BACKGROUND OF THE DISCLOSURE
The present disclosure relates to trays, cartons, containers, etc. for holding food products or other items.
SUMMARY OF THE DISCLOSURE
In general, one aspect of the disclosure is generally directed to a container for holding a product. The container can comprise a tray comprising a plurality of panels extending at least partially around an interior of the tray. The plurality of panels can comprise at least a front panel. The container further can comprise a lid comprising at least a top panel. A closure can comprise at least a locking slot extending in at least the front panel of the tray, a closure aperture extending in at least the top panel, and a closure flap foldably connected to the top panel and extending in the closure aperture. The container comprises an open configuration in which the top panel extends away from the interior of the tray and a closed configuration in which the top panel extends over at least a portion of the tray. At least a portion of the front panel is received in the closure aperture and the closure flap is at least partially received in the locking slot in the front panel when the container is in the closed configuration.
In another aspect, the disclosure is generally directed to a blank for forming a container for holding a product. The blank can comprise a tray portion for at least partially forming a tray of the container formed from the blank. The tray portion can comprise a plurality of panels comprising at least a front panel. The blank further can comprise a lid portion for at least partially forming a lid of the container formed from the blank. The lid portion can comprise at least a top panel. Closure features can comprise a locking slot extending in the front panel of the tray portion, a closure aperture extending in at least the top panel, and a closure flap foldably connected to the top panel and extending in the closure aperture. The container formed from the blank can comprise an open configuration in which the top panel extends away from an interior of the tray formed from the tray portion and a closed configuration in which the top panel extends over at least a portion of the tray formed from the tray portion. At least a portion of the front panel is for being received in the closure aperture and the closure flap is for being at least partially received in the locking slot in the front panel when the container formed from the blank is in the closed configuration.
In another aspect, the disclosure is generally directed to a method of forming a container. The method can comprise obtaining a blank comprising a tray portion, a lid portion, and closure features. The tray portion can comprise a plurality of panels comprising at least a front panel, the lid portion can comprise at least a top panel, and the closure features can comprise a locking slot extending in the front panel of the tray portion, a closure aperture extending in at least the top panel, and a closure flap foldably connected to the top panel and extending in the closure aperture. The method further can comprise forming a tray comprising positioning panels of the plurality of panels of the tray portion to extend at least partially around an interior of the tray. The lid portion can at least partially form a lid of the container. The container can comprise an open configuration in which the top panel extends away from the interior of the tray and a closed configuration in which the top panel extends over at least a portion of the tray. At least a portion of the front panel is received in the closure aperture and the closure flap is at least partially received in the locking slot in the front panel when the container is in the closed configuration.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
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.
FIG. 1 is a plan view of a blank for forming a carton according to exemplary embodiments of the disclosure.
FIG. 2 is a perspective view of the carton formed from the blank of FIG. 1 in an open configuration according to exemplary embodiments of the disclosure.
FIG. 3 is a perspective views\ showing the closing of the carton of FIG. 2 according to exemplary embodiments of the disclosure.
FIG. 4 is a perspective view of the carton of FIGS. 2 and 3 in the closed configuration according to exemplary embodiments of the disclosure.
FIG. 5 is a perspective view of a closure feature of the carton of FIGS. 2-4.
FIG. 6 is a perspective rear view of the carton of FIGS. 2-5 in the closed configuration according to exemplary embodiments of the disclosure.
FIG. 7 is a plan view of a blank for forming a carton according to additional exemplary embodiments of the disclosure.
FIG. 8 is a perspective view of the carton formed from the blank of FIG. 7 in an open configuration according to exemplary embodiments of the disclosure.
