Patent Publication Number: US-8523047-B2

Title: Handle structure

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 61/250,668, filed Oct. 12, 2009, the entirety of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally though not specifically to handle structures for use in cartons for packaging articles. More specifically, though still not exclusively, the invention relates to handle structures comprising foldable flaps that hinge upon insertion of a user&#39;s fingers into the handle structure so as to resist tearing. 
     BACKGROUND OF THE INVENTION 
     It is known in the art to provide handle openings in packaging such as cartons so as to allow users to insert one or more fingers to allow lifting of those packages. When packages are so lifted the weight of those packages is transferred to one or more edges of the handle openings and this load may in some cases lead to tearing. This problem is exacerbated if the material of the packaging is to some degree moistened as moisture weakens the materials such as paperboard of which packaging is often manufactured. 
     Tearing may manifest not only in a “vertical” direction, which is to say parallel to the direction of the force created by the load of the packaging, but also in a “horizontal” perpendicular to the aforesaid vertical direction as the package is manipulated and twisted. 
     There therefore exists a need for a handle opening which lessens or altogether eliminates the risk of tearing in both the aforesaid “vertical” and “horizontal” directions of the handle opening. 
     The present invention seeks fulfill to some degree the aforementioned need by providing a handle opening that resists tearing. 
     SUMMARY OF INVENTION 
     A first aspect of the present invention provides a handle structure for a carton for packaging articles, which handle structure comprises a handle panel, and a reinforcing flap struck from a handle opening defined in the handle opening, the reinforcing flap comprising a first portion and a second portion connected to one another by a narrow portion defined by an indent in a free edge of the reinforcing flap, and being hinged to the handle panel along a fold line so as to allow only partial folding of the first portion out of the plane of the handle opening, whereby to at least partially direct stresses placed upon the first portion, around the indent, and into portions of the handle panel to which the second portion is hinged. 
     Preferably, a base of said indent is positioned proximate, but offset from, the fold line hinging the reinforcing flap to a handle panel. 
     Preferably, the fold line is curved proximate the base of the indent. 
     Preferably, the base of the indent is rounded. 
     Preferably, the reinforcing flap narrows at its terminal ends. 
     Optionally, one portion of the reinforcing flap extends adjacent to an edge of the aperture between a fold line connecting the reinforcing flap to a handle panel in which reinforcing flap is defined, and a connection between the reinforcing flap an that handle panel, proximate a terminal end of that handle panel. 
     Optionally, the handle panel further comprises a cover panel, defined within which is a comfort flap that is hinged thereto. The comfort flap is sized such that is foldable through the handle opening and positioned such that it is in registry with the handle opening, and comprises detents that, when the comfort flap is so-folded, are engageable with the indent of said reinforcing flap to maintain the comfort flap in a fixed position. 
     Preferably, the handle panel is a first end panel of a carton. 
     Preferably, the aperture is formed of a cutout in a free edge of the first end panel, and a second cutout in a free edge of a second end panel of a carton, which first and second end panels are adjacent in coplanar relationship to close an end of the carton. 
     Preferably, a portion of one of the first and second end panels extends to the other of the first and second end panels, so as to form a edge of the carton handle opening, by which the carton can be lifted. 
     A second aspect of the present invention provides a blank for forming a carton having a handle structure, which blank comprises panels for forming opposed side walls and opposed top and bottom wall, to form a tubular structure, and panels to form end closure panels of that tubular structure, which end closure panels comprise a first and a second side end panels, each comprising a free edge furthest from a fold line hinging that end panel to the panels for forming the carton, within which free edge is defined a cutout, defined within which cutout is a reinforcing flap comprising a first portion and a second portion connected to one another by a narrow portion defined by an indent in a free edge of the reinforcing flap, and being hinged to the side end panel so as to allow only partial folding of the first portion out of the plane of the handle opening, whereby to at least partially direct stresses placed upon the first portion, around the indent, and into portions of the side end panel to which the second portion is hinged. 
