[0001 ] The present invention relates generally to carriers or cartons for articles such as beverage bottles. The invention also relates to other types of carriers such as cartons adapted for storage in refrigerators. More particularly, the present invention relates to a carrier or carton with a handle adapted for more comfortable carrying.

[0002] A variety of carriers for articles such as beverage bottles and the like are known. A typical carrier may hold four, six, eight or more bottles or cans. It would be advantageous if such a carrier could be lifted without causing user discomfort because of contact by the fingers with cut edges of the carrier.

[0003] Many types of carriers or cartons are known. For example, EP0,507,941 B1 to Wilson discloses a carrier with a handle on the end, as shown in Wilson's Figures 6 and 7. However, this handle could prove to be uncomfortable due to the sharp edges around the holes by which the carrier is held. Another carrier with a handle on an end or side is disclosed in US 201 1/0198393 to Bates.

[0004] What is needed is a new type of carrier or carton with an improved handle for more comfortable carrying.

SUMMARY

[0005] The various embodiments of the present invention provide a comfort flap for an opening divider that is designed to be placed between two fingers when the handle is in use.

[0006] Generally described, the handle includes one or more apertures or openings defined in a wall of a carton that allows a user to insert fingers therethrough. The opening or openings is generally sized to fit a user's fingers and can have various shapes including an elongated slot, trapezoidal, and rectangular. The handle also includes an arrangement of handle flaps that are configured to provide cushioning along the load-bearing edge of the handle.

[0007] According to one aspect of the disclosure, an arrangement of handle flaps is configured to fold as a unit. For example, when a first handle flap is folded toward the interior of the carton, the first handle flap folds a second handle flap toward the interior of the carton. According to an exemplary embodiment, an end of a first fold line that hingedly connects the first handle flap to an edge of the handle is adjacent to an end of a second fold line that hingedly connects the second handle flap to the edge of the handle and the first handle flap overlaps the second handle flap.

[0008] According to an exemplary embodiment of the disclosure, a wall in which the handle is formed can be a composite wall where an outer handle aperture formed in an outer layer is in registry with an inner handle aperture formed in an inner layer. An outer handle flap is attached to an edge of the outer handle aperture and an inner handle flap is attached to an edge of the inner handle aperture. In an unfolded condition, a portion of the outer handle flap may overlap a portion of the inner handle flap. Accordingly, when the outer handle flap is folded, the outer handle flap can contact the inner handle flap to fold the inner handle flap toward the interior of the carton. Additionally, the outer handle flap can include a portion that folds such that the outer handle flap and the inner handle flap remain in contact as they are each folded toward the interior of the carton. In other words, the outer handle flap and the inner handle flap fold as a unit toward the interior of the carton.

[0009] The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.

DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[00010] FIG. 1 is a plan view of a blank for forming a carton, according to an exemplary embodiment of the disclosure;

[0001 1 ] FIG. 2 is a perspective view of a stage in forming the blank of FIG. 1 into a carton;

[00012] FIG. 3 is a perspective view from the end of the carton nearly completed;

[00013] FIG. 4 is view of inner end panels of the carton being formed;

[00014] FIG. 5 is a view of the end of the carton showing overlapping panels in the vicinity of the handle;

[00015] FIG. 6 is a view of outer end panels of the carton having been formed; and

[00016] FIG. 7 is a view of a carton being lifted by the handle. DETAILED DESCRIPTION

[00017] As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word "exemplary" is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

[00018] As used herein, the term "fold line" refers to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line may be a scored line, an embossed line, or a debossed line. The term "fold line" may refer to a frangible fold line. The terms "fold line" and "frangible fold line" each may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cut line, aligned slits, a line of scores and any combination of the aforesaid options.

[00019] As used herein, the term "severance line" refers to all manner of lines formed in a substrate of sheet material, that facilitate separating portions of the substrate from one another, or otherwise indicate optimal separation locations on the substrate. For example, a severance line or tear line in a substrate of sheet material is predisposed to allow a tear to propagate there along. A severance line or tear line may be one of the following: a single cut, a single half-cut, a single slit, an interrupted cut, a score line, an interrupted score line, a line of perforations, a line of short cuts, a line of short slits, a line of short half cuts, and any combination of the

aforementioned options. A severance line may be a frangible or weakened line.

