Patent Abstract:
A plurality of cartons, preferably fabricated from paper, paperboard and/or corrugated paperboard, and particularly of tray or wrapper-style construction, are provided, having integral lid constructions, and outer overlap panels, operably associated with the at least one top panel, to enable articulation of the carton into a substantially completed structure, without interfering with the subsequent articulation of the at least one top panel to enable loading of the carton subsequent to articulation and affixation of the outer overlap panels.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. patent application Ser. No. 13/101,003, filed May 4, 2011, entitled “INTEGRATED CARTON LID DESIGNS”, which is a divisional application of U.S. patent application Ser. No. 12/267,378, filed Nov. 7, 2008, entitled “INTEGRATED CARTON LID DESIGNS”, which is a continuation application of U.S. patent application Ser. No. 10/831,987, filed Apr. 26, 2004, entitled “INTEGRATED CARTON LID DESIGNS”, the disclosures of each of which are hereby incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     1. Field of the Invention 
     The present invention relates in general to cartons fabricated from paper, paperboard and/or corrugated paperboard material, particularly cartons in the form of wrapper or tray type packages. 
     2. Background Art 
     Machine formed full overlap carton tray and wraparound carton structures have long been used to contain and ship heavy products, where the stacking strength of the carton is of utmost concern. 
     However, the overall stacking strength of such a carton can be negatively affected, if the outer, full overlap flap and attached structures are not properly sealed into position, or are damaged prior to sealing. 
     There are a number of full overlap tray and wrapper type package designs presently in use that fully enclose the product, but are difficult to use due to the outer-full overlap-flaps not being initially sealed at the point of initial carton erecting. This material is attached to the top horizontal flap or flaps of the shipper and extend well beyond the length of the erected carton when the top flap or flaps are upright. For packaging facilities with centralized erecting and sealing areas, this extending material can easily be damaged when the carton is transferred through the facility, which damage may compromise the stacking performance the carton is intended to provide. 
     In addition, some products may slightly overfill the carton&#39;s cavity which can cause the product to extend above the top of the carton, making it difficult to place the top flaps into a horizontal plane, and the outer vertical full overlap flaps properly aligned, which again may compromise the stacking strength of the carton. 
     Therefore, it would be desirable to provide an alternative carton construction which is less susceptible to loss of stacking strength, due to improper sealing of, or damage prior to sealing of, closure or overlap flaps. 
     These and other desirable characteristics of the invention will become apparent in view of the present specification, claims and drawings. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a carton, fabricated from at least one of paper, paperboard and corrugated paperboard, and comprising a bottom panel; two outer side panels emanating from opposing side edges of the bottom panel; and two end panels emanating from opposing end edges of the bottom panel. The opposing end edges of the bottom panel preferably extend perpendicular to the opposing side edges of the bottom panel. Two connection panels are associated with respective end edges of each of the two outer side panels, and are affixed, at least indirectly, to inside surfaces of an adjacent one of the two end panels, for maintaining the two end panels and the two end panels in raised, upright orientation relative to the bottom panel. At least two first outer overlap panels emanate, at least indirectly, from top edges of at least one of the side and end panels, respectively, and are placed in overlying relation and affixed to an outer surface of at least one of the end and outer side panels, respectively. At least one top panel emanates from the top edge of the one of the side and end panels from which the at least two first outer overlap panels emanate, at least indirectly. At least two overlap panel connection structures are operably associated with the at least two outer overlap panels and the at least one top panel, for enabling the at least two first outer overlap panels to be affixed in place without interfering with movement of the at least one top panel, to permit the restrained formation and subsequent loading of the carton, subsequent to positioning and affixation of the at least two first outer overlap panels. 
