Construct with locking features

A construct for holding at least one article. The construct comprises a plurality of panels extending at least partially around an interior of the construct. The plurality of panels can at least partially form a corner of the construct. The construct further comprises locking features for at least partially interlocking the construct with a separate construct. The locking features can comprise at least a locking tab and an engagement aperture, and the locking tab can be proximate the engagement aperture at the corner of the construct.

INCORPORATION BY REFERENCE

The disclosure of U.S. Provisional Patent Application No. 62/176,795, which was filed on Feb. 27, 2015, is hereby incorporated by reference for all purposes as if presented herein in its entirety.

BACKGROUND OF THE DISCLOSURE

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

SUMMARY OF THE DISCLOSURE

In general, one aspect of the disclosure is generally directed to a construct for holding at least one article. The construct comprises a plurality of panels extending at least partially around an interior of the construct. The plurality of panels can at least partially form a corner of the construct. The construct further comprises locking features for at least partially interlocking the construct with a separate construct. The locking features can comprise at least a locking tab and an engagement aperture, and the locking tab can be proximate the engagement aperture at the corner of the construct.

In another aspect, the disclosure is generally directed to a package for holding at least one article. The package can comprise a first construct forming a tray of the package. The tray can comprise a plurality of tray panels extending at least partially around an interior of the package, a tray locking tab, and a tray engagement aperture. The plurality of tray panels can at least partially form a tray corner, the tray locking tab can extend from a tray panel of the plurality of tray panels at the tray corner, and the tray engagement aperture can extend at the tray corner. A second construct can form a lid of the package. The lid can comprise a plurality of lid panels extending at least partially around an interior of the package, a lid locking tab, and a lid engagement aperture. The plurality of lid panels can at least partially form a lid corner, the lid locking tab can extend from a lid panel of the plurality of lid panels at the lid corner, and the lid engagement aperture can extend at the lid corner. The lid locking tab and the lid engagement aperture can be for selectively engaging the respective tray engagement aperture and tray locking tab to at least partially interlock the tray and the lid.

In another aspect, the disclosure is generally directed to a blank for forming a construct for holding at least one article. The blank can comprise a plurality of panels for being disposed at least partially around an interior of the construct formed from the blank to at least partially form a corner of the construct formed from the blank. The blank further can comprise locking features for at least partially interlocking the construct formed from the blank with a separate construct. The locking features can comprise at least a locking tab and an engagement aperture. The locking tab can be proximate the engagement aperture at the corner when the construct is formed from the blank.

In another aspect, the disclosure is generally directed to a method of forming a construct. The method can comprise obtaining a blank comprising a plurality of panels and locking features. The locking features can comprise at least a locking tab and an engagement aperture. The method further can comprise positioning the panels of the plurality of panels to extend at least partially around an interior of the construct. The positioning the panels can comprise forming a corner of the construct, wherein the locking tab is proximate the engagement aperture at the corner of the construct.

In another aspect, the disclosure is generally directed to a method of forming an assembly. The method can comprise obtaining a first construct and a second construct. The first construct can form a tray of the package. The tray can comprise a plurality of tray panels extending at least partially around an interior of the package, a tray locking tab, and a tray engagement aperture. The plurality of tray panels can at least partially form a tray corner, the tray locking tab can extend from a tray panel of the plurality of tray panels at the tray corner, and the tray engagement aperture can extend at the tray corner. The second construct can form a lid of the package. The lid can comprise a plurality of lid panels extending at least partially around an interior of the package, a lid locking tab, and a lid engagement aperture. The plurality of lid panels can at least partially form a lid corner, the lid locking tab can extend from a lid panel of the plurality of lid panels at the lid corner, and the lid engagement aperture can extend at the lid corner. The method further can comprise at least partially interlocking the first construct with the second construct by disposing at least one of the lid locking tab and the tray locking tab to be at least partially received in the respective tray engagement aperture and lid engagement aperture.

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.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The package or assembly of the present disclosure can be useful in containing one or more products (e.g., a food product) or other articles such as any suitable type of product that can be stored, transported, cooled, frozen, heated, and/or cooked (e.g., in a microwave oven). Some suitable products could comprise a sandwich, hot dog, French fries, nachos, fruits, vegetables, popcorn, cuts of meat, or any other suitable food product or other article. Further, the package of the present disclosure can be used for heating, cooking, browning, crisping, etc. the food product by use of a heating or cooking device such as a microwave oven. It is understood that food products (or non-food products) other than the food products listed herein may be contained in the package. Further, products contained in this package may be generally rectangular, triangular, round, square, irregular, or any other 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 packages.