[00020] It should be understood that severance lines and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can have different degrees of weakness such that the line of perforations can be a fold line and/or a severance line. In other words, the line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

[00021 ] Those elements of a fold line or those of a severance/tear line, such as cuts, perforations and scores, can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line, frangible fold line or a severance line. The line of perforations can be designed to facilitate folding and resist breaking to provide a fold line, to facilitate folding and facilitate breaking with more effort to provide a frangible fold line, or to facilitate breaking with little effort to provide a severance line. A frangible fold line may be weaker in terms of breaking resistance than other fold lines in the same blank, in order to facilitate later splitting apart therealong, while it may be stronger in terms of breaking resistance than severance lines in the same blank, in order to facilitate folding therealong.

[00022] The present invention has been illustrated in relation to a particular embodiment which is intended in all respects to be illustrative rather than restrictive. Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope of the invention. For example, as used herein, directional references such as "top", "base", "bottom", "end", "side", "inner", "outer", "upper", "middle", "lower", "front" and "rear" do not limit the respective walls of the carton to such orientation, but merely serve to distinguish these walls from one another. Any reference to hinged connection should not be construed as necessarily referring to a junction including a single hinge only; indeed, it is envisaged that hinged connection can be formed from one or more potentially disparate means for hingedly connecting materials.

[00023] Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton. In the embodiments detailed herein, the term carton refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for grouping, carrying, and dispensing articles, such as beverage cans or bottles. However, it is contemplated that the teachings of the disclosure can be applied to other containers.

[00024] Referring to an exemplary embodiment illustrated in FIGS. 1-7, a carton 300 (FIGs. 5-7) is formed from a blank 100 (FIG. 1 ). The illustrated blank 100 is a single sheet of suitable substrate. As used herein, the term "suitable substrate" includes all manner of foldable sheet material including paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. In the illustrated embodiments, a unitary blank is used to form a carton, although it should be recognized that two or more blanks may be used to form a carton. The illustrated blanks are each configured to form a carton for packaging an exemplary

arrangement of exemplary articles. It is envisaged that the blanks can be

alternatively configured to form a carton for packaging other articles and/or different arrangements of articles. [00025] The blank 100 is substantially symmetric such that opposed ends thereof (e.g. as shown on the upper portion and lower portion of FIG. 1 ) are substantially similar. For clarity, like references have been used with a suffix "a" or "b" affixed to distinguish one end of the blank 100 from the other. The description of an element or group of elements having a suffix "a" is generally suitable for a like- numbered element or group of elements having a suffix "b". In certain instances, only one of like elements may be described unless a description of other or all of the like elements is useful for understanding the invention. In other cases both similar elements may be designated with the suffix "a/b." For the description herein the "a" end of the carton will more often be described, but it will be understood that the description applies to the other end of the carton as well.

[00026] Referring to FIG. 1 , the blank 100 includes a base panel 314, side panels 312, 316 hingedly connected to side edges of the base panel 314, a top panel 310 hingedly connected to side panel 312 (panels 310, 312, 314, 316 collectively may be considered 'primary' panels), a glue flap 318 connected to top panel 310 along fold line 326, and end flaps 330a/b, 332a/b, 333a/b, 334a/b, 335a/b and 336a/b hingedly connected to end edges of the primary panels. The side panels 312, 316 are hingedly connected to the base panel 314 along fold lines 322, 324. The end flaps are hingedly connected to the primary panels along fold lines 340a/b, 342a/b, 343a/b, 344a/b, 346a/b, and 347a/b.

[00027] Side end flaps 332a/b, 333a/b, 335a/b, 336a/b are hingedly connected to opposed ends of side panels 312, 316 along fold lines 342a/b, 343a/b, 346a/b, 347a/b, respectively. Upper end flaps 330a/b are hingedly connected to opposed ends of top panel 310 along fold lines 340a/b, respectively. Lower end flaps 334a/b are hingedly connected to opposed ends of base panel 314 along fold lines 344a/b, respectively. [00028] The blank 100 further includes elements that combine to provide handles at opposed ends of the carton 300. The end flap 330a includes handle apertures 150a and the side end flaps 332a, 336a include handle notches 452a, 454a. Each of the handle apertures 150a and the handle notches 452a, 454a include a handle flap attached along an edge thereof. The handle apertures 150a include an outer handle flap 160a and a comfort flap 161 a. The handle notches 452a, 454a include inner handle flaps 162a, 164a, respectively. The outer handle flap 160a is hingedly connected to a top edge of the handle aperture 150a along a fold line 170a (see FIGs. 3 and 6). The inner handle flaps 162a, 164a are hingedly connected to edges of the handle notches 452a, 454a along fold lines 172a, 174a (see FIG. 2).