     In a preferred embodiment of the invention, the at least two overlap panel connection structures comprise at least two top corner panels, emanating from the panel from which the at least one top panel emanates, and contiguously connected to the at least two first outer overlap panels. The at least two overlap panel connection structures may further comprise lines of weakness frangibly connecting the at least one top panel to the at least two top corner panels, whereby upon articulation of the carton, the at least one top panel is disposed in a closed orientation, prior to loading of the carton, and prior to lifting of the at least one top panel and breaking of the connection between the at least one top panel and the at least two top corner panels. Alternatively, the at least two first outer overlap panels may emanate directly from the at least one top panel, with the at least two overlap panel connection structures comprising lines of weakness frangibly connecting the at least one top panel to the at least two first outer overlap panels. 
     The carton may further comprise a second outer overlap panel emanating from a side edge of each of the at least two outer overlap panels, each second outer overlap panel being folded, relative to its respective first outer overlap panel, and affixed to an outer surface of an adjacent one of the side and end panels, each second outer overlap panel having a height substantially equal to the at least one of the side and end panels to which the second outer overlap panel is affixed. 
     The carton may further comprise an inner side panel, disposed adjacent to and in overlying relationship to each of the outer side panels, each inner side panel being connected to its respective outer side panel, along at least portions of a top edge region of the outer side panel. Minor flaps may at least indirectly emanate from opposing end edges of each of the inner side panels, the minor flaps being affixed to inside surfaces of the two end panels. The carton may further comprise gusset panels, disposed between the inner side panels and their respective minor flaps, the gusset panels extending diagonally across portions of corner regions of an interior area of the carton. The gusset panels may be substantially rectangular. Alternatively, the gusset panels may be substantially triangular. 
     The carton may further comprise minor flaps, at least directly emanating from opposing end edges of each of the outer side panels, the minor flaps being affixed to inside surfaces of the two end panels. The carton may further comprise gusset panels, disposed between the outer side panels and their respective minor flaps, the gusset panels extending diagonally across portions of corner regions of an interior area of the carton. The gusset panels may be substantially rectangular. Alternatively, the gusset panels may be substantially triangular. 
     The carton may further comprise stacking tabs, emanating upwardly from at least one of the outer side panels, the end panels; and stacking tab receiving apertures, disposed in at least one of the bottom panel, bottom edge regions of the outer side panels, bottom edge regions of the end panels. 
     The carton may further comprise at least one top side closure flap, emanating from a side edge of the at least one top panel, and configured to be adhered to an outer surface of an outer side panel. A cut-out region may be disposed in each of the at least two first overlap panels for enabling the at least one top side closure flap to make direct contact with an outer surface of an outer side panel. 
     The carton may further comprise at least one top front closure flap, emanating from a front edge of the at least one top panel, and configured to be adhered to an outer surface of an end panel. 
     The at least one top panel may comprise two top panels emanating from top edges of opposing ones of the side and end panels. 
     The carton may further comprise stacking tabs, emanating upwardly from at least one of the outer side panels, the end panels, the stacking tabs including notches operably configured to engage side edge regions of the at least one top panel. Alternatively, the carton may further comprise stacking tabs, emanating upwardly from at least one of the outer side panels, the end panels. These stacking tabs may include notches operably configured to engage side edge regions of the at least one top panel. Apertures may be disposed in the at least one top panel, for receiving the stacking tabs, when the at least one top panel is in a closed position. 
     The carton may further comprise an extension of the at least one top panel, extending into the one of the side and end panels from which the top panel emanates; and a frangible line of weakness separating the extension from remaining portions of the one of the side and end panels, for enabling separation of the at least one top panel from the one of the side and end panels. 
     The at least one top panel may further comprise inner and outer top panel members foldably connected to one another. 
     The carton may further comprise venting apertures disposed in at least one of the two outer side panels, the end panels, the bottom panel, the at least one top panel. 
     The carton may further comprise at least one hand hole disposed on at least one of the two outer side panels, the end panels. 
     The two connection panels may each have a height substantially equal to the inside surfaces of the adjacent one of the two end panels to which the two connection panels are affixed. 
     The at least two first outer overlap panels may each have a height substantially equal to the at least one of the end and outer side panels to which the at least two outer overlap panels are affixed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a blank of a carton with integrated lid according to a preferred embodiment of the invention. 