     Preferably, the blank further comprises a top end panel that is foldable to overly the first and second end panels, defined within which top end panel is a comfort flap that is foldable through the handle opening and that comprises a tab that is engageable with said indent to maintain the comfort flap in a folded condition. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which: 
         FIG. 1  shows a blank for forming a carton, comprising a handle structure according to a first embodiment of the present invention; 
         FIG. 2  shows an enlarged view of a handle cutout formed in one of the end panels of the blank of  FIG. 1 ; 
         FIG. 3  shows an end view of a partially erected blank of  FIG. 1 , wherein the handle cutouts of two adjacent end panels have been formed together into a carton handle opening; 
         FIG. 4  shows a fully erected carton from the blank of  FIG. 1 ; 
         FIG. 5  shows the carton of  FIG. 4 , wherein the comfort flap has been inserted into the handle cutouts of the end panels view from the exterior of the carton; 
         FIG. 6A  shows a first step in a sequence of folding that takes place as the comfort flap is inserted into the handle cutouts, as viewed from inside the carton; 
         FIG. 6B  shows a second step in a sequence of folding that takes place as the comfort flap is inserted into the handle cutouts, as viewed from inside the carton; and 
         FIG. 7  shows an alternative blank for forming into a carton comprising a handle structure according to a second preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention relates, in a preferred embodiment, to a handle structure  1  comprising a handle opening  3  formed from a first handle cutout  2   a , and a second handle cutout  2   b  (shown best in  FIG. 2 ) defined in adjacent terminal edges of two adjacent handle panels  58 ,  62 , and defined within each of which are reinforcing flaps  22 . 
     The handle cutouts  2   a ,  2   b  in each of the handle panels  58 ,  62  are substantially the mirror image of the other, but differ from one another in the manner set out below. 
     The first handle cutout  2   a  in handle panel  58  is defined partially by upper and lower cut lines  20 ,  4 . The upper cut lines  20  extends from a point inwardly offset from the terminal edge  25  of the handle panel  58 , whilst the lower cut line  4  extend inwardly from the terminal edge  25  itself. A score line  10  connects adjacent terminal ends of those cut lines  4 ,  20 . 
     The upper cut line  20  is linear and co-axial with a linear first portion of the score line  10 , which score line  10  and upper cut line  20  together form an upper boundary of the handle opening  3  when the reinforcing flap  22  is folded or otherwise somewhat deformed into a position of use in the manner described below. The score line  10  terminates in a curved portion that defines an upper corner of the first handle cutout  2   a , and the lower cut line  4  extends from a terminal point on the score line  10  to continue the curve thereof, thereby to define a lower corner of the first handle cutout  2   a , before extending linearly therefrom to the terminal edge of the handle panel  58 . Thus, linear upper and lower boundaries of the cutout  2   a  are defined, joined by a rounded end. 
     The reinforcing flap  22  is connected to the handle panel  58  by the score line  10 , and further is connected to handle panel  58  adjacent the terminal edge thereof, where the upper cut line  20  terminates at a point offset from that edge (as best shown in  FIG. 3 ). 
     The reinforcing flap  22  comprises an upper portion  18 , and a lower portion  12 , connected to one another by a narrow portion  16 . The reduced width of the reinforcing flap  22  at this narrow portion  16  is due to an indent  14  formed in a free edge  15  of the reinforcing flap  22  opposing the score line  10 . 
     The indent  14  in the reinforcing flap  22  is rounded at its base, which is to say, at a point closest to the score line  10 . The base of the indent  14  is spaced from the score line  10 , and is substantially proximate the curved portion thereof described above. The upper portion  18  of the reinforcing flap  22  extends along the linear portion of the score line  10  and continues, adjacent the upper cut line  20 , to the terminal edge of the handle panel  58 , where it is connected to the handle panel  58  across the offset between the first cut line  20  and the terminal edge. The lower portion  12  of the reinforcing flap  22  extends from the indent  14  to a lower terminal end of the score line  10 . 
     The second handle cutout  2   b  is formed in a second end panel  62  (shown in an enlarged view in  FIG. 2 ) and is substantially the mirror image of the first handle cutout  2   a , with the addition that an edge  21  of the handle panel  62  extends along the same axis as the upper cut line  20 , to define an portion of the handle panel  62  extending beyond a terminal end of the reinforcing flap  22  where it is connected to the handle panel  62 . Thus, whereas the portion by which the reinforcing flap  22  of the first cutout  2   a  is connected to the handle panels  58  adjacent a terminal edge thereof, this is not the case in this second handle panel  62 , where there is an extended portion of the handle panel extending away from a terminal point of the reinforcing flap  22 , in the axis of the upper cut line  20 . 
     Referring to  FIGS. 1 and 4 , the handle structure  1  also preferably comprises a comfort flap  30  that is foldable into the handle opening  3 , to act as a reinforcing layer, and to increase the surface area the handle structure  1 , with which the users hands come into contact when the handle structure  1  is being used, as is described below. Preferably, the comfort flap  30  hingedly connected to a cover panel such as a top end panel  64  and is positioned in registry with the handle opening  3  (best shown in  FIG. 3 ) formed by the two juxtaposed handle cutouts  2   a ,  2   b . Specifically, it is advantageous that a fold line  32  about which the comfort flap  30  hinged to the top end panel  64  is in registry with the axis of the upper cut lines  20 , and linear portions of the score lines  10  of the two handle cutouts  2   a ,  2   b.    
