Carton with locking feature

• US 10,086,972 B2
• Filed: 06/08/2016
• Issued: 10/02/2018
• Est. Priority Date: 06/09/2015
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Hajek, Ronald E.
• Primary Examiner(s): Demeree, Christopher
• Application Number:
  US15/176,715
• Publication Number:
  US 20160362217A1
• Time in Patent Office: 846 Days
• Field of Search: 229131, 229114, 229906, 229148, 22912529, 229149, 229150, 22912527, 22912528, 229154, 229195, 229902, 22912519, 22912532, 229920, 493137
• CPC Class Codes: B65D 5/0085 the container body comprising two mating compartments hinged together B65D77/006 takes precedence
• CPC Class Codes: B65D 5/2057 Inter-engaging self-locking flaps B65D5/4254 takes precedence
• CPC Class Codes: B65D 5/302 combined with a slot provided in an adjacent side wall
• CPC Class Codes: B65D 5/4266 Folding lines, score lines, crease lines
• CPC Class Codes: B65D 5/667 Lids in the form of an inverted tray

Abstract

In one aspect, the disclosure is generally directed to a carton for holding at least one article. The carton comprising a plurality of panels comprising a bottom panel, a front panel foldably connected to the bottom panel, at least one back panel, a top panel, a lid panel foldably connected to the top panel. At least one end flap is foldably connected to a respective panel of the plurality of panels. A base comprises at least the bottom panel, and the front panel. A lid is pivotably attached to the base. The lid comprises the top panel and the lid panel and is movable between a closed position preventing access to the base and an open position allowing access to the base. Locking features are for releasably attaching the lid to the base in the closed position. The locking features comprises at least one male portion in the front panel and at least one female portion in the at least one end flap.

Claims

1. A carton for holding at least one article, the carton comprising:

a plurality of panels comprising a bottom panel, a front panel foldably connected to the bottom panel, at least one back panel, a top panel, and a lid panel foldably connected to the top panel;

at least one end flap foldably connected to a respective panel of the plurality of panels, the at least one end flap comprises an end flap foldably connected to the top panel;

a base comprising at least the bottom panel and the front panel;

a lid pivotably attached to the base, the lid comprising the top panel, the lid panel, and the end flap, the lid is movable between a closed position preventing access to the base and an open position allowing access to the base, wherein the lid panel overlaps the front panel when the lid is in the closed position; and

locking features for releasably attaching the lid to the base in the closed position, the locking features comprising at least one male portion in the front panel and at least one female portion being at least partially formed in the end flap.

2. The carton of claim 1, wherein the at least one male portion comprises a projection extending from an upper corner of the front panel and a notch adjacent the projection.

3. The carton of claim 2, wherein the projection comprises a curved edge adjacent the notch, the curved edge engaging a portion of the at least one female portion when the carton in the closed position.

4. The carton of claim 1, wherein the at least one female portion includes at least one cut at least partially forming a locking flap foldably connected to end flap, the locking flap is displaced by the at least one male portion when the carton is in the closed position to create a locking opening in the end flap.

5. The carton of claim 4, wherein the at least one cut comprises two longitudinal cuts and a lateral cut extending between a respective end of each of the two longitudinal cuts.

6. The carton of claim 1, wherein the lid panel comprises a curved edge comprising a first convex portion, a second convex portion, and a concave portion connecting the first convex portion and the second convex portion.

7. The carton of claim 6, wherein the curved edge is a first curved edge and the concave portion is a first concave portion, the front panel comprises a second curved edge comprising a second concave portion, a third concave portion, and a third convex portion connecting the second concave portion and the third concave portion.

8. The carton of claim 1, wherein the at least one back panel comprises a first back panel foldably connected to the bottom panel, and a second back panel foldably connected to the first back panel and the top panel, the lid comprising the second back panel and being hingedly connected to the first back panel, and the base comprising the first back panel.

9. The carton of claim 1, wherein the end flap is a first end flap, the at least one end flap comprises a second end flap foldably connected to the bottom panel.