         FIG. 2  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 1 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 3  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 4  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 3 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 5  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 6  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 5 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 7  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 8  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 7 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 9  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 10  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 9 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 11  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 12  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 11 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 13  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 14  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 13 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 15  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 16  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 15 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 17  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 18  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 17 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 19  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 20  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 19 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 21  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 22  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 21 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 23  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 24  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 23 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 25  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 26  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 25 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 27  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 28  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 27 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 29  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 30  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 29 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 31  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 32  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 31 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 33  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 34  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 33 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 35  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 36  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 35 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 37  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 38  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 37 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 39  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 40  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 39 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 41  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 42  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 41 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 43  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 44  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 43 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 45  is a plan view of a blank of a carton with integrated lid according to another preferred embodiment of the invention. 
         FIG. 46  is a simplified perspective view of a carton with integrated lid according to the embodiment of  FIG. 45 , shown in its erected configuration, with the top open prior to loading and sealing. 
         FIG. 47  illustrates the first several steps in a method for forming a package, using the carton blank from  FIGS. 1-2 . 
         FIG. 48  illustrates the remaining steps in a method for forming a package, using the carton blank from  FIGS. 1-2 . 
         FIG. 49  illustrates the first several steps in a method for forming a package, using the carton blank from  FIGS. 21-22 . 
         FIG. 50  illustrates the remaining steps in a method for forming a package, using the carton blank from  FIGS. 21-22 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail, a preferred embodiment with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment so illustrated. 
     The cartons of the present invention are preferably fabricated from paper, paperboard and/or corrugated paperboard, although other materials having similar performance characteristics may be employed, as desired or dictated by the requirements of a particular application. 
     When referring to the plan illustrations of the blanks, the usual drawing conventions for illustration of carton blanks fabricated from paper, paperboard and/or corrugated paperboard, as are customarily employed in the art, are applied. That is, unless otherwise noted, broken lines indicate scores, fold lines or other lines of weakness such as perforations; scalloped lines indicate lines of weakness forming a tear strip or similar structure; and solid lines within the interior of, or extending to the edge of, a blank, indicate through-cuts. 
     A first embodiment of the invention is illustrated in  FIGS. 1 and 2 , which features a single top panel. Carton  10  ( FIG. 2 ) is formed from blank  11 , which is preferably fabricated from corrugated paperboard, although similarly performing alternative materials may be employed. If corrugated paperboard is employed, the preferred direction of the flutes is indicated by the double-headed arrow in  FIG. 1 . Blank  11  includes bottom panel  12 ; side panels  13 ,  14 ; fold lines  15 ,  16 ; minor flaps  17 - 20 ; fold lines  21 - 24 ; (front) end panel  25 ; (rear) end panel  26 ; fold lines  27 ,  28 ; top panel  29 ; top side closure flaps  30 ,  31 ; top front closure flap  32 ; top corner panels  33 ,  34 ; fold lines  35 - 38 ; first overlap panels  39 ,  40 ; second overlap panels  41 - 44 ; and fold lines  45 - 48 . 
     Inner side panels  13 ,  14  include hand-holes  49 ,  50 , which are preferably formed by oval perforations  51 ,  52 , to enable the centers  49 A,  50 A to be pushed out, as desired. Outer side panels  39 ,  40  include upper edge cutouts  53 ,  54 . In this embodiment, front panel  25  is slightly trapezoidal (although it could be rectangular in alternative embodiments). Rear panel  26  has an hourglass shape, though it too, could be rectangular in alternative embodiments. Blank  11  also includes fold lines  55 ,  56  and perforations  57 ,  58 ,  59 ,  60 . 
     In order to erect carton  10 , side panels  13  and  14  have been folded up perpendicular to bottom panel  12 . Minor flaps  17 - 20  have been folded perpendicular to side panels  13 ,  14  and may be, if desired, adhered to the inside surfaces of (front) end panel  25  and (rear) end panel  26 . First overlap panels  39 ,  40  have been positioned to the outside of and adhered to side panels  13 ,  14 . First overlap panels  41 - 44  have been folded perpendicular to first overlap panels  39 ,  40  and adhered to the outwardly facing surfaces of (front) end panel  25  and (rear) end panel  26 . 
