Carton with Interlocking Features

This application claims the benefit of U.S. Provisional Patent Application No. 63/650,432, filed on May 22, 2024.

The disclosure of U.S. Provisional Patent Application No. 63/650,432, which was filed on May 22, 2024, is hereby incorporated by reference for all purposes as if presented herein in its entirety.

The present disclosure generally relates to cartons for holding food items or other types of articles. More specifically, the present disclosure relates to cartons that may include interlocking features.

In general, one aspect of the disclosure is directed to a carton for holding one or more products. The carton can comprise a plurality of panels that extends at least partially around an interior of the carton, and the plurality of panels can comprise at least a front panel and a back panel. The front panel can extend opposite at least a portion of the back panel, and at least a portion of the back panel can extend past a top edge of the front panel. The carton further can comprise a plurality of locking elements for at least partially interlocking the carton with a second carton for at least partially forming a carton assembly.

In another aspect, the disclosure is generally directed to a carton assembly for holding one or more products. The carton assembly can comprise a first carton comprising a first plurality of panels that extends at least partially around a first carton interior. The first carton can comprise a first plurality of locking elements. The carton assembly further can comprise a second carton comprising a second plurality of panels that extends at least partially around a second carton interior. The second carton can comprise a second plurality of locking elements. The first carton can engage the second carton so that the first carton interior cooperates with the second carton interior to form an assembly interior of the carton assembly, and the first plurality of locking elements can engage the second plurality of locking elements for at least partially retaining the first carton and the second carton in the carton assembly.

In another aspect, the disclosure is generally directed to a blank for forming a plurality of cartons for holding one or more products. The blank can comprise a first part for at least partially forming a first carton of the plurality of cartons. The first part can comprise a first plurality of panels and a first plurality of locking elements. The blank further can comprise a second part for at least partially forming a second carton of the plurality of cartons. The second part can comprise a second plurality of panels and a second plurality of locking elements, and the first part and the second part can be separable from one another along at least a tear line. The first carton formed from the first part can be for engaging the second carton formed from the second part for at least partially forming a carton assembly, and the first plurality of locking elements and the second plurality of locking elements can be for being engaged for at least partially retaining the first carton and the second carton in engagement with one another when the carton assembly is formed from the blank.

In another aspect, the disclosure is generally directed to a method of forming a plurality of cartons for holding one or more products. The method can comprise obtaining a blank comprising a first part and a second part. The first part can comprise a first plurality of panels and a first plurality of locking elements, and the second part can comprise a second plurality of panels and a second plurality of locking element. The blank can comprise a tear line extending along at least a portion of each of the first part and the second part. The method further can comprise forming the blank into at least a first carton and a second carton of the plurality of cartons by folding the blank. The first carton and the second carton can be separable from one another along the tear line. The first carton can be for engaging the second carton for at least partially forming a carton assembly, and the first plurality of locking elements and the second plurality of locking elements can be for being engaged for at least partially retaining the first carton and the second carton in engagement with one another when the carton assembly is formed from the first carton and the second carton.

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. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

The present disclosure generally relates to constructs, boxes, cartons, carriers, containers, or the like, for holding one or more products or articles such as food items (e.g., for food service, for display and/or sale, for storage, etc.) or other articles such as any suitable type of product that can be served, stored, displayed, transported, cooled, frozen, heated, and/or cooked. Some suitable products could include wraps and/or other sandwiches, burritos, hot dogs, French fries, vegetables, nachos, tacos, cookies, chips, pastries, fruits, popcorn, cuts of meat, and/or any other suitable food product or other article. It is understood that food products (and/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 with multiple walls, panels, portions, tabs, flaps, fold lines, cut lines, tear lines, and/or other aspects, 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.

is a plan view of the exterior sideof a blank, generally indicated at, used to form a folded construct() that can be separated into two containers or cartons,() according to exemplary embodiments of the disclosure. One or both of the cartons,can be used to hold one or more food products P (), such as a wrap or other sandwich and/or other suitable food items and/or other suitable products. Further, the two cartons,can cooperate to form a package or carton assemblyand to at least partially enclose a package interior() for holding a food product P in the enclosed package interior. For example, a food product P can be placed in one or both of the cartons,and/or can be enclosed in the carton assemblyfor serving and/or transporting the food item (e.g., to a consumer).