10. The carton of claim 9, wherein the first end flap has a concave edge and the second end flap has a convex edge.

11. The carton of claim 1, wherein the plurality of panels further comprises an attachment flap foldably connected to the end flap, the attachment flap being in face-to-face contact with the lid panel to attach the end flap to the lid panel and form a corner of the lid.

12. The carton of claim 1, wherein each of the front panel and the lid panel is disposed opposite to the at least one back panel.

13. The carton of claim 12, wherein the end flap extends from the at least one back panel to the lid panel.

14. The carton of claim 1, wherein the front panel is foldably connected to the bottom panel along a first fold line, the end flap is foldably connected to the top panel along a second fold line, and the first fold line and the second fold line are perpendicular to one another.

15. The carton of claim 1, wherein the front panel is foldably connected to the bottom panel along a first lateral fold line, the lid panel is foldably connected to the top panel along a second lateral fold line, and the end flap is foldably connected to the top panel along a longitudinal fold line.

16. The carton of claim 1, wherein the end flap extends from the at least one back panel toward the front panel when the carton is in the closed position.

17. A blank for forming a carton for holding at least one article, the blank comprising:

a plurality of panels comprising a bottom panel, a front panel foldably connected to the bottom panel, at least one back panel, a top panel, and a lid panel foldably connected to the top panel;

at least one end flap foldably connected to a respective panel of the plurality of panels, the at least one end flap comprises an end flap foldably connected to the top panel;

base features for forming a base in the carton formed from the blank, the base features comprising at least the bottom panel and the front panel;

lid features for forming a lid in the carton formed from the blank, the lid pivotably attached to the base, the lid features comprising the top panel, the lid panel, and the end flap, the lid is movable between a closed position preventing access to the base and an open position allowing access to the base, wherein the lid panel is for overlapping the front panel when the lid is in the closed position; and

locking features for releasably attaching the lid to the base in the closed position, the locking features comprising at least one male portion in the front panel and at least one female portion being at least partially formed in the end flap.

18. The blank of claim 17, wherein the at least one male portion comprises a projection extending from an upper corner of the front panel and a notch adjacent the projection.

19. The blank of claim 18, wherein the projection comprises a curved edge adjacent the notch, the curved edge for engaging a portion of the at least one female portion when the carton in the closed position.

20. The blank of claim 17, wherein the at least one female portion includes at least one cut at least partially forming a locking flap foldably connected to the end flap, the locking flap is displaced by the at least one male portion when the carton is in the closed position to create a locking opening in the end flap.

21. The blank of claim 20, wherein the at least one cut comprises two longitudinal cuts and a lateral cut extending between a respective end of each of the two longitudinal cuts.

22. The blank of claim 17, wherein the lid panel comprises a curved edge comprising a first convex portion, a second convex portion, and a concave portion connecting the first convex portion and the second convex portion.

23. The blank of claim 22, wherein the curved edge is a first curved edge and the concave portion is a first concave portion, the front panel comprises a second curved edge comprising a second concave portion, a third concave portion, and a third convex portion connecting the second concave portion and the third concave portion.

24. The blank of claim 17, wherein the at least one back panel comprises a first back panel foldably connected to the bottom panel, and a second back panel foldably connected to the first back panel and the top panel, the lid features comprising the second back panel and the lid is for being hingedly connected to the first back panel, and the base features comprising the first back panel.

25. The blank of claim 17, wherein the end flap is a first end flap, the at least one end flap comprises a second end flap foldably connected to the bottom panel.

26. The blank of claim 25, wherein the first end flap has a concave edge and the second end flap has a convex edge.

27. The blank of claim 17, wherein the plurality of panels further comprises an attachment flap foldably connected to the end flap, the attachment flap being in face-to-face contact with the lid panel to attach the end flap to the lid panel and form a corner of the lid in the carton formed from the blank.

28. The blank of claim 17, wherein each of the front panel and the lid panel is disposed opposite to the at least one back panel.