     Because of perforations  57 ,  58 ,  59 ,  60  are maintained intact when the overlap panels are positioned and glued, top panel  29  is initially positioned over the carton opening, parallel to bottom panel  12 , but top side closure flaps  30 ,  31  and top front closure flap  32  are not glued. To place product in carton  10  (if blank  11  was not, in fact formed around a load of product), a worker (or machine) pulls up on top panel  29 , breaking perforations  57 ,  58 . 
     After product has been placed in carton  10 , which placement may occur early in the carton erecting process while the carton is wrapped around the load in the usual manner of wrapper type container blanks, top panel  29  is then folded over parallel to bottom panel  12  and then top side closure flaps  30 ,  31  are folded down and adhered to outwardly facing surfaces of inner side panels  13 ,  14  and top front closure flap  32  is folded down perpendicular to top panel  29  and adhered to an outwardly facing surface of (front) end panel  25 . 
       FIGS. 47-48  illustrate the steps in a method for setting up a carton, such as may be fabricated from the blank of  FIGS. 1-2 . These methods may be performed using suitably modified carton forming machinery such as are known in the art, and such modifications may be readily accomplished by one of ordinary skill in the art, having the present disclosure before them. The steps are as follows: 
     I. A flat blank is indexed into a forming station from the top of a stack of blanks. 
     II. The blank is then indexed laterally as adhesive is applied to the inside surfaces of the blank, such as on panels  25 ,  26 ,  39 ,  40 ,  41 ,  42 ,  43 ,  44 . 
     III. A mandrel then pushes the blank down through a forming chamber in the forming station into a compression station. 
     IV. At a secondary forming station, the top and side panels are folded while the overlap panels are articulated and glued. 
     V. As a new carton is received in the forming chamber, the just-formed carton is discharged from the compression section onto a powered take-away conveyor. 
     VI. Formed cartons are pushed down a chute from a case-erecting room located on an upper floor to a production floor of a production facility. 
     VII. Cartons are moved laterally, e.g., at shoulder height, on a powered belt conveyor, past manual packing stations. 
     VIII. A worker selects an empty carton from the belt conveyor, and positions the carton at the worker&#39;s pack station, e.g., at waist or thigh height. 
     IX. The top front closure flap is pulled up to open the carton for packing. 
     X. Product, such as Cryovac™ wrapped meat cuts are packed into the open carton. 
     XI. The filled carton is pushed forward onto a take-away conveyor to a sealing device, such as an Elliott Top &amp; Side Sealer, a Pearson side flange sealer or a Smurfit-Stone Container Corporation side flange sealer. 
     XII. The top panel is plowed down and the top front closure flap is sealed with hot melt adhesive. 
     XIII. The carton is then rotated 90° and the top side closure flaps are sealed with hot melt adhesive. 
     XIV. Sealed cartons are then transported, e.g., by roller conveyor to a manual palletizing area. Pallet Loads are built, transferred by lift trucks to temporary storage, and then shipped to customers as required. 
       FIGS. 3-4  illustrate an embodiment which features a two panel top. Carton  100  is formed from a blank  101 , which is preferably symmetrical about longitudinal axis L and transverse axis T. Again, for a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 3 . Blank  101  includes bottom panel  102 ; side panels  103 ,  104 ; fold lines  105 ,  106 , which are interrupted by cutouts  107 ,  108  and  109 ,  110 , respectively; end panel  111 ; fold line  112  interrupted by cutouts  113 ,  114 ; end panel  115 ; fold line  116  interrupted by cutouts  117 ,  118 ; gusset panels  119 - 122 ; minor flaps  123 - 126 ; fold lines  127 - 134 ; first top panels  135 ,  136 ; second top panels  137 ,  137 A; top corner panels  138 - 141 ; fold line  142 , interrupted by vent hole  143  and die-cut tabs  144 ,  145 ; fold line  146 , interrupted by vent hole  147  and die-cut tabs  148 ,  149 ; fold lines  150 ,  151 ; first overlap panels  152 - 155 ; second overlap panels  156 - 159 ; fold lines  160 - 167 . Blank  102  also includes slots  168 - 171 , which are configured to receive or fit over hooked tabs  172 - 175 , as shown in  FIG. 4 . Side panels  103 ,  104  also may include hand holes  176 ,  177 . Separation lines  180 - 183 , between top corner panels  138 - 141  and first top panels  135 ,  136  may be perforations or through-cuts. If perforations, upon gluing and folding down of first overlap panels  152 - 155  and second overlap panels  156 - 159 , first top panels  135 ,  136  will be in a “closed” position, and will have to be pulled up (in the manner described relative to the embodiment of  FIGS. 1-2 ) to permit loading of the carton, if carton  100  were not already formed around a load. 