FIG. 1is a plan view of a blank, generally indicated at103, used to form a construct105(FIGS. 2-5) of an exemplary embodiment of the disclosure. In one embodiment, two constructs105, which can be identical, substantially identical, generally identical, or similar to one another, can form a respective lid105aand tray105bof a package178and can be interlocked to form an assembly180(FIGS. 6-9). The construct105can include locking features107at each corner109so that the two constructs can be at least partially interlocked in the assembly180. In the illustrated embodiment, the blank103and the construct105can have an interior surface101(FIGS. 2 and 4) and an exterior surface102(FIGS. 1-3). The construct105is used to hold and/or support and/or cover a food product (not shown), such as a French bread pizza, sandwich, hot dog, turnover, burrito, meats, French fries, and/or any other food product, during serving (e.g., at a quick-service and/or takeout restaurant), cooking, refrigerating, freezing, etc. of the food product. In one embodiment, at least a portion of the construct105may have an element (not shown) for use in cooking, heating, browning, and/or shielding (e.g., a microwave energy interactive element, such as, but not limited to, a susceptor) mounted thereto. Alternatively, a microwave energy interactive element can be omitted from the construct105. In an alternative embodiment, the construct105can hold and/or support and/or cover a non-food item or article.

The blank103has a longitudinal axis L1and a lateral axis L2. The blank103includes a central panel110foldably connected to a first side panel112at a first longitudinal fold line114. A second side panel116is foldably connected to the central panel110along a second longitudinal fold line118. In the illustrated embodiment, the longitudinal fold lines114,118are slightly curved so that the middle of central panel110bulges outwardly somewhat. Alternatively, the longitudinal fold lines114,118could be straight or could be alternatively curved without departing from the disclosure. A first end panel120is foldably connected to the central panel110along a first lateral fold line122at one longitudinal end of the central panel110, and a second end panel124is foldably connected to the central panel110along a second lateral fold line126at another longitudinal end of the central panel110.

In the illustrated embodiment, the blank103includes end flaps130,132foldably connected at respective ends of the first side panel112along respective fold lines134,136. End flaps138,140are respectively foldably connected at respective ends of the second side panel116along the respective fold lines142,144. In one embodiment, each of the end flaps130,138,132,140is at least partially separable from the respective end panel120,124along respective cut lines146. The blank103could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, the end flaps130,138,132,140could be foldably connected to the respective end panels120,124. Alternatively, the end flaps130,132,138,140could be omitted from the blank103without departing from the disclosure.

As shown inFIG. 1, the locking features107can include a locking projection or locking tab148disposed at each end of each of the side panels112,116and an opening or engagement aperture150extending in each of the end flaps130,132,138,140and into the respective side panels112,116. The locking features107can also include an engagement notch156on each side of each of the end panels120,124. The engagement notches156can be formed by each of the cut lines146. Each of the locking tabs148can include a respective locking edge152, and each of the engagement apertures150can include a respective engagement edge154. Accordingly, when two constructs105are assembled into an interlocking relationship (e.g.,FIGS. 7-9), the locking tabs148of one construct105can be at least partially received in the respective engagement apertures150of the other construct105so that the locking edges152of the first construct engage the respective engagement edges154and/or engagement notches156of the second construct. Any of the locking features107could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, the engagement apertures150could be disposed in the respective end flaps130,132,138,140adjacent the respective fold lines134,136,142,144so that the engagement apertures do not interrupt the fold lines and extend into the side panels112,116. In another example, the engagement notches156could be formed in edges of the end panels120,124that are spaced from the respective cut lines146and/or the respective end flaps30,132,138,140.