[00029] Referring to FIG. 2, an exemplary method of folding and securing the blank 100 to form the carton 300 is now described although a method of erecting the carton 300 is not limited to the steps described herein. Rather, the order of the steps can be altered according to manufacturing requirements, steps may be added or omitted, and means for securing components to one another may vary. For example, although the surfaces of sheet material together are described as being glued together, the sheet material may alternatively be secured together by tape, staples, interlocking folds, hook and loop fasteners, other adhesives, combinations thereof, and the like. The exemplary method can be performed by automatic erecting machinery and/or manually.

[00030] In FIG. 2, the side panels 312, 316 are folded upward relative to base panel 314, along fold lines 322, 324 so as to be substantially perpendicular or upright relative to base panel 314. As seen in the foreground, side end flaps 332a/333a and 335a/336a are then folded along fold lines 342a', 342a", 343a', 343a" and 346a', 346a", 347a', 347a" such that the distal end portions of the side end flaps

332a/333a, 335a/336a overlap and are secured together with glue. The lower end flap 334a is then folded along fold line 344a to overlap exposed outer surfaces of the end wall portions of the side end flaps 333a, 335a and is secured thereto with glue. In alternative embodiments, the side end flaps do not overlap or are not secured together although the notches approximate an aperture formed in an inner layer defined by the side end flaps. Further, the side end flaps 332a, 333a, 335ab, 336a can form an outer layer of an end wall.

[00031 ] Continuing, as also depicted in FIG. 2, the top panel 310 may be folded along fold line 320 connecting it to side panel 312, and the upper end flaps 330a, 330b and glue flap 318 folded along fold lines 340a, 340b, and 326 relative to top panel 310.

[00032] Continuing as shown on FIG. 3, folding of the carton may be completed by attaching glue flap 318 to side panel 316, and folding the upper end flaps 330a, 330b downward after which they may be glued to side end flaps 332a, 336a. Thus the upper end flap 330a, lower end flap 334a, and side end flaps 332a, 333a, 335a, 336a are secured together to provide a first composite end wall of the carton. Similarly the upper end flap 330b, lower end flap 334b, and side end flaps 332b, 333b, 335b, 336b are secured together to provide a second composite end wall of the carton. Additionally, the side panels 312, 316 provide side walls of the carton and the base panel 314 provides a base wall of the carton.

[00033] Referring to FIG. 4, a view of the inner layer of the carton end wall shows handle notches 452a, 454a provided in the side end flaps 332a/333a and 335a/336a respectively. Inner handle flaps 162a, 164a are provided within the handle notches, and connected to side end flaps 332a, 336a through fold lines 172a, 174a respectively. The inner handle flaps 162a, 164a may fold inwardly when the handle is activated as shown in the later Figures. The upper edge of the handle notches 452a, 454a will then be bounded by fold lines 172a, 174a rather than sharp cut edges, so that a user fingers within the handle notches will be more comfortable.

[00034] The handle notches 452a, 454a and inner handle flaps 162a, 164a may be sized and positioned so that they provide some clearance between the contents of the carton and the fingers of a user lifting the carton. In the example shown in Figure 4, the carton is a 3 x n carton, may contain n rows of 3 bottles, with 3 bottles B1 , B2, B3 adjacent each end. The inner handle flaps 162a, 164a may be so that when folded inward they partially pass around the sides of the neck of bottle B2. Inner handle flap 162a may pass between bottles B1 and B2, while inner handle flap 164a may pass between bottles B2 and B3. The inner handle flaps may be provided with one or more fold lines as desired such as fold lines 167a, 167b (See Fig. 1 ) to encourage portions of the flaps to fold around or between bottles. The inner handle flaps may provide some cushioning against the bottles or bottle necks. Furthermore they may guide a user's fingers between the bottles, or provide cushioning for a user's fingers, for example allowing the fingers to bear against a relatively smooth fold line 172a, 174a instead of against a cut edge of the handle notches.

[00035] FIG. 5 shows an end view of the completed carton 300, including the handle apertures 150a formed in the upper end flap 330a. For clarity the left aperture including its fold lines is shown in slightly heavier solid lines. Also shown in FIG. 5 in broken lines is the now hidden (inner layer) side end flap 332a/333a with the handle notch 452a. As shown, the handle aperture 150a is aligned with and overlaps the handle notch 452a, so that when the outer handle flap 160a and comfort flap 161 a are pushed inward, the inner handle flaps 162a, 164a will likewise be pushed inward. The outer handle flap 160a and comfort flap 161 a will thus provide a folded edge that will be more comfortable to a user's fingers than would be a cut edge.