     In forming carton  100 , side panels  103  and  104  have been folded perpendicular to bottom panel  102  as have end panel  111  and end panel  115 . Minor flaps  124  and  125  have been adhered to the inside surface of end panel  115  while minor flaps  123  and  126  have been adhered to an inner surface of end panel  111  so that gusset panels  119 - 122  extend diagonally across the corners of the interior of the carton, acting as stacking support structures. (See gusset panel  120  in  FIG. 4 ). In an embodiment in which this carton  100  is wrapped around a load, after the load has been placed and the front rear and side panels have been folded up, the first and second top panels  135 - 137 A may be folded over. In particular, corner panels  138 - 141  are folded over to positions parallel to bottom wall  102 . Then, first overlap panels  152 - 155  are folded down to positions parallel to and the outside surfaces of side panels  103 ,  104 . Second overlap panels  156 - 159  are then folded perpendicular to first overlap panels  152 - 155  and adhered to outwardly facing surfaces of end panel  111  and end panel  115 . Carton  100  is a self-locking carton, in that stacking tabs  172 - 175  are provided with notches which engage end edge regions of slots  168 - 171  of second top panels  137  and  137 A. 
       FIGS. 5-6  illustrate an embodiment which features a two panel top. Carton  200  is formed from a blank  201 , which is preferably bilaterally symmetrical, in the manner of the embodiment of  FIGS. 3 and 4 . Again, for a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 5 . Blank  201  includes bottom panel  202 ; side panels  203 ,  204 ; fold lines  205 ,  206 , which are interrupted by cutouts  207 ,  208  and  209 ,  210 , respectively; end panel  211 ; fold line  212  interrupted by cutouts  213 ,  214 ; end panel  215 ; fold line  216  interrupted by cutouts  217 ,  218 ; gusset panels  219 - 222 ; minor flaps  223 - 226 ; fold lines  227 - 234 ; first top panels  235 ,  236 ; second top panels  237 ,  237 A; top corner panels  238 - 241 ; fold line  242 , interrupted by vent hole  243  and die-cut tabs  244 ,  245 ; fold line  246 , interrupted by vent hole  247  and die-cut tabs  248 ,  249 ; fold lines  250 ,  251 ; overlap panels  252 - 255 ; fold lines  260 - 263 . Blank  202  also includes slots  268 - 271 , which are configured to receive or fit over hooked tabs  272 - 275 , as shown in  FIG. 6 . Side panels  203 ,  204  also may include hand holes  276 ,  277 , and separation lines  280 - 283 , which as in the embodiment of  FIGS. 3-4 , may be perforations or through-cuts, with the corresponding modes of operation as discussed in that embodiment. 
     Carton  200  of  FIGS. 5 and 6  is erected and affixed to itself in substantially the same manner as the carton of  FIGS. 3-4 , except that since there are only overlap panels  252 - 255 , they must be adhered to outer facing surfaces of side panels  203 ,  204 , to be held in place there. The closure of the top panels is accomplished in the same manner as in the embodiment of  FIGS. 3-4 . 