As shown inFIGS. 2-5and described in the following in accordance with one acceptable example, the construct105is formed from the blank103by first upwardly folding the side panels112,116along the respective longitudinal fold lines114,118and folding the end panels120,124along the respective lateral fold lines122,126. Each of the end flaps130,138can be folded along the respective lateral fold lines134,142into face-to-face contact with the interior surface of the first end panel120and at least partially glued and/or otherwise secured to the first end panel120(FIGS. 4 and 5). Additionally, each of the end flaps132,140can be folded along the respective lateral fold lines136,144into face-to-face contact with the interior surface of the second end panel124and at least partially glued and/or otherwise secured to the second end panel124(FIGS. 2 and 4). Accordingly, the first end panel120and the end flaps130,132cooperate to form a first closed end164of the tray105, and the second end panel124and the end flaps138,140cooperate to form a second closed end166of the tray105. In addition, as shown inFIGS. 2-5, the four corners109of the construct105are formed at the respective junctions between each of the side panels112,116and the respective closed ends164,166so that the fold lines134,136,142,144extend along each of the corners109. In the illustrated embodiment, the locking features107are disposed in each of the corners109(FIGS. 2-5). As shown inFIGS. 2 and 4, the central panel110, the side panels112,116, and the closed ends164,166form an interior170of the tray105.

In the illustrated embodiment, as the end panels120,124and the end flaps130,132,138,140are folded relative to one another, the end panel120separates from the end laps130,138at the cut lines146to form two corner edges158along each of the end panels120,124. Each of the corner edges158is disposed in the respective corners109of the construct105and defines a respective one of the engagement notches156(FIG. 3). As shown inFIGS. 2-5, the end flaps130,138,132,140are glued to the respective end panels120,124so that the engagement apertures150extend partially beyond the corner edges158of the respective end panels120,124to provide clearance for receiving the locking tabs148of another construct105. In one embodiment, as shown inFIG. 3, the engagement notches156can be generally aligned with the respective engagement edges154at each corner109so that the locking edges152of the locking tabs148of another construct can engage the engagement edge154and/or the engagement notch156at the respective corners109. Alternatively, the engagement notch156could be proximate to the engagement apertures150at each corner, or the engagement notches156could be omitted.

Alternative assembling, loading, and closing steps may be used without departing from the scope of the disclosure. For example, the end flaps130,138,132,140can be folded into face-to-face contact with the exterior surfaces of the respective end panels120,124. In addition, the construct105can be formed by press-forming a blank in a forming tool, or the construct150could be formed by other methods.

According to one embodiment,FIG. 5shows the closed end164and two corners109of the construct105from the interior of the construct. The opposing corners109and the closed end166are similarly or identically configured. As shown inFIG. 5, the locking tabs148are disposed proximate to the respective engagement apertures150at each corner109. In the illustrated embodiment, the locking tabs148extend outwardly from a respective end edge160of the respective side panels112,116and along or adjacent a respective top edge162of the respective side panels112,116. Accordingly, the locking edges152can extend from the respective end edges160at the respective corners109. Alternatively, any of the corners109and/or the locking features107could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

As shown inFIGS. 6-9, two constructs105, which can be selected from a stack of constructs (not shown) in one embodiment, can form the package178and can be assembled into an interlocking relationship to form the assembly180. While the constructs shown inFIGS. 6-9are generally identical, each of the constructs105being formed from a respective blank103, the top construct or lid and the features thereof are indicated by an appended “a” on the reference number (e.g., the lid105a), and the bottom construct or tray and the features thereof are indicated by an appended “b” on the reference number (e.g., the tray105b). As shown inFIG. 6, the lid105acan be positioned over the tray105bwith the interiors170a,170bof the trays directed toward one another. As shown inFIG. 7, the lid105acan be moved toward the tray105bso that the lid side panels112a,116aare generally inside the tray side panels112b,116band the lid corners109aare generally aligned with the respective tray corners109b.

In the illustrated embodiment, as shown in at leastFIGS. 8 and 9, the lid locking tabs148aare inserted into the respective tray engagement apertures150bso that each of the lid locking edges152aengages the respective tray engagement edges154band/or the respective tray engagement notches156bto at least partially interlock the lid105aand the tray105band to help retain the lid105ain the assembly with the tray105b. In one embodiment, the lid105acan be pivoted so that the lid locking features107aat one of the lid ends164a,166aare interlocked with the tray locking features107bat one of the tray ends164b,166band then the opposing lid end is lowered to be engaged with the opposing tray end. For example, as shown inFIG. 6, the lid locking features107aat the lid corners109aadjacent the lid end166acan be interlocked with the tray locking features107bat the tray corners109badjacent the tray end166b. The lid105acan be pivoted so that the lid end164amoves toward the tray end164band the lid locking features107aat the lid corners109aadjacent the lid end164acan be interlocked with the tray locking features107bat the tray corners109badjacent the tray end164b. In the illustrated embodiment, as shown inFIGS. 7 and 8, the lid end164aand the tray end164bform a first end182of the package178and the assembly180and the lid end166aand the tray end166bform a second end184of the package178and the assembly180. In an alternative embodiment, the lid ends164a,166acould be aligned with the respective tray ends166b,164b.