     The comfort flap  30  is of the same size and shape as, or slightly smaller than, the handle opening  3 , to aid insertion of the one into the other. The first fold line  32  by which the comfort flap  30  may be hinged to the top end panel  64  of a carton, for example, is mirrored by an offset fold line  40 , spaced from the first fold line  32  by a small distance preferably equal to the maximum width of the upper portion  18  of the reinforcing flap  22 . Separating a central portion of the comfort flap  30  from end tabs  35  thereof are fold lines  42 , one at each end. 
     The comfort flap  30  is insertable through the handle opening  3  by folding it about the fold line  32  as shown in  FIGS. 5 ,  6 A and  6 B. This movement will break nick portions  38  (shown in  FIG. 4 ) that are preferably provided to frangibly connect an otherwise free edge  36  (best shown in  FIGS. 6A and 6B ) of the comfort flap  30  to the top end panel  64  or otherwise to the surrounding portions of material from which the comfort flap  30  is formed. As the comfort flap  30  is so folded, it causes inward deflection of the lower portion  12  and upper portion  18  of the reinforcing flap  22  as adjacent parts of the comfort flap  30  are pushed there-against. The material from which the upper and lower portions  18 ,  12  of the reinforcing flap  22  are formed will stretch proximate the free edge  15  of the reinforcing flap  22  defining the indent  14 , and will bunch as necessary at the narrow portion  16  thereof as a result of the stress placed upon the upper portion  18  of the reinforcing flap  22  by the user&#39;s fingers. As this occurs, the upper and lower portions  18 ,  12  of the reinforcing flap  22  will deform partially inwardly of the handle opening  3  and the comfort flap  30  will deform around the upper portion  18  of the reinforcing flap  22  by virtue of the offset fold lines  32 ,  40 . 
     The end tabs  35  of the comfort flap  30  extend across the free edge  15  of the indent  14  of the reinforcing flap  22 . By virtue of the stretching and bunching of those lower  12  and upper  18  portion of the reinforcing flap  22 , the indent  14  forms a “valley” into which a proximate edge of the aforementioned end tab  35  of the comfort flap  30  may rest. The upper edges (as viewed in  FIG. 4 ) of the end tabs  35  engages the inside surfaces of the lower portions  12  of the reinforcing flaps  22  as shown in  FIG. 6B . This overcomes the natural tendency of the comfort flap  30  to return to its original plane by hinging back about fold line  32  and thereby the comfort flap  30  remains in the folded position once folded and inserted into the aperture  3 . 
     In use, the user inserts a hand through the handle opening  3  and thereby folds the comfort flap  30  inwardly through the hand aperture  3 . As a result, the reinforcing flaps  22  fold or otherwise deform inwardly about the curved fold lines  10 . This places a load upon an uppermost edge of the handle opening  3  and the upper portion  18  of the reinforcing flap  22 . The lower portion  12  of the reinforcing flap  22  prevents vertical tearing of the material of the handle panel  58 ,  62 , by transferring a portion of the stress from this load to the adjacent portion of the handle panel  58 ,  62 , via the lower portion  12  of the reinforcing flap  22 . The connection between the lower  12  and upper  18  portions of the reinforcing flap  22  (i.e., the narrow portion  16 ) prevents the upper portion  18  from fully folding into coplanar contact with the respective one of the handle panel  58 ,  62  and therefore ensure that a portion of any load under which the upper portion  18  is placed is necessarily transferred to the lower portion  12 , and thereby mitigate tearing. This stress acts from a point of maximal stress along the score line  10 , around the rounded base of the indent  14 , and into the adjacent material via lower portion  12  of the reinforcing flap  22 . In addition, the lower portion  12  of the reinforcing flap  22  equally resists tearing of the material of the respective handle panel  58 ,  62 , in a direction that is at least partially transverse to the force of the load placed upon the uppermost edge of the handle opening. More specifically, the lower portion  12  of each reinforcing flap  22  transfer any such transverse force to the reinforcing flap  22 , around the rounded base of the indent  14 , into the material of the handle panel  58 ,  62  above the upper portion  18  of the respective reinforcing flap  22 . 
     This is advantageous in that it prevents “vertical tearing” and “horizontal tearing” of the handle structure  1 , and thus the handle panels  58 ,  62  and is particularly advantageous in conditions where the packaging material has become moistened and thereby weakened. It is further advantageous that as stated above the lower portion  12  of each reinforcing flap  22  serves to retain the comfort flap  30  in a set up or folded position ready for subsequent use. 
     In the illustrated embodiment of  FIG. 1 , the handle structure  1  is shown applied to a blank  100  for forming a carton  110 , shown in  FIGS. 4 and 5 . Specifically, the handle panels  58 ,  62  are side end panels  58 ,  62  of the blank  100  and the comfort flap  30  is defined within a top end panel  64  that is foldable into co-planar contact with the outside surfaces of those two side end panels  58  and  62 . 
