Abstract:
The present invention is a carton carrying packaging box such as the ones used to carry multiple aluminum cans of soft drinks and the like, that is, after this initial usage, transformed and modified by disposing of certain portions of the carton blank and re-assembled into another type of hand-carried container, such as a lunch box and the like.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a multiple use of a carton box, and more specifically to the assembling of a hand-carried lunch box and the like from a previous portable packaging box made out of paperboard or other stiff sheet material such as cartons plastics and the like. 
     BACKGROUND OF THE INVENTION 
     Recycled goods are becoming more and more fashionable with the realization of our diminishing natural resources. Various types of papers and cartons are more and more collected by specialized firms to be transformed into reusable materials, especially since the quantities of trees in the forests of this world have been in progressive decline. A cost is however unfortunately associated with this recycling, hence, the possible transformation of a given everyday item into another everyday item before the chemical recycling process is undertaken certainly makes economical sense. Similarly, a non-recyclable product that has a double-usage before being disposed of is equally logical. 
     Take for those two items or products the traditional packaging box to carry cans of soft drinks or the like in a sizable quantity, such as twelve, or any other quantity, and the small lunch box such as for school kids. Families of our societies with children will often consume and buy both. It could also bring an economical advantage to those families if one item such as the lunch box would come freely and with a simple transformation and assembly from the other usually disposable (or recyclable) one, i.e. from the packaging box. They are relatively the same size, and could be of the same material. Children could furthermore easily get a great sense of pride towards their friends by possibly having differently adorned lunch boxes from time to time, and since they would all come as a bonus to the parents with the soft drinks or the likes, the whole family would be satisfied. 
     It is already known to provide various items from carton blanks, such as a litter box as disclosed in U.S. Pat. No. 4,782,788 issued on Nov. 8, 1988 to Arcand entitled “Litter box with handle and blank therefor”. But this type of prior art does not relate to lunch boxes transformable from previous carrying boxes. Similarly, prior art disclosed in U.S. Pat. No. 4,230,261 issued on Oct. 28, 1980 to Austin entitled “Lunch box carton and a blank for forming the same” relates to lunch boxes transformable from a cardboard blank of flattened configuration but not from a previously used packaging box. 
     Other prior arts, such as in U.S. Pat. No. 4,535,928 issued on Aug. 20, 1985 to Capo and entitled “Dual purpose carton”, U.S. Pat. 4,837,865 issued on Jun. 13, 1989 to Roth and entitled “Sun visor formed from a food and beverage carrier”, and U.S. Pat. No. 5,358,172 issued on Oct. 25, 1994 to Hollander et al. and entitled “Transformable carton” all suggest items (caddy for pencils, sun visor, and various containers) transformable initially from a packaging box or the like, but none of the transformed items is a lunch box or an item of the containing-carrier type with a handle and a purpose of bringing a given content outdoors if necessary such as a lunch box. 
     OBJECTS OF THE INVENTION 
     It is therefore a general object of the present invention to provide a carton structure that is re-usable and transformable into a hand-carried lunch box of the character described which obviates the above noted disadvantages. 
     Another object of the present invention is to provide a carton structure that is re-usable and transformable into a containing-carrier type item with a handle and a purpose of bringing a given content outdoors if necessary such as a lunch box. 
     A further object of the present invention is to provide a carton structure that is re-usable and quickly transformable into a carrying lunch box by simple means preferably not requiring other tools or equipment than a person&#39;s hands. 
     Another object of the present invention is to provide a carton structure that is re-usable and transformable into a virtually free carrying lunch box by providing a mean of combining the easy and economical production of two largely consumed family items. 
     SUMMARY OF THE INVENTION 
     The present invention provides a carton structure including main and secondary sides, bottom flaps connected to said secondary and main sides along fold lines, and at least one top flap connected to one of said main sides along fold lines; and at least one of said main sides and each of said secondary sides having perforated and scored lines therein for separating from said carton structure parts of a lunch box and the like, wherein said lunch box includes tapered and main panels each formed integrally therewith from that one of said secondary and main sides respectively of said structure, bottom panels each formed integrally therewith from that one of said bottom flaps of said structure hingedly connected to the respective one of said tapered or main panels, and wherein said lunch box is of polygon shape in cross-section and at least one of said panels having weakening lines for separating a portion thereof to form a handle member for hand-carrying said lunch box therefrom. 
     Preferably, the lunch box is rectangular in cross-section and at least one of said main panels having weakening lines for separating a portion thereof to form a handle member for hand-carrying said lunch box therefrom. 