In the illustrated embodiments, the blankhas a longitudinal axis Lextending generally in the direction of the length of the blank and a lateral axis Lextending generally in the direction of the width of the blank. As shown in, the blankcan include a first section or partconnected to a second section or partalong two tear lines(e.g., cut lines interrupted by a plurality of nicks and/or other suitable lines of weakening). The first partand the second partcan include a respective first plurality of panels and second plurality of panels, wherein each of the first plurality of panels and the second plurality of panels comprises a respective front panelfoldably connected to a respective back panelalong a respective longitudinal fold line. In embodiments, the front paneland the back panelof the first partare separable from the respective back paneland front panelof the second partalong the tear lines. As shown in, each of the front panelscan be foldably connected to a respective front bottom flapalong a respective arcuate fold lineand each of the back panelscan be foldably connected to a respective back bottom flapalong a respective arcuate fold line. In embodiments, each of the front bottom flapscan have a convex outer edge, and the back bottom flapscan be similarly shaped as the front bottom flapsexcept that each of the back bottom flapscan include a concave portion. Alternatively, the bottom flaps,could have any suitable shape. Any of the panels,and/or the flaps,could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

As shown in, the first partcan include a first attachment flapfoldably connected to the front panelof the first partalong a first longitudinal fold line, and the second partcan include a second attachment flapfoldably connected to the back panelof the second partalong a second longitudinal fold line. In the illustrated embodiments, the blankcan include a cutout(e.g., a central cutout) extending along respective edges of each of the front and back panels,. As shown in, the longitudinal fold linescan be collinear (e.g., approximately, generally, and/or substantially collinear) and can be spaced apart by the cutout. Similarly, the longitudinal fold linescan be collinear (e.g., approximately, generally, and/or substantially collinear) and can be spaced apart by a recessin the blankbetween the attachment flaps,. Any of the attachment flaps,, the cutout, and/or the recesscould be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

In the illustrated embodiments, the blankcan include locking features (e.g., first locking features and second locking features associated with the respective first partand second partand the respective cartons,) that can help retain the cartons,formed from the respective parts,in engagement with one another in the form of the carton assembly. As shown in, the locking features can include cuts(e.g., four cutswith two cutsin the first partand two cutsin the second part) extending in the panels,and the attachment flaps,, each of the cutsinterrupting a respective one of the fold lines,. In embodiments, the cutseach can include an oblique portion extending between two curved ends, wherein the curved ends closest to a center of the blank(e.g., to a lateral centerline of the blank) can be larger than the respective opposing ends. As shown in, the locking features further can include friction locks such as protrusions or tabs(e.g., four curved tabs) or other suitable elements extending from respective free edges,of the back panels. For example, one tabcan extend into the cutoutfrom each of the back panelsand one tabcan extend from each of the back panelsfrom outer free edges of the blank. For example, two of the tabscan extend from the free edgesof the respective back panelsalong the cutout, and two of the tabscan extend from the free edgesof the respective back panelsalong outer edges of the blank, wherein the free edgeof the second partcan extend along the recess. In embodiments, the two tabsextending from each of the back panelscan be opposing one another (e.g., so that the tabsare aligned along the lateral direction Lin each of the back panels). The locking features, including any of the cutsand/or the tabs, could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

The blankcould be otherwise shaped, arranged, and/or configured without departing from the disclosure.

As shown in, the blankcan be formed into the constructin a flattened, collapsed configuration. For example, the attachment flaps,can be folded along the respective longitudinal fold linesover the interior surfaces of the respective front panelof the first partand back panelof the second part(e.g., into face-to-face contact with the respective panels,of the respective parts,). In embodiments, glue can be applied to the exterior surfaces of the attachment flaps,and/or to the interior surfaces of the back panelof the first partand the front panelof the second part. The blankcan be folded along the longitudinal fold linesso that the back panelsare in an at least partially overlapping relationship with one another and so that the front panelsof the parts,are in an at least partially overlapping relationship with the back panelsof the respective parts,. In embodiments, the folding of the blankcan bring the attachment flaps,into an at least partially overlapping relationship with the respective back panelof the first partand front panelof the second part(e.g., gluing the attachment flaps,in face-to-face contact with the interior surfaces of the respective back paneland front panel). In embodiments, the formation of the constructalso forms the cartons,from the respective parts,(e.g., when the blankis folded and the attachment flaps,are glued in place). In the illustrated embodiments, the cartons,are connected to one another and are separable from one another along the tear lines.