       FIGS. 7 and 8  illustrate a covered tray with integral lid structure. Again, for a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 7 . Tray  300  is formed from blank  301  (preferably bilaterally symmetrical), which includes bottom panel  302 ; outer side panels  303 ,  304 ; fold line  305  interrupted by die-cut slots  306 ,  307 ; fold line  308  interrupted by die-cut slots  309 ,  310 ; end panels  311 ,  312 ; fold line  313  interrupted by vent hole  314 ; fold line  315  interrupted by vent hole  316 ; inner side panels  317 ,  318 ; web fold lines  319 - 322 ; minor flaps  322 A- 325 ; fold lines  326 - 329 ; gusset panels  330 - 333 ; inner side panel minor flaps  334 - 337 ; fold lines  338 - 345 ; top corner panels  346 - 349 ; first overlap panels  350 - 353 ; second overlap panels  354 - 357 ; fold lines  358 - 361 ; fold lines  362 - 365 ; top panels  366 ,  367 ; notches  368 - 371 ; vent holes  372 - 379 ; and fold lines  380 - 381 . In addition, blank  301  includes separation lines  390 - 393 , which may be perforations or through-cuts, as in the embodiment of  FIGS. 1-2 , with similar modes of operation as discussed. When the inner side panels are folded in, the webs that connect the inner side panels and the outer side panels form stacking tabs, the top edges of which are defined by the fold lines  319 - 322 . 
     Covered tray  300  is formed by folding up outer side panels  303 ,  304  perpendicular to bottom panel  302  while folding up end panels  311 ,  312  perpendicular to bottom  302 . Inner side panel minor flaps  322 A- 325  are adhered to inside surfaces of end panels  311  and  312 , while panels  334 - 337  are adhered to inside surfaces of minor flaps  322 A- 325 , so that gusset panels  330 - 333  are positioned spanning the corners of the interior of the carton. Triangular top panels  346 - 349  are folded to positions over the corners of the carton parallel to bottom panel  302  to enable first overlap panels  350 - 353  to be folded down over the outside surfaces of and adhered to, if desired, to outer side panels  303 ,  304 . Second overlap panels  354 - 357  are folded perpendicular to first overlap panels  350 - 353  and adhered to outer surfaces of end panels  311 ,  312 . Top panels  366 ,  367  are then folded down parallel to bottom panel  302  so that notches  368 - 371  fit along the inside surfaces of the stacking tabs formed by the webs connecting outer side panels  303 ,  304  with their respective inner side panels  317 ,  318 . Panels  317 ,  318  are folded over 180 degrees to be located parallel and to the inside of panels  303  and  304 , so that the two sets of inner and outer minor flaps overlap one another, with the inner minor flaps not contacting the outer walls of the container. 
       FIGS. 9 and 10  illustrate a covered tray with integral lid structure. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 9 . Tray  400  is formed from blank  401  (preferably bilaterally symmetrical), which includes bottom panel  402 ; outer side panels  403 ,  404 ; fold line  405  interrupted by die-cut slots  406 ,  407 ; fold line  408  interrupted by die-cut slots  409 ,  410 ; end panels  411 ,  412 ; fold line  413  interrupted by vent hole  414 ; fold line  415  interrupted by vent hole  416 ; inner side panels  417 ,  418 ; web fold lines  419 - 422 ; minor flaps  422 A- 425 ; fold lines  426 - 429 ; gusset panels  430 - 433 ; inner side panel minor flaps  434 - 437 ; fold lines  438 - 445 ; top corner panels  446 - 449 ; first overlap panels  450 - 453 ; second overlap panels  454 - 457 ; fold lines  458 - 461 ; fold lines  462 - 465 ; top panels  466 ,  467  with extensions  466 A,  467 A; notches  468 - 471 ; vent holes  472 - 479 ; top side closure flaps  480 - 483 ; fold lines  484 - 487 ; and fold lines  488 ,  489 . When the inner side panels are folded in, the webs that connect the inner side panels and the outer side panels form stacking tabs, the top edges of which are defined by the fold lines  419 - 422 . 