29. The blank of claim 28, wherein the end flap extends from the at least one back panel to the lid panel.

30. The blank of claim 17, wherein the front panel is foldably connected to the bottom panel along a first fold line, the end flap is foldably connected to the top panel along a second fold line, and the first fold line and the second fold line are perpendicular to one another.

31. The blank of claim 17, wherein the front panel is foldably connected to the bottom panel along a first lateral fold line, the lid panel is foldably connected to the top panel along a second lateral fold line, and the end flap is foldably connected to the top panel along a longitudinal fold line.

32. The blank of claim 17, wherein the end flap extends from the at least one back panel toward the front panel when the carton formed from the blank is in the closed position.

33. A method of forming a carton, comprising:

obtaining a blank comprising a plurality of panels comprising a bottom panel, a front panel foldably connected to the bottom panel, at least one back panel, a top panel, and a lid panel foldably connected to the top panel, at least one end flap foldably connected to a respective panel of the plurality of panels, the at least one end flap comprises an end flap foldably connected to the top panel, the blank comprising base features, lid features, and locking features, the base features comprising at least the bottom panel, and the front panel, the lid features comprising the top panel, the lid panel, and the end flap, and locking features comprising at least one male portion in the front panel and at least one female portion at least partially formed in the end flap;

forming the base by positioning the front panel relative to the bottom panel;

forming the lid by positioning the lid panel relative to the top panel, the lid being pivotably attached to the base and movable between a closed position preventing access to the base and an open position allowing access to the base;

releasably attaching the lid to the base in the closed position by engaging the locking features, wherein the lid panel overlaps the front panel when the lid is in the closed position.

34. The method of claim 33, wherein the at least one male portion comprises a projection extending from an upper corner of the front panel and a notch adjacent the projection and the projection comprises a curved edge adjacent the notch, the releasably attaching comprises engaging the curved edge with a portion of the at least one female portion when the carton in the closed position.

35. The method of claim 33, wherein the at least one female portion includes at least one cut at least partially forming a locking flap foldably connected to the at least one end flap, the releasably attaching the lid to the base comprises displacing the locking flap by the at least one male portion when the carton is in the closed position to create a locking opening in the end flap.

36. The method of claim 35, wherein the releasably attaching the lid to the base comprises engaging the male portion with an edge of the locking opening.

37. The method of claim 33, wherein the lid panel comprises a first curved edge comprising a first convex portion, a second convex portion, and a first concave portion connecting the first convex portion and the second convex portion, the front panel comprises a second curved edge comprising a second concave portion, a third concave portion, and a third convex portion connecting the second concave portion and the third concave portion.

38. The method of claim 33, wherein the at least one back panel comprises a first back panel foldably connected to the bottom panel, and a second back panel foldably connected to the first back panel and the top panel, the lid features comprising the second back panel and the lid is hingedly connected to the first back panel, and the base features comprising the first back panel.

39. The method of claim 38, wherein the lid is connected to the base at hinge between the first back panel and the second back panel, the releasably attaching the lid to the base comprises pivoting the lid at the hinge from the open position to the closed position.

40. The method of claim 33, wherein the plurality of panels further comprises an attachment flap foldably connected to the end flap, the forming the lid comprises positioning the attachment flap being in face-to-face contact with the lid panel to attach the end flap to the lid panel and form a corner of the lid.

41. The method of claim 33, further comprising disengaging the locking features and moving the lid from the closed position to the open position.

42. The method of claim 33, wherein each of the front panel and the lid panel is disposed opposite to the at least one back panel.

43. The method of claim 42, wherein the end flap extends from the at least one back panel to the lid panel.

44. The method of claim 33, wherein the front panel is foldably connected to the bottom panel along a first fold line, the end flap is foldably connected to the top panel along a second fold line, and the first fold line and the second fold line are perpendicular to one another.

45. The method of claim 33, wherein the front panel is foldably connected to the bottom panel along a first lateral fold line, the lid panel is foldably connected to the top panel along a second lateral fold line, and the end flap is foldably connected to the top panel along a longitudinal fold line.

46. The method of claim 33, wherein the end flap extends from the at least one back panel toward the front panel when the carton is in the closed position.