support panel  76   a,    76   b,    78   a  and  78   b  as well as side flaps  74   a  and  74   b.    
         [0053]      FIG. 7  illustrates the structure of the present invention is not unduly visible in the set up carton and therefore does not detract from the aesthetic appeal of the product. 
         [0054]    Referring to  FIGS. 1 and 7 ; in use, the user pushes his hands through the hand apertures  54 , causing the finger flaps  60  to be struck from the hand apertures  54 , interior of the package about fold lines  61 . Fold line  62  defined with the largest finger flap  60 , within each hand aperture, allows the finger flap to fold around the thickness of the reinforced handle structure and into substantially face contacting relationship with the interior face of the first reinforcing panel. 
         [0055]    It is envisaged that the features of the various embodiments herein described could be altered without departing from the scope of the present invention. For example the reinforced carton handle structure may be applied to cartons of different designs such as top gripping, wrap around, tray, end or top loading. Also, the sizing and orientation of the handle structure may well be altered to suit the specific carton design in which it is embodied, and may well be located other than in opposing end walls. 
         [0056]    It will be recognised that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. Any reference to hinged connection should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from one or more of the following, a score line, a frangible line or a fold line without departing from the scope of the invention.