     Blank  401  further includes separation lines  490 ,  491  which are preferably continuous perforations. To load carton  400  (if not formed around a load), top panels  466 ,  467  are pulled up, breaking the perforations of separation lines  490 ,  491 , up to (but preferably not beyond) fold lines  488 ,  489 . After filling, top panels  466 ,  467  are folded down, and top side closure flaps  480 - 483  will be glued and folded down. Removal of top panels  466 ,  467  is accomplished, in part, by tearing along the remaining unbroken perforated portions of separation lines  490 ,  491 . 
     Carton  400  is formed in substantially the same manner as carton  300  except that for carton  400 , blank  401  is provided with additional closure flaps  480 - 483 , which are adhered to outside surfaces of outer side panels  403 ,  404 . In addition, top panels  466 ,  467  terminate in extensions  466 A and  467 A, which are defined by perforations  494 ,  495 . Extensions  466 A and  467 A can be used to open the container, and permit removal of the lid portion. 
       FIGS. 11 and 12  illustrate a covered tray, similar to tray  400 . Tray  500  is formed from blank  501  (preferably bilaterally symmetrical), which includes bottom panel  502 ; outer side panels  503 ,  504 ; fold line  505  interrupted by die-cut slots  506 ,  507 ; fold line  508  interrupted by die-cut slots  509 ,  510 ; end panels  511 ,  512 ; fold line  513  interrupted by vent hole  514 ; fold line  515  interrupted by vent hole  516 ; inner side panels  517 ,  518 ; web fold lines  519 - 522 ; minor flaps  522 A- 525 ; fold lines  526 - 529 ; gusset panels  530 - 533 ; inner side panel minor flaps  534 - 537 ; fold lines  538 - 545 ; top corner panels  546 - 549 ; first overlap panels  550 - 553 ; second overlap panels  554 - 557 ; fold lines  558 - 561 ; fold lines  562 - 565 ; top panels  566 ,  567  with extensions  566 A,  567 A; top side closure flaps  596 - 599  (which when folded, form or expose slots, for fitting over the stacking tabs formed when the inner side panels are folded in against the outer side panels) and fold lines  588 A,  588 B,  589 A,  589 B. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 11 . When the inner side panels are folded in, the webs that connect the inner side panels and the outer side panels form stacking tabs, the top edges of which are defined by the fold lines  519 - 522 . Separation lines  590 ,  592 ,  593  and  595  are preferably through-cuts, while separation lines  591 ,  594  are preferably perforation lines. 
       FIGS. 13-14  illustrate a covered tray with integral lid, and having stacking tabs. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 13 . Covered tray  600  is formed from blank  601  (preferably bilaterally symmetrical), which includes bottom panel  602 , end panels  603 ,  604 ; fold lines  605 ,  606 ; outer side panels  607 ,  608 ; fold line  609 , interrupted by vent holes  610 ,  611 ; fold line  612 , interrupted by vent holes  613 ,  614 ; inner side panels  615 ,  616 ; double fold line  617 , interrupted by T-tab structures  620 ,  621  including offset tab fold lines  618 ,  619 ; double fold line  622 , interrupted by T-tab structures  625 ,  626  including offset tab fold lines  623 ,  624 ; outer side panel minor flaps  627 - 630 ; fold lines  631 - 634 ; inner side panel minor flaps  635 - 638 ; fold lines  639 - 642 ; inner side panel notches  643 - 646 ; top panels  647 ,  648 ; fold lines  649 ,  650 ; top corner panels  651 - 654 ; first overlap panels  655 - 658 ; fold lines  659 - 662 ; second overlap panels  663 - 666 ; fold lines  667 - 670 ; top panel notches  671 - 674 . Blank  601  also includes through-cuts  674 - 676  (which may be substituted by perforations, with the corresponding modes of operation as discussed herein). 