     Preferably, both of said main panels of said lunch box include corresponding male and female portions respectively of a locking member, said locking member releasably locks said lunch box into a closed state for hand carrying purpose. 
     Alternatively, the main panels of said lunch box include a male portion of a locking member and said tapered panels of said lunch box include a corresponding female portion of said locking member, said locking member releasably locks said lunch box into a closed state for hand carrying purpose. 
     Preferably, the male portion of said locking member includes at least one ear tab and said female portion includes at least one corresponding slit opening adapted to lockingly receive said ear tab. 
     Preferably, the lunch box further includes a retaining member formed from a so far unused portion of anyone of said sides or flaps of said structure with weakening lines for separation therefrom, said retaining member being secured internally to said lunch box to provide support for at least one content carried therein. 
     Alternatively, the carton structure further includes a retaining member properly secured in place over two adjacent of said panels so as to be internal to said lunch box and having perforated and scored lines therein to partially separate therefrom, said retaining member of said lunch box thereby providing support for at least one content carried therein. 
     Preferably, the handle member includes a folding flap to structurally reinforce itself and to more ergonomically adapt to a user&#39;s hand carrying said lunch box. 
     Alternatively, the one top flap of said structure having perforated and scored lines therein for separating from said carton structure part of said lunch box, wherein one of said main panels of said lunch box is further formed integrally therewith from that one of said main sides of said structure and said top flap hingedly connected thereto. 
     Preferably, both of said main panels of said lunch box include corresponding male and female portions respectively of a locking member, said locking member releasably locks said lunch box into a closed state for hand carrying purpose. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the annexed drawings, like reference characters indicate like elements throughout. 
     FIG. 1 is a plan view of an embodiment according to a blank of the present invention; 
     FIG. 2 is a perspective view of the embodiment of FIG. 1 in an assembled condition forming a carton structure for its first use as a packaging box; 
     FIG. 3 is a perspective view of the embodiment of FIG. 1 in an transformed condition forming a lunch box for its second use; 
     FIGS. 4,  5  and  6  are views similar to FIGS. 1,  2  and  3  respectively showing a second embodiment according to the present invention; and 
     FIGS. 7,  8  and  9  are views similar to FIGS. 1,  2  and  3  respectively showing a third embodiment according to the present invention, also FIG. 9 is partially broken to show a retaining member internally secured to the lunch box. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1,  2  and  3 , there is shown an embodiment of a generally rectangular blank  20  according to the present invention and comprising all the parts necessary to assemble a polygon in cross-section carton construction structure, preferably a rectangular packaging box  22 . Once the packaging box  22  shown in FIG. 2 has been used, it is preferably partially unassembled, essentially at the top, the bottom preferably remaining unchanged. A re-use of the blank  20  is provided by separating specific parts from the latter along specific scored and perforated lines, or weakening lines, as described hereinafter to enable the assembly of a generally rectangular lunch box  24  as shown in FIG. 3, preferably following a first usage as the packaging box  22 . The initial useful packaging box  22  is therefore transformed into the useful lunch box  24 . 
     The blank  20  preferably comprises, from left to right on FIG. 1, a generally rectangular secondary narrow side  26 , a generally rectangular main side  28 , preferably at least three times as wide as the narrow side  26 , a generally rectangular secondary narrow side  30  slightly narrower than twice the width of narrow side  26  and of a width generally less than that of the main side  28 , a generally rectangular main side  32  of the same width as the main side  28 , and a generally rectangular secondary narrow side  34  slightly narrower than the width of the narrow side  26 . Each side is hingedly secured to its adjacent side or sides at fold lines shown is dotted lines. 
     In all the figures, dotted lines identify fold lines while dashed lines identify tear lines required to obtain the lunch box  24 . 
     Generally rectangular bottom flaps  36 ,  38 ,  40 ,  42 , and  44  are hingedly secured at their longest edge by fold lines at the short edge of and below their respective side  26 ,  28 ,  30 ,  32 , and  34 . Bottom flaps  36 ,  38 ,  40 ,  42 , and  44  are also essentially of the same width as their respective side. Generally rectangular top flaps  46 ,  48 ,  50 ,  52  and  54  are hingedly secured at their longest edge by fold lines at the other short edge of and above their respective side  26 ,  28 ,  30 ,  32 , and  34 . Top flaps  46 ,  48 ,  50 ,  52 , and  54  are also of essentially the same width as their respective side. Each of the bottom flaps is opposed to its respective top flap about its respective side. 
     Fastening members, preferably adhesive straps or glue lines  56 , are all secured on a same side of the blank  20 , on bottom  42  and top  52  flaps, as well as along the external edge of narrow side  26 . 