FIGS. 9 and 10 are perspective views of the carton of FIG. 8 in a closed configuration according to exemplary embodiments of the disclosure.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
The present disclosure generally relates to constructs, boxes, cartons, carriers, trays, containers, or the like, and packages for holding one or more products or articles such as food items (e.g., for display and/or sale, for storage, for food service, etc.) or other articles such as any suitable type of product that can be stored, displayed, served, transported, cooled, frozen, heated, and/or cooked. Some suitable products could comprise berries and/or other fruits, vegetables, prepared foods, salad, sandwiches, tacos, desserts, pastries, cookies, chips, hot dogs, French fries, nachos, popcorn, cuts of meat, or any other suitable food product or other article. It is understood that food products (or non-food products) other than the food products listed herein may be contained in the package. Constructs according to the present disclosure can accommodate products or articles of any shape.
In this specification, the terms “inner,” “interior,” “outer,” “exterior,” “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright constructs and cartons. As described herein, constructs can be formed from blanks by being glued with multiple panels, portions, tabs, and/or flaps, which may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or nonsequential reference, without departing from the disclosure.
FIG. 1 is a plan view of a blank 101 used to form a container or carton 103 (FIGS. 2-6) of a first embodiment of the disclosure. FIG. 1 shows an interior surface 104 of the blank 101. The carton 103 can be used to hold a food product (not shown), such as berries and/or other fruits, vegetables, and/or another suitable food items and/or other suitable products. For example, a food product can be placed in the carton for transport, display, sale, and/or storage. The carton 103 includes a tray 107 that is sized to hold the food product and a lid 111 foldably connected to the tray 107 at a hinge 115. In embodiments, the lid 111 and the tray 107 have features for facilitating locking of the lid 111 in a closed configuration.
As shown in FIG. 1, the carton blank 101 has a longitudinal axis L1 and a lateral axis L2. The blank 101 includes a first or tray portion 117 for forming the tray 107 and a second or lid portion 119 for forming the lid 111. The tray portion 117 includes a bottom panel 121 foldably connected to a back panel or first side panel 123 at a lateral fold line 125. A front panel or second side panel 129 is foldably connected to the bottom panel 121 at a lateral fold line 131. In the illustrated embodiments, the tray portion 117 includes two end panels 135, 137 foldably connected to opposite ends of the bottom panel 121 along respective longitudinal fold lines 138. Two end flaps 139, 141 are foldably connected to opposite ends of the first side panel 123 along respective oblique fold lines 143, and two end flaps 145, 147 are foldably connected to opposite ends of the second side panel 129 along respective oblique fold lines 149.
In the illustrated embodiment, a bottom closure feature can include a locking opening or slot 155 extending in the second side panel 129. In embodiments, a protrusion 151 can extend from a distal edge 153 of the second side panel 129. Alternatively, the protrusion could be omitted. As shown in FIG. 1, each of the end panels 135, 137 can include a respective recess 157 extending from a distal edge of the respective end panels 135, 137, which recesses 157 can define extensions 159 of the end panels 135, 137 extending on either side of the recesses 157. In the illustrated embodiments, the recesses 157 each can have a longitudinal edge and oblique edges extending from the ends of the longitudinal edge. Any of the features that form the tray portion 117 and the tray 107 could be omitted or could be otherwise shaped, arranged, configured, and/or positioned without departing from the disclosure.
