Carton With Handle-Reinforcement Insert

Abstract

A carton includes a substantially tubular structure having an outer top panel. The carton also has an end wall structure including an outer top end flap foldably connected to the outer top panel along its end edge. The outer top end flap includes a handle opening having a weight-bearing region. The carton also has an insert including an inner top panel and an inner top end flap. The inner top panel is disposed in flat-face condition substantially in registry with the outer top panel. The inner top end flap is foldably connected to the inner top panel along an end edge of the inner top panel. The inner top end flap is substantially in registry with the outer top end flap and has a distal edge disposed adjacent the weight-bearing region of the handle opening. The insert further includes at least one auxiliary reinforcement flap disposed in flat-face condition with the inner top end flap so as to provide multiple-ply structure adjacent the handle opening weight-bearing region.

1 . A carton comprising:
 a substantially tubular structure including an outer top panel;   an end wall structure including an outer top end flap foldably connected to the outer top panel along an end edge thereof, the outer top end flap including a handle opening having a weight-bearing region; and   an insert including an inner top panel disposed in flat-face condition substantially in registry with the outer top panel and an inner top end flap foldably connected to the inner top panel along an end edge thereof, the inner top end flap being substantially in registry with the outer top end flap and having a distal edge disposed adjacent the weight-bearing region of the handle opening.   
   
   
       2 . The carton of  claim 1 , wherein the insert further includes at least one auxiliary reinforcement flap disposed in flat-face condition with the inner top end flap so as to provide multiple-ply structure adjacent the weight-bearing region. 
   
   
       3 . The carton of  claim 2 , wherein the at least one auxiliary reinforcement flap is foldably adjoined to the inner top end flap. 
   
   
       4 . The carton of  claim 1 , wherein the outer top panel includes an outer access opening and the inner top panel includes an inner access opening in substantial registry with the outer access opening. 
   
   
       5 . The carton of  claim 4 , wherein at least one at least partially removable outer access opening panel substantially fills the outer access opening and at least one at least partially removable inner access opening flap substantially fills the inner access opening. 
   
   
       6 . The carton of  claim 2 , wherein the inner top end flap extends downwardly from the inner top panel to a lower end edge of the inner top end flap, and the at least one auxiliary reinforcement flap is foldably adjoined to the inner top end flap along the lower end edge and extends upwardly to be disposed in flat-face condition with an inner surface of the inner top end flap opposite to an outer surface of the inner top end flap along which the end wall structure is disposed. 
   
   
       7 . The carton of  claim 1 , wherein the tubular structure further includes a pair of opposed side panels, the end wall structure further includes a pair of side end flaps foldably connected to the side panels respectively, and the side end flaps are disposed at least in part along the top end flap, each of the side end flaps including a handle cutout that is positioned in registry with a part of the handle opening. 
   
   
       8 . The carton of  claim 7 , wherein the tubular structure further includes a bottom panel, the end wall structure further includes a bottom end flap foldably connected to an end edge of the bottom panel, and the side end flaps are disposed at least in part along the bottom end flap. 
   
   
       9 . The carton of  claim 1 , wherein the tubular structure further includes a pair of opposed side panels, and the insert is hingedly connected to one of the side panels. 
   
   
       10 . A carton, comprising:
 an outer top panel;   first and second side panels hingedly connected the outer top panel;   a bottom panel hingedly connected to the first and second side panels;   an end wall including a top end flap hingedly connected to the outer top panel and having a handle opening with a weight bearing region;
 first and second side end flaps hingedly connected to the first and second side panels respectively; and 
 a bottom end flap hingedly connected to the bottom panel; and 
 an insert including an inner top panel defined by side edges and end edges, and a handle panel structure hingedly connected to the inner top panel along one of the end edges, 
 wherein a reinforcing portion of the handle panel structure is placed in reinforcing proximity to the weight bearing region of the handle opening. 
   
   
   
       11 . The carton of  claim 10 , wherein the reinforcing portion of the handle panel structure comprises an inner top end flap, and each side end flap comprises a cutout having dimensions complementary to the dimensions of at least part of the handle opening. 
   
   
       12 . The carton  claim 11 , wherein the inner top end flap of the handle panel structure is disposed in substantial alignment with the weight bearing region of the handle opening. 
   
   
       13 . The carton of  claim 10 , wherein the insert further includes at least one auxiliary reinforcement flap disposed in flat-face condition with the reinforcing portion of the handle panel structure so as to provide multiple-ply structure adjacent the weight-bearing region. 
   
   
       14 . The carton of  claim 13 , wherein the at least one auxiliary reinforcement flap is foldably adjoined to the reinforcing portion of the handle panel structure. 
   
   
       15 . The carton of  claim 11 , wherein the inner top panel extends entirely along the length of the carton. 
   
   
       16 . The carton of  claim 11  wherein the insert further includes a second handle panel structure hingedly connected to the inner top panel.