     For its transformation into the lunch box  24 , the packaging box  22  is assembled by folding the sides  26  to  34  (with the first narrow side  26  slightly overlapping the last narrow side  34 ) and the flaps  36  to  54  along the fold lines and using the glue lines  56  preferably located on the back side of blank  20  of FIG. 1; towards the inside of packaging box  22 . 
     It would be obvious to anyone skilled in the art to modify the blank  20  so as to have, for example, one of narrow sides  26 ,  34  of the same width as narrow side  30  with the other of the two being small enough to remain a simple flap extending from its respective main side to overlap the first narrow side. Also, that cutout between two adjacent sides could be at any suitable location on the blank  20 . 
     The blank  20  further includes the followings: 
     Narrow sides  26 ,  34  comprise a tapered panel  68 ,  70  respectively having a perforated and scored generally curved fold line  84 ,  86  respectively separating an inferior portion  72 ,  74  respectively from a superior portion  76 ,  78  respectively, when transforming the packaging box  22  into the lunch box  24 . Top flaps  46 ,  54  are respectively being disposed of via scored lines  101 . 
     Main panel  80  formed by main side  28  includes part of a handle member, preferably a horizontally centered opening  88  and a female part of a locking member, preferably two narrow and pre-perforated slit openings  90 , or really narrow openings. The opening  88  is substantially rectangular as to fit someone&#39;s hand and is obtained by separating a disposable portion  92  from the main panel  80  along perforated line  96 . Top flap  48  is being disposed of via scored line  101 . 
     Similarly to narrow sides  26 ,  34 , narrow side  30  comprises a tapered panel  102 , having a perforated and scored generally curved fold line  112  separating an inferior portion  104  from two superior portions  106 ,  108 , when transforming the packaging box  22  into the lunch box  24 . Top flap  50  is being disposed of via scored line  101 . 
     Main panel  82  comprises main side  32  and part of top flap  52  folding along a perforated line  94 . Top flap  52  includes a covering flap portion  118  separated from a disposable portion  120  by a scored line  124 . The covering flap  118  is generally trapezoidal and has two ear tabs  122  located at its free side being also a male part of the locking member and adapted to engage corresponding slit openings  90  of main panel  80 . Both the main side  32  and the covering flap  118  of main panel  82  include part of the handle member each, preferably a horizontally centered opening  58 ,  58   a  respectively, and being a mirror image of each other with respect to fold line  94 . Each opening  58 ,  58   a  is substantially rectangular and is obtained by separating a respective disposable portion  60 ,  60   a  from the main panel  82  along a respective perforated line  62 ,  62   a . A respective protection flap  66 ,  66   a  is secured to the respective upper and lower side of the opening  58 ,  58   a  by a respective fold line  64 ,  62   a . The flaps  66 ,  66   a  provide a structural reinforcement of the handle member and a more ergonomic support of the latter for a user&#39;s hand. 
     Bottom panels  132 ,  134 ,  136 ,  138 , and  140  of lunch box  24  are associated with unaltered bottom flaps  36  to  44  of the packaging box  22  respectively. 
     By manually separating from the blank  20  along the perforated and scored lines  62 ,  62   a ,  96 ,  101  and  124 , the disposable portions  60 ,  60   a ,  92  and  120 , and the disposable top flaps  46 ,  48 ,  50 , and  54 , the blank  20  will be left with the following parts: the bottom panels  132 ,  134 ,  136 ,  138 , and  140 , the tapered panels  68 ,  70 , and  102 , and the main panels  80  and  82 . Preferably, this separation of the disposable portions is performed without any tool. By folding together the remaining above-mentioned parts along the different fold lines, particularly pushing slightly towards each other the upper parts of inferior portions  72  and  74  (already assembled together from previously formed packaging box  22 ) and  104 , one can easily assemble the lunch box  24 . The lunch box  24  can be furthermore closed by optionally engaging the two ear tabs  122  into the two corresponding slit openings  90 , operation that brings the three openings  58 ,  58   a  and  88  aligned to offer a handle  100  to carry the lunch box  24 , after flipping covering flap  118  of main panel  82  over main panel  80 . 
     Now referring to FIGS. 4,  5  and  6 , there is shown a second embodiment of a generally rectangular blank  20 ′ comprising all the parts necessary to assemble a rectangular packaging box  22 ′. Similarly to the first embodiment  20 , once the packaging box  22 ′ shown in FIG. 5 has been used, it is transformed into a generally rectangular lunch box  24 ′ as shown in FIG.  6 . 