     Specifically, the illustrated blank  100  comprises a linear series of first side wall  50 , bottom panel  52 , second side wall  54 , top panel  56  and glue panel  57  hinged one to the next by a series of fold lines  70 ,  72 ,  74  and  75  respectively. Hinged to the end edges of the first side wall  50  are side end panels  58 . Corresponding side end panels  62  are hinged to the end edges of the second side panel  54  also. Hinged to the end edges of the bottom panel  52  are bottom end panels  60  and hinged to the end edges of the top panel  56  are top end panels  64 . 
     With respect to the placement of panels, the blank  100  is symmetrical about the longitudinal axis of the linear series above, and therefore only one end of the blank  100  will be described. 
     To set up the blank  100  of  FIG. 1  into a carton  110  (best shown in  FIG. 4 ), the first  50  and second  54  side walls are folded up about their corresponding fold lines  70  and  72  so as to be set perpendicular to the bottom panel  52 . The top panel  56  is then folded over to secure it to the glue panel  57  thereby forming a tubular structure having two opposed side walls  50 ,  54  and opposed top  52  and bottom wall  56 . Each end of the tubular structure may then be closed by folding side end panels  58 ,  62  towards one another so as to become co-planar with one another, as best shown in  FIG. 3 . The top end panel  64  is then folded about the fold line  82  downwardly into co-planar contact with the proximate portions of the side end panels  58 ,  62  and is secured thereto by some means including, amongst others, adhesion or mechanical fastening. Bottom end panel  60  is then folded about the fold line  78  upwardly into co-planar contact with the proximate portions of the side end panels  58 ,  62  and the proximate portions of top end panel  64 , and is secured thereto by some means including, amongst others, adhesion or mechanical fastening. This completes the closure of the respective end of the carton  110 . This results in the set up carton configuration shown in  FIG. 4 . 
       FIG. 7  shows an alternative embodiment of a blank  200  for forming a carton incorporating the handle structure  1  described above. Like numerals have been used for like features raised by 100, only the differences between this second embodiment and the first are described herein below. 
     The second embodiment has side end panels  158  and  162 , wherein one of those side end panels  162  stops short of meeting the other  158  when folded to close the carton and to form a handle opening. This is due to the lack of an extended portion in first handle panel  162  that extends beyond a terminal point of the reinforcing flap  22 . This means that no substantially continuous upper edge of the handle opening  3  is formed in the set up carton according to the second embodiment. Nonetheless, sufficient structural rigidity in this manner is accomplished through the securement of the top end panel  164  to the two side end panels  158 ,  162 . The functionality of the handle cutout in each side end panel  158 ,  162  remains the same as in the first embodiment. 
     It is further contemplated that a third embodiment of the invention may incorporate the handle structure  1  described above formed entirely in a single handle panel (such as an end panel of a carton), rather than formed of two halves, one in each of two panels. In this third embodiment, a single side end panel extending at least far enough toward the opposing side panel to provide sufficient space to accommodate the entire handle opening  3 , comprising score lines  10  in both of its upper corners, and connected by upper  20  and lower  4  cut lines along the continuous aperture edge. In this embodiment, a single reinforcing flap may be provided across the entire upper edge of the handle opening, or two reinforcing flaps may be provided, one for each upper corner of the aperture, as in the first embodiment. 
     It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape. 
     In other embodiments of the invention it is envisaged that the carton may be formed without the use of glue, and that alternative means of securing panels of the blank together may be used such as, amongst other, welding, mechanical fasteners and provision of complementary locking tabs. 
     The blanks  100 ,  200  shown if  FIGS. 1 and 7  respectively illustrate exemplary embodiments of access means formed by detachable portions of the carton that are defined by frangible lines. It is envisaged that these access means could be defined in portions of the top panel  56  and adjacent portions of the second side panel  54 , as shown in  FIG. 1 . Alternatively, as shown in  FIG. 7 , the access means could extend from these portion into one of the ends of the carton such that the handle structure at that end is removable together with the access means. Alternative access means are contemplated within the scope set out in the attached claims. 
     It will be recognized 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 short slit, a frangible line or a fold line without departing from the scope of the invention. The “score lines” described above are interchangeable with, amongst others, weakened lines, fold lines or perforations. Also, mention of “fold lines” throughout this description is not limited to single fold lines, and incorporate double fold lines or more, as necessary. 
     The folding process described above is strictly exemplary in nature, and it is envisaged that alternative procedures may be used. It is contemplated that the top end panels  64 ,  164  may be outermost from the end of the carton  110  such that each of them is secured to the outside surface of the respective bottom end panel  60 ,  160 .