In the illustrated embodiments, the lid portion 119 includes a top panel 161 foldably connected to the first side panel 123 along two lateral fold lines 163 (e.g., collinear fold lines 163 spaced apart by a window as discussed in more detail below). As shown in FIG. 1, a top closure feature can include a closure aperture 165 extending in the top panel 161 and a closure flap 167 extending in the closure aperture 165. In the illustrated embodiments, the closure aperture 165 can be spaced inwardly from an outer edge of the top panel 123. In embodiments, the closure flap 167 can be foldably connected to the top panel 161 along a curved fold line 169 extending generally in the lateral direction L2 and can extend across the closure aperture 165 so that the closure flap 167 is separable from the top panel 161 along a tear or cut line 171 opposite to the curved fold line 169. In an example, the line of weakening 171 can be a cut line with one or more nicks that can hold the closure flap 167 in place in the plane of the top panel 161 until the nick is broken to allow the closure flap 167 to fold along the curved fold line 169. As shown in FIG. 1, the top panel 161 can include extensions or tabs 173 extending outwardly in the lateral direction L2 from respective end edges 175 of the top panel 161. In embodiments, the tabs 173 can be sized and positioned for being at least partially received in the respective recesses 157 in the top edges of the respective end panels 135, 137 when the carton 103 is formed and the lid 111 is closed (FIGS. 4 and 6). As shown in FIG. 1, the closure flap 167 can be in a center or a central portion of the top panel 161. In exemplary embodiments, the closure flap 167 and the locking slot 155 in the second side panel 129 of the tray portion 117 can be aligned along a longitudinal axis CL of the blank 101. Any of the features that form the lid portion 119 and the lid 111 could be omitted or could be otherwise shaped, arranged, configured, and/or positioned without departing from the disclosure.
As shown in FIG. 1, a cutout, opening, or window 177 can be defined in at least the top panel 161 and the first side panel 123 with edges of at least the top panel 161 and the first side panel 123 extending along the window 177 and the window extending between the lateral fold lines 163. In other embodiments, the window 177 can extend into other portions of the blank 101. In exemplary embodiments, a film 179 or other suitable material can be applied to the interior surface 104 of at least the top panel 161 and the first side panel 123, such as by gluing, heat scaling, welding, and/or other suitable attachment methods. For example, the film 179 can be attached to the interior surface 104 by a bead of glue or a glue strip G (e.g., a continuous glue strip or bead extending around the perimeter of the window 177 to seal the film 179 around the window 177). Alternatively, the film 179 can be attached to the surface 104 by one or more glue features, discontinuous glue strips, glue dots, and/or other suitable features. In the illustrated embodiments, the film 179 can be transparent or translucent so that the items contained in the container 103 can be seen when the container 103 is closed (FIGS. 4 and 6). In embodiments, the film 179 can be sealed to the interior surface 104 of the top panel 161 around the entirety of the window 177 so that the film 179 protects the items in the interior of the container 103.
As shown in FIG. 1, the bottom end panel 135 and the end flaps 139, 145 can extend along a first marginal area of the blank 101, and the bottom end panel 137 and the end flaps 141, 147 can extend along a second marginal area of the blank 101. In the illustrated embodiments, the blank 101 can include a plurality of vents or other openings and cutouts (e.g., in the shape of circles, partial circles, slots, and/or other suitable shapes). The blank 101 could be otherwise shaped, arranged, configured, and/or positioned without departing from the disclosure. For example, the blank 101 could include any suitable number of closure flaps 167 and locking slots 155 positioned along the top panel 161 and the second side panel 129.
In exemplary embodiments, the carton 103 is formed by forming the tray portion 117 of the blank 101 into the tray 107 with the lid portion 119 extending from the first side panel 123 at the hinge 115 (e.g., the fold lines 163) to form the lid 111. In an exemplary method, the tray 107 is formed by folding the side panels 123, 129 and the end panels 135, 137 relative to the bottom panel 121 to extend at least partially around an interior 181 of the tray 107 and the carton 103 (FIG. 2). In embodiments, the end flaps 139, 145 can be inwardly folded and overlapped with the end panel 135 to form a first end wall 183a of the tray 107, and the end flaps 141, 147 can be overlapped with the end panel 137 to form an opposing second end wall 183b of the tray 107. In embodiments, the end flaps 139, 145 and 141, 147 can be glued to the respective end panels 135, 137. In embodiments, the side panels 123, 129 and the end walls 183a, 183b can cooperate to at least partially form a sidewall extending around the interior 181 of the tray 107. The tray 107 could be formed by other forming steps without departing from the disclosure. For example, the end flaps 139, 145, and 141, 147 can be attached to the interiors of the respective end panels 135, 137.