     As for the first embodiment  20 , similar numerals used for the second embodiment  20 ′ are identified with a single-quote indicia. The packaging box  22 ′ formed from blank  20 ′ is essentially identical to packaging box  22 , with same sides  26 ′ to  34 ′, flaps  36 ′ to  54 ′ and glue lines  56 ′. Also, the lunch box  24 ′ essentially includes the same side  68 ′,  70 ′ and  102 ′ main  80 ′,  82 ′ and bottom  132 ′ to  140 ′ panels. 
     For its transformation into the lunch box  24 ′, the blank  20 ′ of FIG. 4 further includes the followings that are essentially different from the first blank  20 : 
     Narrow sides  26 ′,  34 ′ comprise respective generally rectangular lower sections  150 ,  152  separated from respective disposable upper sections  154 ,  156  by perforated and scored broken lines  162 ,  164  respectively. The lower sections  150 ,  152  forming tapered panels  68 ′,  70 ′ respectively includes respective inferior portions  72 ′,  74 ′ separated from superior portions  76 ′,  78 ′ by perforated and scored fold lines  84 ′,  86 ′ respectively. 
     Main panel  80 ′ formed by main side  28 ′ comprises a rectangular lower side  158  separated from a disposable upper side  160  by a perforated line  166 . The lower side  158  further includes a second female part of a locking member, preferably a pre-perforated essentially horizontal slit opening  196   a.    
     Narrow side  30 ′ comprises a generally rectangular lower section  210  separated from a disposable upper section  212  by a perforated and scored broken line  214 . The lower section  210  forming second tapered panel  102 ′ includes an inferior portion  104 ′ separated from superior portion  106 ′ by perforated and scored fold lines  112 ′. 
     Main panel  82 ′ is formed by main side  32 ′ and part of top flap  52 ′. Main side  32 ′ includes substantially rectangular lower side  174 , first intermediate side  176 , and second intermediate side  178  alternatively secured to each adjacent one by fold lines  182  and  184  respectively. The first intermediate side  176  includes part of a handle member, preferably a substantially horizontally centered rectangular, as to fit someone&#39;s hand, opening  188 . The latter is obtained by separating a disposable portion  218  from the main panel  82 ′ along perforated line  220 . On the lower edge of the opening  188 , is hingedly secured by a fold line  190  a generally trapezoidal first locking ear tab  192  forming the first male part of the locking member. The second intermediate side  178  includes a corresponding substantially horizontally centered rectangular opening  188   a . A protecting flap  194  obtained by tearing off perforated U-shaped line  204  is hingedly secured to the upper edge of opening  188   a  by a fold line  198 . The flap  194  includes at its approximate geometrical center a preferably pre-perforated horizontal slit opening  196  adapted to lockingly receive the ear tab  192  and forming a first female part of the locking member. Top flap  52 ′ include a substantially trapezoidal protecting extension  180  separated from a disposable portion  202  by a perforated and scored line  124 ′. The extension  180  is secured to the second intermediate side  178  by fold line  186  and includes the second male part of the locking member, preferably a second locking ear tab  192   a  adapted to engage slit opening  196   a  of main panel  80 ′ and obtained by tearing off perforated line  210  delimited by two pre-perforated vertically elongated lateral holes  208 . Second intermediate side  178  and extension  180  form a closing flap  200  to be folded over the first intermediate side  176  and main panel  80 ′ to close the lunch box  24 ′. 
     By manually separating from the blank  20 ′ along the perforated and scored lines  124 ′,  162 ,  164 ,  166  and  214  (including top flaps  46 ′,  48 ′,  50 ′ and  54 ′) and the disposable portions  202  and  218 , the blank  20 ′ will be left with the following parts: the bottom panels  132 ′,  134 ′,  136 ′,  138 ′, and  140 ′, the tapered panels  68 ′,  70 ′ and  102 ′, the main panels  80 ′ and  82 ′. By folding together the remaining above-mentioned parts along the different fold lines, particularly pushing slightly towards each other the three superior portions  76 ′,  78 ′ and  106 ′, one can easily assemble the lunch box  24 ′. The lunch box  24 ′ can optionally be furthermore closed by engaging the locking tabs  192 ,  192   a  into the respective slit openings  196 ,  196   a , operation that brings the two openings  188 ,  188   a  aligned to each other to offer a handle  100 ′ to carry the lunch box  24 ′. 
     Referring to FIGS. 7,  8  and  9 , there is shown a third embodiment a generally rectangular blank  20 ″ comprising all the parts necessary to assemble a rectangular packaging box  22 ″. Similarly to the first embodiment  20 , once the packaging box  22 ″ shown in FIG. 8 has been used, it is transformed into a generally rectangular lunch box  24 ″ as shown in FIG.  9 . 