[00036] FIG. 6 shows the right handle aperture 150a having been activated so the outer handle flap 160a and comfort flap 161 a are pushed inward, separating from one another along severance line 163a. Outer handle flap 160a also separates along its lower edge from upper end flap 330a along severance line 165a while hinging inward along fold lines 170a, 173a. [00037] Although Fig. 6 shows only the right handle aperture pressed inward, in use, both handle apertures 150a would be pressed in, that is, both of outer handle flaps 160a and both of comfort flaps 161 a would be pushed inward as a user put his fingers into the handle 150 (see Figure 7). The handle 150 thus created is basically an opening divided by a finger guide 175a that guides the fingers into the carton and around bottle B2, with the outer handle flaps and comfort flaps together with their fold lines providing a comfortable handle 150. The fold lines 171 a of the comfort flaps 161 a are spaced apart from each other to define therebetween the finger guide 175a. These fold lines 171 a are optionally coextending and parallel with each other. However, in an alternative embodiment, the fold lines 171 a may be disposed divergently toward the top panel or toward the base panel 314.

[00038] The comfort flap 161 a' once pressed inward may fold around bottle B2 or its neck and may provide some cushioning against the bottle, while the fold line 171 a provides a folded edge that is more comfortable to a user's fingers than would be a cut edge. The outer handle flap 160a' may fold inward around bottle B2 or its neck (as shown by the cross-hatched area, a portion of outer handle flap 160a' may wrap around behind the bottle or bottle neck), or between bottles B2 and B3, and may provide some cushioning against the bottle or bottles, while the fold lines 170a/173a provide a folded edge that is more comfortable to a user's fingers than would be a cut edge. A load bearing edge is also provided for the user's fingers by fold lines 170a and 173a in the outer handle flaps. The severance line 163a between the outer handle flap 160a and comfort flap 161 a may be shaped approximately like a "V" as shown, or may be sized or shaped according to manufacturing preference.

[00039] The fold line 170a between outer handle flap 160a and upper end flap 330a may be considered a proximal, hinged edge of the outer handle flap 160a, and may be approximately parallel to the fold line 340a between top panel 310 and upper end flap 330a, as shown in Figure.6. Thus the outer handle flap 160a may swing inward like an awning. The fold lines 170a and 340a need not be exactly parallel, but the angle of fold line 170a may be adjusted according to manufacturing preference to provide clearance or cushioning for one or more of the bottles, or cushioning or comfort for a user's fingers. The proximal or hinged edge 170a of the outer handle flap 160a may be nearer to the fold line 340a between top panel 310 and upper end flap 330a, as compared with the distal edge (eventually free edge) defined by the lower portion of severance line 165a which is further from the fold line 340a.

[00040] The fold line 171 a between comfort flap 161 a and finger guide 175a may be approximately perpendicular to the fold line 340a between top panel 310 and upper end flap 330a, as shown in Figure.6. Thus the outer handle flap 160a may swing sideways like a door. The fold lines 171 a and 340a need not be exactly perpendicular, but the angle of fold line 171 a may be adjusted according to manufacturing preference to provide clearance or cushioning for one or more of the bottles (mostly like bottle B2) or cushioning or comfort for a user's fingers.

[00041 ] The fold lines 170a, 171 a may be approximately perpendicular to each other as shown in Figure 6. However the lines need not be exactly perpendicular to each other, by many be positioned according to manufacturing preference.

[00042] FIG. 7 shows both handle apertures 150a activated and a user's hand H lifting carton 300 after having inserted fingers F through the handle apertures.

[00043] In addition to helping guide a user's fingers into the carton, and providing cushioning for articles or fingers, the outer handle flaps 160a, 161 a while yet undeployed (that is, in the blank 100 or finished carton 300) remain attached to the larger blank (or carton) and thus do not create waste material that would be undesirable in the process of forming the blank or carton, or in shipping and storage of the carton. The entirety of both handle apertures 150a is thus covered by these flaps until the flaps are deployed by the user when the carton is first lifted from a retail shelf.

[00044] The blank 100 includes a severance line 350 that defines a detachable portion 352a, 352b. The detachable portion 352a, 352b is dimensioned and positioned such that, when the blank 100 has been formed into carton 300, the detachable portion 352a, 352b can be at least partially separated from the carton to provide an opening in the carton through which articles can be removed. The detachable portion 352a, 362b can have any size or shape so as to provide a suitable opening for dispensing articles and the illustrated version is provided as a non-limiting example.

[00045] Blank 100 and carton 300 may be made from paperboard such as 0.021 CARRIER KOTE made by MeadWestvaco Corporation.

[00046] The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above- described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.