The disclosure of U.S. Provisional Patent Application No. 61/459,052, which was filed on Dec. 6, 2010, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
The present disclosure relates to the cartons and/or packages for holding food products or other items.
In general, one aspect of the disclosure is generally directed to a carton for holding a product. The carton can comprise a tray comprising a plurality of tray panels that extend at least partially around an interior of the tray. The plurality of tray panels can comprise a bottom panel and at least one tray side panel foldably connected to the bottom panel, and the at least one tray side panel can comprise a tray hinge side panel. The carton also can comprise a lid comprising a plurality of lid panels that extend at least partially around an interior of the lid. The plurality of lid panels comprises a top panel and at least one lid side panel foldably connected to the top panel. The at least one lid side panel can comprise a lid hinge side panel, and the lid can cooperate with the tray to at least partially close the carton when the carton is configured in a closed position. The carton further can comprise a hinge at least partially foldably connecting the lid and the tray. The hinge can comprise a first hinge fold line, a second hinge fold line, and a cut extending between the first hinge fold line and the second hinge fold line. The first hinge fold line and the second hinge fold line are generally aligned along a hinge axis, and the cut comprises a central portion that is generally parallel to the hinge axis and is offset from the hinge axis. A first portion of the tray hinge side panel is foldably connected to a first portion of the lid hinge side panel along the first hinge fold line, and a second portion of the tray hinge side panel is foldably connected to a second portion of the lid hinge side panel along the second hinge fold line.
In another aspect, the disclosure is generally directed to a blank for forming a carton. The blank can comprise a tray portion for forming a tray in the carton formed from the blank. The tray portion can comprise a plurality of tray panels comprising a bottom panel and at least one tray side panel foldably connected to the bottom panel, and the at least one tray side panel can comprise a tray hinge side panel. The blank further can comprise a lid portion for forming a lid in the carton formed from the blank. The lid portion can comprise a plurality of lid panels comprising a top panel and at least one lid side panel foldably connected to the top panel, and the at least one lid side panel can comprise a lid hinge side panel. The carton also can comprise hinge features for forming a hinge at least partially foldably connecting the lid and the tray in the carton formed from the blank. The hinge features can comprise a first hinge fold line, a second hinge fold line, and a cut extending between the first hinge fold line and the second hinge fold line. The first hinge fold line and the second hinge fold line are generally aligned along a hinge axis, and the cut comprises a central portion that is generally parallel to the hinge axis and is offset from the hinge axis. A first portion of the tray hinge side panel is foldably connected to a first portion of the lid hinge side panel along the first hinge fold line, and a second portion of the tray hinge side panel is foldably connected to a second portion of the lid hinge side panel along the second hinge fold line.
In another aspect, the disclosure is generally directed to a method of forming a carton. The method can comprise obtaining a blank comprising a tray portion, a lid portion, and hinge features. The tray portion can comprise a plurality of tray panels comprising a bottom panel and at least one tray side panel foldably connected to the bottom panel. The at least one tray side panel can comprise a tray hinge side panel. The lid portion can comprise a plurality of lid panels comprising a top panel and at least one lid side panel foldably connected to the top panel. The at least one lid side panel can comprise a lid hinge side panel, and the hinge features comprise a first hinge fold line, a second hinge fold line, and a cut extending between the first hinge fold line and the second hinge fold line. The first hinge fold line and the second hinge fold line are generally aligned along a hinge axis, and the cut comprises a central portion that is generally parallel to the hinge axis and is offset from the hinge axis. A first portion of the tray hinge side panel is foldably connected to a first portion of the lid hinge side panel along the first hinge fold line, and a second portion of the tray hinge side panel is foldably connected to a second portion of the lid hinge side panel along the second hinge fold line. The method further can comprise forming an interior of a tray by folding the at least one tray side panel relative to the bottom panel, and forming an interior of a lid by folding the at least one lid side panel relative to the top panel. The lid can be foldably connected to the tray at a hinge that comprises the hinge features. The method also can comprise positioning the lid and the tray between an open configuration and a closed configuration by folding the lid relative to the tray at the hinge.
Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.
According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
The carton 3 may have an element (not shown) for use in cooking, heating, browning, and/or shielding (e.g., a microwave energy interactive element such as, but not limited to, a susceptor) mounted to one or more surfaces of the tray 7 and/or the lid 11. Alternatively, or in addition, the carton 3 can also include a window in one or more of the panels of the tray 7 and/or the lid 11. For example, a window could include an opening defined a top panel of the tray 7 and a transparent or translucent liner material covering the opening. It is understood that the microwave energy interactive elements or features and the window may be omitted from the carton 3 without departing from the disclosure. In this specification, the terms “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright packages.