The carton 103 is shown in an open configuration in FIG. 2 with the lid 111 extending upwardly from the hinge 115 so that the tray 107 is accessible and items can be loaded into and/or removed from the interior 181 of the tray 107.
As shown in FIGS. 3 and 4, the carton 103 can be moved to a closed configuration (FIGS. 4-6) by folding the lid 111 toward the tray 107 at the hinge 115. As the lid 111 is closed, moving the top panel 161 over the tray 107, the tabs 173 can move between the extensions 159 of the end panels 135, 137 so that the tabs 173 are at least partially received in the respective recesses 157 (FIGS. 4 and 6). In embodiments, as the lid 111 is moved to the closed position, the protrusion 151 can move at least partially through the closure aperture 165, pushing the closure flap 167 upwardly so that it folds along the fold line 169 and separates from the top panel 161 along the cut line 171 (FIG. 3). As shown in FIG. 3, the protrusion 151 has an upper edge that is spaced upwardly from the distal edge 153 of the second side panel 129 (FIGS. 1 and 2), and the upper edge of the protrusion 151 pushes against an underside of the closure flap 167 as the lid 111 is closed, which can push the closure flap 167 upwardly, out of the plane of the top panel 161. In the illustrated embodiments, a distal edge of the closure flap 167 can be formed when the closure flap 167 separates from the top panel 161 along the line of weakening 171, and the distal edge of the closure flap 167 can be pushed upwardly as the protrusion 151 moves into the closure aperture 165 as shown in FIG. 3. When the protrusion 151 is sufficiently received in the closure aperture 165 as the lid 111 is closed, the closure flap 167 can move downwardly along an interior surface of the protrusion and into the locking slot 155 (FIGS. 4 and 5) to lock the lid 111 in the closed configuration. In some embodiments, the curve of the fold line 169 can bias the closure flap 167 toward the plane of the top panel 161 so that the closure flap 167 snaps into the locking slot 155 when it is able to during the closing of the lid 111. As shown in FIGS. 4 and 5, when the top panel 161 is moved into the closed position, the protrusion 151 can be at least partially received through the closure aperture 165 in the top panel 161 (e.g., so that the protrusion 151 extends upwardly with respect to the top panel 161 and the lid 111) and the closure flap 167 can engage (e.g., can be at least partially received in) the locking slot 155 in the second side panel 129 to help lock the lid 111 and the tray 107 in the closed position. In the illustrated embodiments, the at least partially interlocked closure features of the lid 111 and the tray 107 can form a closure 185 for helping to hold the carton 103 in its closed configuration (FIGS. 4-6).
In embodiments, the carton 103 can be opened by pivoting the lid 111 upwardly, away from the tray 107 at the hinge 115 so that the protrusion 151 is moved out of the closure aperture 165 in the top panel 161. As the distal end of the lid 111 is moved upwardly, the closure flap 167 can be forced downwardly by the protrusion 151 (e.g., by the upper edge of the locking slot 155) so that the closure flap 167 folds downwardly relative to the top panel 161 along the fold line 169 until the protrusion 151 is removed from the closure aperture 165. For example, the distal edge of the closure flap 167 can be pushed downwardly by the upper edge of the locking slot 155 so that the distal edge of the closure flap 167 moves along the interior surface of the protrusion 151 as the lid 111 is opened until the distal edge of the closure flap 167 clears the upper edge of the protrusion 151. In embodiments, when the protrusion 151 is removed from the closure aperture 165, the closure flap 167 can move back into the plane of the top panel 161 (e.g., due to the bias of the curved fold line 169). With the closure features of the lid 111 and the tray 107 separated, the lid 111 can pivot away from the tray 107 at the hinge 115 so that items can be removed from or added to the interior 181 of the tray 107 through the open top of the tray 107. The lid 111 could be otherwise closed and/or opened without departing from the disclosure.