     As for the first embodiment  20 , similar numerals used for the third embodiment  20 ″ are identified with a double-quote indicia. The packaging box  22 ″ formed from blank  20 ″ is essentially identical to packaging box  22 , with same sides  26 ″ to  34 ″, flaps  36 ″ to  52 ″ and glue lines  56 ″. Also, the lunch box  24 ″ essentially includes the same side  68 ″,  70 ″ and  102 ″ main  80 ″,  82 ″ and bottom  132 ″ to  138 ″ panels. 
     For its transformation into the lunch box  24 ″, the blank  20 ″ of FIG. 7 further includes the followings that are essentially different from the first two blanks  20 ,  20 ′: 
     All narrow sides  26 ″,  30 ″ and  34 ″ and main sides  28 ″ and  32 ″ all comprise respective generally rectangular lower sections  240  separated from respective disposable upper sections  242  by perforated and scored broken lines  244  respectively. The lower sections  240  forming tapered panels  68 ″,  102 ″ and  70 ″ main panels  80 ″ and  82 ″ respectively includes respective inferior portions  72 ″ separated from superior portions  76 ″ by perforated and scored fold lines  84 ″ respectively. 
     Narrow sides  26 ″ and  30 ″ both include in their respective superior portion  76 ″ a female part of a locking member, preferably an essentially vertical slit  250 . 
     Each of superior portions  76 ″ of main sides  28 ″ and  32 ″ has two ear tabs  252  located at its free side and being also a male part of the locking member and adapted to lockingly engage preferably pre-perforated corresponding slit openings  250  of tapered panels  68 ″ and  102 ″. Similarly to main panel  82 , the superior portions  76 ″ of main panels  80 ″ and  82 ″ also includes part of the handle member, preferably a substantially horizontally centered rectangular, as to fit someone&#39;s hand, opening  254 . The latter is obtained by separating a disposable portion  256  from the main panel  80 ″,  82 ″ along a perforated line  258 . Preferably on main panel  82 ″ only, a protection flap  260  is secured to the upper side of the opening  254  by a fold line  262 . 
     By manually separating from the blank  20 ″ along the perforated and scored lines  244  (including top flaps  46 ″,  48 ″,  50 ″ and  52 ″) and the disposable portions  256 , the blank  20 ″ will be left with the following parts: the bottom panels  132 ″,  134 ″,  136 ″ and  138 ″, the tapered panels  68 ″,  70 ″ and  102 ″, the main panels  80 ″ and  82 ″. By folding together the remaining above-mentioned parts along the different fold lines, particularly by pushing the corresponding handle openings  254  against each other and aligned, one can easily assemble the lunch box  24 ″. The lunch box  24 ″ can optionally be furthermore closed by engaging the locking ear tabs  252  into the respective slits  250 , operation that keeps the two openings  254  aligned to each other to offer a handle  100 ″ to carry the lunch box  24 ″. 
     Furthermore, it would be obvious to anyone skilled in the art to replace the scored lines used to detach disposable portions from the blank  20 ,  20 ′,  20 ″, that could eventually weaken for the latter too much, by marked lines that would therefore require use of a tool such as scissors or the like. 
     Optionally, a retaining member, preferably a generally elongated retainer tab  280  (as shown in FIGS.  7  and  9 ), could be provided on any side  26 ″ to  34 ″ or flap  36 ″ to  54 ″ (flap  52 ″ shown in the present case on FIG.  7 ), or any combination thereof, with available space. The tab  280  is detached from flap  52 ″ using perforated and scored line  282  and preferably includes a plurality of fold lines  284 . The latter are used to properly install the retainer tab  280  inside the lunch box  24 ″ on two adjacent panels. The tab  280  is preferably used to firmly hold any content, preferably a soft drink can C and the like, inside the lunch box  24 ″. 
     Alternatively, the retainer tab  280 , with the same perforated lines  284 , could be pre-secured, preferably pre-glued, in proper position onto the back side of the blank  20 ″ and sized to retain a standard size soft drink can C and the like. 
     Although preferably rectangular packaging boxes and corresponding lunch boxes are described herein, it would be obvious to anyone skilled in the art to similarly transform a hexagon or octagon in cross-section packaging box into a corresponding hexagon or octagon in cross-section lunch box respectively. 
     Preferably, the packaging box  22  is a standard box to carry aluminum cans of soft drinks, a large cereal box or the like, made out of rigid paperboard, carton or plastic material. 
     Although embodiments have been described herein with some particularity and details, many modifications and variations of the preferred embodiments are possible without deviating from the scope of the present invention.