As shown in, the constructcan be in the form of an open-ended sleeve with the bottom flaps,extending at the respective open ends′. In embodiments, the construct, and the cartons,that make up the construct, can be in a collapsed/flattened condition (e.g., with the overlapping panels at least partially in face-to-face contact with one another) for compact storage and/or transportation. For example, a plurality of the flattened constructscan be arranged in a stack in a restaurant so that the constructscan be obtained from the stack for filing with a food item for food service. The constructcould be otherwise formed and/or used without departing from the disclosure.

In some embodiments, the constructcan be moved from the flattened configuration ofto an erected configuration as shown in. For example, the constructcan be pressed inwardly at its edges (e.g., along the longitudinal fold lines,) so that the front and back panels of the constructmove apart and extend along a construct interior. In embodiments, the opposing ends′ of the constructcan be closed for enclosing the construct interior and for holding the constructin the erected configuration. For example, the bottom flaps,can be folded along the respective curved fold lines,inwardly over the respective bottom ends′ of the construct. In exemplary embodiments, the curved shapes of the fold lines,and/or the shapes of the bottom flaps,can cause the constructto shape up with the front panelsand the respective back panelscurving away from one another so that the panels and the bottom flaps of the constructextend along and around at least a portion of the construct interior. A food item can be inserted into the erected construct(e.g., through at least one of the ends of the construct) before closing the end(s)′ (e.g., for serving, take-away, display, consuming, etc.). In embodiments, the food item can be accessed and/or removed for eating by tearing the constructopen (e.g., along the tear lines) and/or by opening at least one of the ends′. The constructcould be otherwise shaped, arranged, and/or configured without departing from the disclosure.

As shown in, the cartons,can be separated from one another by tearing the construct(e.g., in the flattened configuration of) along the tear linesand pulling the cartons,apart from one another. In embodiments, the cartons,can be in the form of open-ended sleeves (e.g., flattened/collapsed sleeves) after separating the cartons,from the construct(). In embodiments, the arcuate shape of the tear linescan result in the front panelshaving a free top edgethat is concave and in the back panelshaving a free top edgethat is convex. As shown in, the larger back panelscan extend past the top edgesof the respective front panelsat the open top endsof the respective cartons,so that the back panelof one or both of the cartons,can support a food product and/or a portion of a food product extending from an interiorof the carton through the open top endfor display and/or consumption of the food product and/or partial food product (). For example, one or more food items can be partially enclosed between the front paneland the back panelin the interiorof one of the cartons,, can extend past the top edgeof the front panel, and can be supported on the back panelin the interiorof the carton as well as upwardly from the top edgeof the front panel. The cartons,could be otherwise formed from the constructwithout departing from the disclosure.

As shown in, the cartons,can be moved to an erected configuration by pressing inwardly at the edges of the cartons (e.g., along the longitudinal fold lines,) so that the front panelsand the back panelsof the of the respective cartons,move apart and extend along a carton interiorof the respective cartons,. The cartons,further can be erected by folding the bottom flaps,along the respective curved fold lines,inwardly over the bottom endsof the cartons. In embodiments, the folded bottom flaps,can be at least partially overlapped at the bottom endsto at least partially form a bottom wallat least partially closing the bottom ends. In the illustrated embodiments, the curved shapes of the fold lines,and/or the shape of the bottom flaps,can cause the cartons,to shape up with the front panelsand the respective back panelscurving away from one another so that the front panel, the back panel, and the bottom wallof each carton,extends along and around at least a portion of the carton interiorof the respective carton,. In exemplary embodiments, the shape of the bottom flaps,and/or the curved fold lines,can help resist folding of the bottom flaps,outwardly to open the bottom endsand/or can help resist collapsing of the cartons,(e.g., until the bottom flaps,are deliberately folded outwardly to collapse the cartons).