In embodiments, the closure features and the closure 185 can facilitate easy closing of the carton 103 and locking the carton 103 in its closed configuration. For example, the carton 103 can be closed with one hand, as shown in FIG. 3. In exemplary embodiments, the closure 185 provides vertical and horizontal lock integrity that can resist or prevent disengagement of the closure features due to extreme temperatures and/or humidity that can cause deformation (e.g., curl) of the material of the carton 103 (e.g., paper-based substrates). For example, the engagement of the protrusion 151 with the closure aperture 165 can help reduce or prevent unwanted movement of the lid 111 relative to the tray 107 in a horizontal plane (e.g., front to back perpendicular to the side panels 123, 129 and/or end to end perpendicular to the end walls 183a, 183b), and the engagement of the closure flap 167 with the locking slot 155 can help reduce or prevent unwanted movement of the lid 111 relative to the tray 107 in at least the vertical direction and/or the end to end direction. In some embodiments, deformation of a carton (e.g., due to heat and/or humidity) could cause disengagement of a closure that does not have the protrusion 151 engaged with the closure aperture 165 (e.g., curl of the lid could cause a locking flap to move towards a back of the carton out of a locking slot).
FIG. 7 illustrates a blank 301 for forming a carton 303 (FIGS. 8-10) according to additional embodiments of the disclosure similar to the carton 103 and blank 101 of the prior embodiments. Accordingly, like or similar features are indicated with like or similar reference numbers between the two embodiments. The second embodiment is generally similar to the first embodiment, except for variations noted and variations that will be apparent to one of ordinary skill in the art. As shown in FIG. 7, the tray portion 317 can include end panels 335, 337 that do not include the recesses 157, and the end panels 335, 337 extend upwardly relative to the side panels 123, 129 when the tray 307 is formed so that the distal or top edges of the end panels 335, 337 are spaced upwardly from the hinge 315 and the distal edge 153. In the illustrated embodiments, the window 377 and the film 379 extend in the top panel 361 of the lid portion 319 so that the window 377 and the film 379 are spaced apart from the first side panel 123. The top panel 361 can be foldably connected to the first side panel 123 along a lateral fold line 363, which becomes the hinge 315 connecting the lid 311 and the tray 307 when the carton 303 is formed from the blank 301. As shown in FIG. 7, the lid portion 319 can include top end flaps 387, 389 foldably connected to the top panel 361 along respective longitudinal fold lines 391. Any of the features that form the blank 301 and the carton 303 could be omitted or could be otherwise shaped, arranged, configured, and/or positioned without departing from the disclosure.
In the illustrated embodiments, the carton 303 can be formed in a similar or identical manner as the cartons of the prior embodiments, with the end panels 335, 337 cooperating with the respective end flaps 139, 145 and 141, 147 to form the respective end walls 383a, 383b. When the carton 303 is moved from its open configuration (FIG. 8) to its closed configuration (FIGS. 9 and 10), the top panel 361 is folded along the hinge 315 (the lateral fold line 363) toward the interior 181 of the tray 307. In the illustrated embodiments, as the lid 311 is moved downwardly, the top end flaps 387, 389 can engage (contact) the end panels 335, 337, which can push the top end flaps 387, 389 so that they fold upwardly along the respective fold lines 391 with respect to the top panel 361. As shown in FIGS. 9 and 10, when the lid 311 is closed and the closure 185 is secured, the top end flaps 387, 389 can be folded upwardly relative to the top panel 361 and can engage (e.g., can be in face-to-face contact with) the interior surfaces of the respective end panels 335, 337. The carton 303 could be otherwise formed and/or could be otherwise closed without departing from the disclosure.
Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure. In addition, the panels, flaps, and other features shown and described in conjunction with the blanks 101, 301 and the cartons 103, 303 are included by way of example.
The blanks according to any of the embodiments of 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 exemplary 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 include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed 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. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.
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 of 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, 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.
The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, 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. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.