Granted Patent B2

US 9,033,210 · App. 13/653,536 · Granted May 19, 2015

Abstract

Claims (62)

1. A carton for containing a plurality of articles, the carton comprising:

a plurality of panels that extends at least partially around an interior of the carton, the plurality of panels comprises a top panel, a bottom panel, a first side panel, and a second side panel;

at least three first end flaps respectively foldably connected to respective panels of the plurality of panels, the at least three first end flaps cooperate to close a first end of the carton, the at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel; and

a handle in the first end of the carton for grasping and carrying the carton, wherein:

the first side end flap comprises a first main panel, a first handle feature for forming the handle, a first reinforcement portion above the first handle feature, and a first reinforcement flap foldably connected to the first reinforcement portion,

the second side end flap comprises a second main panel, a second handle feature for forming the handle, a second reinforcement portion above the second handle feature, a second reinforcement flap foldably connected to the second reinforcement portion, and an interior surface facing the interior of the carton and an exterior surface opposite the interior surface, and

the first reinforcement flap and the second reinforcement flap are downwardly folded to at least partially overlap the second reinforcement portion to reinforce the handle, and the first reinforcement flap and the second reinforcement flap are in face-to-face contact with at least a portion of the exterior surface of the second side end flap.

2. The carton of claim 1 , wherein the first reinforcement portion at least partially overlaps the second reinforcement portion.

3. The carton of claim 1 , wherein the reinforcement flap, the first reinforcement portion, and the second reinforcement portion form three plies of material located above the handle to reinforce the handle.

4. The carton of claim 1 , wherein the carton comprises an attachment flap and an attachment end flap foldably connected to the attachment flap, the attachment end flap comprises a base portion and the second reinforcement flap, the second reinforcement flap being foldably connected to the base portion.

5. The carton of claim 4 , wherein the base portion is adhesively connected to the second reinforcement portion.

6. The carton of claim 5 , wherein the attachment flap is adhesively connected to the second side panel, the second side panel overlapping the attachment flap and the second reinforcement portion overlapping the base portion.

7. The carton of claim 5 , wherein the attachment end flap, the second reinforcement portion, the first reinforcement portion, the first reinforcement flap, and the second reinforcement flap comprise five plies of material located above the handle to reinforce the handle.

8. The carton of claim 1 , wherein the top end flap comprises a third handle feature, the first handle feature comprises a first handle opening, the second handle feature comprises a second handle opening, and the third handle feature comprises a handle flap foldably connected to the top end flap, the handle flap, the first handle opening, and the second handle opening cooperate to form the handle.

9. The carton of claim 8 , wherein the handle flap is upwardly folded and in face-to-face contact with an interior surface of each the first side end flap and the second side end flap to reinforce the handle.

10. The carton of claim 1 , wherein the top end flap is in face-to-face contact with the first reinforcement flap and the second reinforcement flap.

11. The carton of claim 1 , wherein the top end flap is foldably connected to the top panel at a fold line, a peripheral free edge of the first reinforcement flap is spaced apart from the fold line by a first distance, a peripheral free edge of the second reinforcement flap is spaced apart from the fold line by a second distance.

12. The carton of claim 11 , wherein the first distance is substantially equal to the second distance.

13. The carton of claim 12 , wherein the peripheral edge of the top end flap is spaced apart from the fold line by a third distance, the third distance being greater than the second distance.

14. The carton of claim 11 , wherein the first distance is substantially greater than the second distance.

15. A carton for containing a plurality of articles, the carton comprising:

a plurality of panels that extends at least partially around an interior of the carton, the plurality of panels comprises a top panel, a bottom panel, a first side panel, and a second side panel;

at least three first end flaps respectively foldably connected to respective panels of the plurality of panels, the at least three first end flaps cooperate to close a first end of the carton, the at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel; and

a handle in the first end of the carton for grasping and carrying the carton, wherein:

the first side end flap comprises a first main panel, a first handle feature for forming the handle, a first reinforcement portion above the first handle feature, and a first reinforcement flap foldably connected to the first reinforcement portion,

the second side end flap comprises a second main panel, a second handle feature for forming the handle, a second reinforcement portion above the second handle feature, and a second reinforcement flap foldably connected to the second reinforcement portion,

the first reinforcement flap and the second reinforcement flap are downwardly folded to at least partially overlap the second reinforcement portion to reinforce the handle, and the first side end flap comprises a notch between the first reinforcement flap and the first reinforcement portion, the notch being at a free edge of the first side end flap.

16. The carton of claim 15 , wherein the at least a portion of the second reinforcement portion is received in the notch.

17. The carton of claim 16 , wherein at least a portion of the second reinforcement flap is received in the notch.

18. A blank for forming a carton, the blank comprising:

a plurality of panels comprising a top panel, a bottom panel, a first side panel, and a second side panel;

at least three first end flaps respectively foldably connected to respective panels of the plurality of panels, the at least three first end flaps being configured to cooperate to close a first end of a carton formed of the blank, the at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel; and

features for forming a handle in the at least three first end flaps, wherein:

the first side end flap comprises a first main panel, a first handle feature for forming the handle, a first reinforcement portion above the first handle feature, a first reinforcement flap foldably connected to the first reinforcement portion, and a notch between the first reinforcement flap and the first reinforcement portion, the notch being at a free edge of the first side end flap,

the second side end flap comprises a second main panel, a second handle feature for forming the handle, a second reinforcement portion above the second handle feature, and a second reinforcement flap foldably connected to the second reinforcement portion, and

the first reinforcement flap and the second reinforcement flap are configured to be downwardly folded to at least partially overlap the second reinforcement portion to reinforce the handle when the blank is formed into a carton.