As shown in, a food product P (e.g., a sandwich wrap, a gyro, a burrito, a lettuce wrap, etc.) is inserted into the cartonso that a portion of the product P is received in the carton interiorbetween the front paneland the back panelthrough the open top endof the carton. In the illustrated embodiments, a top portion of the food product P can extend through the open top endof the carton(e.g., past the free top edgeof the front panelso that the top portion is visible and/or accessible in the carton. Accordingly, the top portion can be inspected and/or consumed while the product P is held in the carton. In embodiments, the back panelcan support the food product P, including the top portion of the food product, while the food product P is held in the carton. For example, the back panelcan act as a plate or protector for the food product P, such as when the carton is placed on a surface (e.g., a table, not shown). The cartons,could be otherwise erected from the collapsed configuration ofand/or could otherwise hold a product without departing from the disclosure.

As shown in, the carton assemblycan be formed by engaging and/or interlocking the cartons,. For example, as shown in, the cartons,can be arranged opposite to one another with the top endsfacing one another and with one carton having the front panelfacing upwardly and the other carton having the back panelfacing upwardly. In the illustrated embodiments, the top portions of the back panelscan face one another and the top edgesof the back panelscan be inserted into the interiorof the opposite carton,(e.g., so that a top portion of the back panelsof the cartons,are in face-to-face contact with an interior surface of the respective front panelsof the respective opposite cartons,). In exemplary embodiments, the cartons,can be moved together to engage one another to form the carton assembly(e.g., with the carton interiorsof the cartons,cooperating to at least partially form the assembly interiorof the carton assembly. In the illustrated embodiments, one or more food products P held in at least one of the cartons,when the cartons,are assembled can be held in the assembly interiorof the carton assembly.

As shown in, the locking elements of each carton,can engage the locking elements of the respectively opposing carton,to help retain the cartons,engaged with one another in the carton assembly(e.g., until the cartons,are deliberately pulled apart). For example, as the back panelsof the cartons,are inserted into the respective opposite cartons,, the tabsextending from the respective back panelscan be received in (e.g., can extend at least partially through) respective slotsin the respective cartons,, wherein the slotscan be at least partially formed from the respective cutswhen the blankis folded along the longitudinal fold lines,. In embodiments, the tabscan engage the slotsto form friction locks that can help resist forces that could otherwise cause the cartons,to separate (e.g., until the cartons are deliberately pulled apart to open the carton assembly). The carton assemblycould be otherwise formed and/or the cartons,could be otherwise engaged without departing from the disclosure.

In exemplary embodiments, one or more food items can be loaded into the construct, one or both of the cartons,, and/or the carton assembly. In embodiments, the interiorof the carton assemblycan be at least partially enclosed by the cartons,with the front panels, the back panelsand the bottom wallsextending along the interiorso that the carton assemblycan enclose and protect one or more food products in the interior(e.g., during food service and/or transportation/delivery of the one or more products). In embodiments, the carton assemblycan be separated back into the cartons,, such as for consuming the one or more food products in the carton assembly. The one or more food products and/or portions of the one or more food products can be supported in one or both of the cartons,after breaking up the carton assemblyinto the cartons and/or during consumption of the one or more food products.

In embodiments, the construct, the cartons,, and/or the carton assemblycan help reduce packaging waste since the construct/cartons/carton assembly can be used in multiple ways. For example, the constructcan be separated into the two cartons,, which can be used to hold separate food items for one or more customers (e.g., in a dine-in situation). In another example, the two cartons,can be engaged to form the carton assembly, which can enclose one or more food products (e.g., in a take-out/delivery situation). Further, the extended back panelsof the cartons,can help protect one or more food products like a plate while allowing a user to view and/or to consume the product held in the respective carton,

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.

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 blanks 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 blanks may then be coated with a varnish to protect any information printed on the blank. The blanks 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 blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks 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 blanks 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 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 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 commonly 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 that are within the scope of the claims. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept 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.