As shown in
The end flaps 35, 39, 45 extend along a first marginal area of the tray portion 17 and are foldably connected at a first longitudinal fold line 51. The end flaps 37, 41, 47 extend along a second marginal area of the tray portion 17, and are foldably connected at a second longitudinal fold line 53. The longitudinal fold lines 51, 53 may be, for example, substantially straight, or offset at one or more locations to account for blank thickness or for other factors. Additionally, the ends of the longitudinal fold lines 51, 53 can be at least slightly oblique to help in positioning the sides and ends of the carton 3 to be oblique with respect to the top and bottom of the carton. The features that form the tray portion 17 and the tray 7 could be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure.
In the illustrated embodiment, the lid portion 19 is shaped generally similar to the tray portion 17 and includes a top panel 61 foldably connected to a first side panel 63 at a lateral fold line 65 and a second side panel 67 at a lateral fold line 69. The top panel 61 includes two end panels 73, 83 foldably connected to opposite ends of the top panel 61. The first side panel 63 has two end flaps 75, 85 foldably connected to opposite ends of the first side panel. The end panels 73, 83 include respective end flaps 77, 87 foldably connected to the respective end panels 73, 83 adjacent opposite ends of the second side panel 67. In the illustrated embodiment, the end flaps 77, 87 include locking projections 56, 58 for engaging the respective locking projections 55, 57 in the tray 7 when the carton 3 is in the closed configuration (
The end panel 73 and the end flaps 75, 77 extend along a first marginal area of the lid portion 19. The end panel 83 and the end flaps 85, 87 extend along a second marginal area of the lid portion 19. The end panels 73, 83 are foldably connected to the top panel 61 at a respective first longitudinal fold line 91 and second longitudinal fold line 93. The end flaps 75, 85 are foldably connected to the first side panel 63 at respective ends of the respective first longitudinal fold line 91 and second longitudinal fold line 93. The end flaps 77, 87 are foldably connected to the respective end panels 73, 83 along respective ends of the lateral fold line 69. As with the tray portion 17, the longitudinal fold lines 91, 93 can have portions that are offset, oblique, and/or spaced apart from other portions of the fold line. The features that form the lid portion 19 and the lid 11 could be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure.
As shown in
As shown in
As shown in
In one exemplary embodiment, the carton 3 is formed by forming the tray portion 17 of the blank 1 into the tray 7 and forming the lid portion 19 of the blank into the lid 11. In one exemplary method, the tray 7 is formed by folding the side panels 23, 29 and the end flaps 35, 37 relative to the bottom panel 21. The end flaps 39, 45 are inwardly folded and overlapped with the end flap 35 to form respective reinforced corners 131, 133 of the tray 7. The end flaps 41, 47 are overlapped with the end flap 37 to form respective reinforced corners 135, 137 of the tray 7. In one embodiment, the end flaps can be glued to the respective end flaps 35, 37. The tray 7 could be formed by other forming steps without departing from the disclosure.
The lid 11 is formed in a similar manner as the tray 7. In one exemplary method, the lid 11 is formed by folding the side panels 63, 67 and the end panels 73, 83 relative to the top panel 61. The end flaps 75, 85 are inwardly folded and overlapped with the respective end panels 73, 83 to form respective reinforced corners 141, 145 of the lid 11. The end flaps 77, 87 are inwardly folded and overlapped with the side panel 67 to form respective reinforced corners 143, 147 of the lid 11. The lid 11 could be formed by other forming steps without departing from the disclosure.
A food product or other product can be placed on the bottom wall 21 of the tray 7 and the lid 11 can be folded in the direction of arrow A1 (
In the embodiment of
The hinge 215 functions in a similar manner as the hinge 15 of the first embodiment. The cut 321 forms a protrusion extending from the tray hinge side panel 223 and a corresponding recess in the edge of the lid hinge side panel 263. As the lid hinge side panel 263 pivots relative to the tray hinge side panel 223, the recess can pivot past the protrusion, and the recess provides room to help reduce interference between the side panels 223, 263. The debossed area 311 is pressed inwardly from the remaining portions of the side panel 223 so that the edge of the side panel 223 formed at the cut line 321 is offset from the edge of the side panel 263 formed at the cut line 321. In this manner, the hinge 215 facilitates movement of the lid 211 while helping to reduce or eliminate buckling or interference of the material in the side panels 223, 263.
The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blank can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blank may then be coated with a varnish to protect any information printed on the blank. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blank can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.
In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines may include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.
As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, cut line, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.
The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives used to secure carton panels in place such as heat sealing, or any other manner than may or may not include glue, adhesive, or other bonding agent.
The foregoing description illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. It will be understood by those skilled in the art that while the present disclosure has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 61/459,052, filed Dec. 6, 2010.
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