19. The blank of claim 18 , further comprising an attachment flap and an attachment end flap foldably connected to the attachment flap, the attachment end flap comprises a base portion and the second reinforcement flap, the second reinforcement flap being foldably connected to the base portion.

20. The blank of claim 18 , wherein the notch is configured to receive at least a portion of the second reinforcement portion in a carton assembled from the blank.

21. The blank of claim 18 , wherein the top end flap comprises a third handle feature, the first handle feature comprises a first handle opening, the second handle feature comprises a second handle opening, and the third handle feature comprises a handle flap foldably connected to the top end flap, the handle flap, the first handle opening, and the second handle opening are configured to cooperate to form the handle in a carton assembled from the blank.

22. The blank of claim 21 , wherein the handle flap is configured to be upwardly folded and placed in face-to-face contact with an interior surface of each the first side end flap and the second side end flap to reinforce the handle in a carton assembled from the blank.

23. The blank of claim 18 , wherein the top end flap is foldably connected to the top panel at a fold line, a peripheral free edge of the first reinforcement flap is spaced apart from the fold line by a first distance, a peripheral free edge of the second reinforcement flap is spaced apart from the fold line by a second distance.

24. The blank of claim 23 , wherein the first distance is substantially equal to the second distance.

25. The blank of claim 24 , wherein the peripheral edge of the top end flap is spaced apart from the fold line by a third distance, the third distance being greater than the second distance.

26. The blank of claim 23 , wherein the first distance is substantially greater than the second distance.

27. A method of forming a carton for containing a plurality of articles, the method comprising:

obtaining a blank comprising a plurality of panels, the plurality of panels comprises a top panel, a bottom panel, a first side panel, and a second side panel, the blank further comprising at least three first end flaps respectively foldably connected to respective panels of the plurality of panels, the at least three first end flaps comprise a first side end flap foldably connected to the first side panel, a second side end flap foldably connected to the second side panel, and a top end flap foldably connected to the top panel, wherein, the first side end flap comprises a first main panel, a first handle feature, a first reinforcement portion above the first handle feature, and a first reinforcement flap foldably connected to the first reinforcement portion, and the second side end flap comprises a second main panel, a second handle feature, a second reinforcement portion above the second handle feature, a second reinforcement flap foldably connected to the second reinforcement portion, and an interior surface facing the interior of the carton and an exterior surface opposite the interior surface;

forming at least a portion of an interior of the carton by folding the plurality of panels;

folding the at least three first end flaps to at least partially close a first end of the carton;

at least partially forming the handle from the first handle feature and the second handle feature; and

downwardly folding the first reinforcement flap and the second reinforcement flap to position the first reinforcement flap and the second reinforcement flap in face-to-face contact with at least a portion of the exterior surface of the second side end flap and to at least partially overlap the second reinforcement portion to reinforce the handle.

28. The method of claim 27 , further comprising positioning the first reinforcement portion to at least partially overlap the second reinforcement portion.

29. The method of claim 27 , further comprising positioning the first reinforcement flap, the first reinforcement portion, and the second reinforcement portion to form three plies of material located above the handle to reinforce the handle.

30. The method of claim 27 , wherein the blank comprises an attachment flap and an attachment end flap foldably connected to the attachment flap, the attachment end flap comprises a base portion and the second reinforcement flap, the second reinforcement flap being foldably connected to the base portion.

31. The method of claim 30 , further comprising adhesively connecting the base portion to the second reinforcement portion.

32. The method of claim 31 , further comprising adhesively connecting the attachment flap to the second side panel, the second side panel overlapping the attachment flap and the second reinforcement portion overlapping the base portion.

33. The method of claim 31 , further comprising positioning the attachment end flap, the second reinforcement portion, the first reinforcement portion, the first reinforcement flap, and the second reinforcement flap to form five plies of material located above the handle to reinforce the handle.

34. The method of claim 27 , wherein the top end flap comprises a third handle feature, the first handle feature comprises a first handle opening, the second handle feature comprises a second handle opening, and the third handle feature comprises a handle flap foldably connected to the top end flap, the handle flap, the first handle opening, and the second handle opening cooperate to form the handle.

35. The method of claim 34 , further comprising upwardly folding the handle flap to be in face-to-face contact with an interior surface of each the first side end flap and the second side end flap to reinforce the handle.

36. The method of claim 27 , wherein the top end flap is foldably connected to the top panel at a fold line, a peripheral free edge of the first reinforcement flap is spaced apart from the fold line by a first distance, a peripheral free edge of the second reinforcement flap is spaced apart from the fold line by a second distance.

37. The method of claim 36 , wherein the first distance is substantially equal to the second distance.

38. The method of claim 37 , wherein the peripheral edge of the top end flap is spaced apart from the fold line by a third distance, the third distance being greater than the second distance.

39. The method of claim 3 , wherein the first distance is substantially greater than the second distance.

Assignments (9)