The assembly180of the tray105band the lid105ais shown inFIGS. 7-9. The lid105acan be removed from the tray105bby disengaging the lid locking tabs148afrom the tray engagement apertures150band pulling the lid105aaway from the tray105b. In one embodiment, the lid locking tabs148acan be disengaged from the tray engagement apertures150bby pinching the lid side panels112a,116aso that the lid locking tabs148aat the ends of the lid side panels112a,116aare moved towards the tray interior170baway from the tray side panels112b,116b. The constructs105can be alternatively erected and/or the assembly180can be alternatively formed and/or disassembled without departing from the disclosure.

In an alternative embodiment, the lid side panels112a,116acan be generally outside the tray side panels112b,116b, and the tray locking tabs148bcan be received in the respective lid engagement apertures150awithout departing from the disclosure. In one embodiment, to disengage the lid105afrom the tray105bin this alternative configuration, the tray side panels112b,116bcan be pinched to move the tray locking tabs148btowards the lid interior170away from the lid side panels112a,116aand to disengage the tray locking tabs148bfrom the respective lid engagement apertures150a. The tray105band/or the lid105acould be alternatively configured, shaped, positioned, and/or arranged without departing from the disclosure.

In the illustrated embodiment, the terms “lid” and “tray” are generally interchangeable and are used in the description and claims only to differentiate between the constructs and their features for clarity since the constructs105a,105bare identical, substantially identical, or generally identical. Stated another way, the assembly180could be inverted so that the construct105aforms the “tray” on the bottom of the assembly and the construct105bforms the “lid” on top of the assembly. In addition, the lid locking tabs148aengaging the tray engagement apertures150bas shown and described in the illustrated embodiment is essentially equivalent to the “tray” locking tabs148aengaging the “lid” engagement apertures150b.

In the illustrated embodiment, the construct105is versatile, convenient, and efficient at least because the construct105has both a locking tab148and an engagement aperture150at each of its corners109(e.g., at each end of the side panels112,116). Each corner109of the construct105can act as female locking feature (e.g., receiving locking tabs from a separate construct in the respective engagement apertures150in the construct105) or a male locking feature (e.g., the locking tabs148being received in respective engagement apertures in a separate construct). Accordingly, when serving food for takeout, for example, the food product can be placed in a first construct105(e.g., that was taken from a stack of nested constructs, not shown), and a second construct105(e.g., which can be taken from the same stack as the first construct) can be interlocked with the first construct to form the assembly180as described above. In one embodiment, only one stack of constructs105is needed for the supply of lids and trays. In alternative packages where the lid is different than the tray, the lids and trays would be arranged in separate stacks that can take up valuable space. In situations where a lid is not needed, such as for when a patron is dining in at a quick-service restaurant in one example, a single construct105can be used as a tray to serve a food product without a lid. In contrast, in a different style of container with a lid that is different than the tray or wherein the lid is attached to the tray (e.g., a clamshell container), the unneeded lid is wasted material and takes up additional space. Accordingly, in situations where a lid is needed for the tray in some occasions and a lid is not needed for the tray in other occasions, the construct105, which can serve as either a tray or as a lid in cooperation with another construct105, is more convenient and efficient.

The blank103and/or the construct105and/or the assembly180could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. The blank and construct described above are included by way of example. For example, the shapes of the overall construct and/or the locking features could be any suitable shape. The shapes described above and included in the figures are included by way of example, and the construct105could have any suitable number of corners109and/or locking features107without departing from the disclosure.

In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blank may then be coated with a varnish to protect information printed on the blanks. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the exemplary embodiments, 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.

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 exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and 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. 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.