Carton with handle reinforcement structure

Abstract

A carton with a handle opening formed in an end wall includes one or more inserts—each being hingedly connected to a handle panel structure for reinforcing and improving the ergonomics of the handle opening. Each handle panel structure includes a reinforcing portion that reinforces the weight-bearing edge of the handle opening. In certain embodiments, this reinforcing portion is formed by folding the multiple panels of the handle panel structure into a hollow box beam shape with a handle edge that reinforcingly aligns with the weight-bearing edge of the handle opening to provide structural integrity. In certain other embodiments, the reinforcing portion is the outermost edge of the handle panel structure, which similarly aligns to support the integrity of the handle opening. The handle opening is further cushioned and reinforced by a punchout flap that folds inward through the handle opening and wraps around the handle panel structure.

1 . A carton, comprising: 
 an outer top panel;    first and second side walls hingedly connected said outer top panel;    a bottom wall hingedly connected to said first side panel and secured to said second side panel;    an end wall, comprising: 
 a top end panel hingedly connected to said outer top panel and including a handle opening having a weight bearing portion;  
 first and second side end panels hingedly connected to said first and second side walls, respectively; and  
 a bottom end panel hingedly connected to said bottom panel; and  
   an insert blank, comprising: 
 an inner top panel defined by side edges and end edges; and  
 a handle structure panel hingedly connected to said inner top panel along one of said end edges;  
   wherein a reinforcing portion of said handle structure panel is aligned with and in reinforcing proximity to said weight bearing portion of said handle opening.    
   
   
       2 . The carton of  claim 1 , wherein: 
 said handle structure panel comprises: 
 a first handle structure section;  
 a handle edge hingedly connected to said first handle structure section;  
 a second handle structure section hingedly connected to said handle edge; and  
 a handle attachment section hingedly connected to said second handle structure section and secured to said inner top panel; and  
   said reinforcing portion comprises the hinged connection between said first handle structure section and said handle edge.    
   
   
       3 . The carton of  claim 1 , wherein: 
 said reinforcing portion of said handle structure panel comprises an end edge; and    each side end flap comprises a cutout having dimensions complementary to the dimensions of at least part of the handle opening.    
   
   
       4 . A carton, comprising: 
 an outer top panel;    first and second side walls hingedly connected said outer top panel;    a bottom wall hingedly connected to said first side panel and secured to said second side panel;    an end wall, comprising: 
 a top end panel hingedly connected to said outer top panel and including a handle opening having a weight bearing portion;  
 first and second side end panels hingedly connected to said first and second side walls, respectively; and  
 a bottom end panel hingedly connected to said bottom panel;  
   an insert blank, comprising: 
 an inner top panel defined by side edges and end edges;  
 a handle structure panel hingedly connected to said inner top panel along one of said end edges.  
   
   
   
       5 . The carton of  claim 4 , said handle structure panel comprising: 
 a first handle structure section;    a handle edge hingedly connected to said first handle structure section;    a second handle structure section hingedly connected to said handle edge; and    a handle attachment section hingedly connected to said second handle structure section and secured to said inner top panel;    a hinged connection between said first handle structure section and said handle edge.    
   
   
       6 . The carton of  claim 4 , wherein the inner top panel extends the length of the carton.  
   
   
       7 . The carton of  claim 4  wherein the inner to panel is further hingedly connected to a second handle structure panel.  
   
   
       8 . A carton, comprising: 
 a plurality of panels that cooperate to form the top, sidewalls, bottom, and ends of said carton;    an inner top panel defined by side edges and end edges;    a handle structure panel hingedly connected to said inner top panel along one of said edges, wherein said handle structure panel comprises a first handle structure section;    a first handle edge hingedly connected to said first handle structure section;    a second handle structure section hingedly connected to said first handle edge; and    a handle attachment section hingedly connected to said second handle structure section and secured to said inner top panel.    
   
   
       9 . The carton of  claim 8 , further comprising an outer top panel defined by side edge and end edges, positioned adjacent to said inner top panel.  
   
   
       10 . The carton of  claim 9 , wherein said outer top panel further comprises a second handle edge and a handle punchout.  
   
   
       11 . The carton of  claim 10 , wherein said out top panel is folded such that said second handle edge is positioned proximate to said first handle edge and said punchout is positioned proximate to said second handle structure.  
   
   
       12 . A carton, comprising: 
 a plurality of panels that cooperate to form the top, sidewalls, bottom, and ends of said carton;    a top panel defined by side edges and end edges;    a handle structure panel hingedly connected to said top panel along one of said edges, wherein said handle structure panel comprises a first handle structure section;    a first handle edge hingedly connected to said first handle structure section;    a second handle structure section hingedly connected to said handle edge; and    a handle attachment section hingedly connected to said second handle structure section and secured to said top panel.    
   
   
       13 . The carton of  claim 12 , further comprising a bottom panel defined by side edge and end edges, positioned opposite said top panel.  
   
   
       14 . The carton of  claim 13 , further comprising a bottom end panel hingedly connected to said bottom panel.  
   
   
       15 . The carton of  claim 14 , wherein said bottom end panel further comprises a second handle edge and a handle punchout.  
   
   
       16 . The carton of  claim 15 , wherein said bottom end panel is folded to position said second handle edge proximate to said first handle edge and said punchout proximate to said second handle structure.  
   
   
       17 . A carton, comprising: 
 a plurality of panels that cooperate to form the top, sidewalls, bottom, and ends of said carton;    a top panel defined by side edges and end edges and hingedly connected to one of said plurality of panels;    a handle structure panel hingedly connected to said top panel along one of said edges, wherein said handle structure panel comprises a reinforcing portion that is aligned with and in reinforcing proximity to said weight bearing portion of the said handle opening.    
   
   
       18 . The carton of  claim 17 , further comprising a bottom panel defined by side edge and end edges, positioned opposite said top panel.  
   
   
       19 . The carton of  claim 18 , further comprising a bottom end panel hingedly connected to said bottom panel.  
   
   
       20 . The carton of  claim 19 , wherein said bottom end panel further comprises a second handle edge and a handle punchout.  
   
   
       21 . The carton of  claim 20 , wherein said bottom end panel is folded to position said second handle edge proximate to said first handle edge and said punchout proximate to said second handle structure.