     In carton  600 , when inner side panel  615 ,  616  are folded over their respective double fold lines to positions parallel to and overlying the inside surfaces of outer side panels  607 ,  608 , the offset fold line  618 ,  619 ,  623  and  624  cause the upside down t-shaped tab  620 ,  621 ,  625 ,  626  to separate from the surrounding portions of the inner side panels  615 ,  616 , as shown in  FIG. 14 . Inner side panel minor flaps  635 - 638  are adhered to the inside surfaces of minor flaps  627 - 630 . Outer side panel minor flaps  627 - 630  are adhered to the inside surfaces of side panels  603 ,  604 . First overlap panels  655 - 658  have been folded down to positions overlying the outside surfaces of outer side panels  607 ,  608  with second overlap panels  663 - 666  folded perpendicular thereto and adhered to outside surfaces of end panels  603 ,  604 . The closure of carton  600  is an indicated in  FIG. 14 . 
       FIGS. 15-16  illustrate a carton with integral lid according to another embodiment of the invention. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 15 . Carton  700  is formed from blank  701  (preferably bilaterally symmetrical), which includes bottom panel  702 ; end panels  703 ,  704 ; fold lines  705 ,  706 ; side panels  707 ,  708 ; fold lines  707 A,  708 A; side panel minor flaps  709 - 712 ; fold lines  713 - 716 ; top panels  717 ,  718 ; fold lines  719 ,  720 ; top corner panels  721 - 724 ; perforations  725 - 728 ; top flaps  729 - 732 ; fold lines  733 - 736 ; contoured cuts  737 - 740 ; overlap  741 - 744 ; and fold lines  745 - 748 . Blank  701  also includes knock-outs  750 ,  751 , formed by perforations  752 ,  753 . 
     In carton  700 , side panel minor flaps  709 - 712  have been adhered to the inside surfaces the end panels  703 ,  704  and overlap panels  741 - 744  have been preferably adhered to outside surfaces of side panels  707 ,  708 . Upon closure of top panel  717 ,  718  the inner facing edges of these two panels may overlap and top flap  729 - 732  are folded down and adhered to outer surfaces of end panels  707 ,  708  where they are exposed by the contoured cuts  737 - 740 . 
       FIGS. 17-18  illustrate a carton with integral lid, including diagonal corner support panels. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 17 . Carton  800  is formed from blank  801  (preferably bilaterally symmetrical), and includes bottom panel  802 ; end panels  803 ,  804 ; fold lines  805 ,  806 ; side panels  807 ,  808 ; fold lines  809 ,  810 ; gusset panels  811 - 814 ; fold lines  815 - 818 ; side panel minor flaps  819 - 822 ; fold lines  823 - 826 ; top panels  827 ,  828 ; fold lines  829 ,  830 ; top panel flaps  833 - 836 ; fold lines  837 - 840 ; top corner panels  841 - 844 ; countered cuts  845 - 848 ; overlap panels  849 - 852 ; fold lines  853 - 856 ; knock-outs  857 ,  868 , formed by perforations  859 ,  860 . Blank  801  also includes cuts  861 - 864  (which may be substituted with perforations, if desired, with the corresponding modes of operation as discussed herein). 
     Carton  800  is formed in a substantially similar manner as carton  700 , except that blank  801  for  800  includes gusset panels  811 - 814 . 
     In a further alternative embodiment of the carton of  FIGS. 17 and 18 , gusset panels  811 - 814  may be omitted, by eliminating fold lines  815 - 818 . Such an alternative construction is illustrated in  FIGS. 19-20 , by carton  800 ′, formed by blank  801 ′ (preferably bilaterally symmetrical), which has all the other panels, fold lines and other features of blank  800  of  FIGS. 17-18 . For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 19 . 
     In another alternative embodiment, shown in  FIGS. 21-22 , a covered carton with two top panels, and with outer corner support panels, is shown. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 21 . Carton  900  is formed from blank  901  (preferably bilaterally symmetrical), which includes bottom panel  902 ; end panels  903 ,  904 ; fold lines  905 ,  906 ; side panels  907 ,  908 ; fold lines  909 ,  910 ; minor flaps  911 - 914 ; fold lines  915 - 918 ; top panels  919 ,  920 ; fold lines  921 ,  922 ; top corner panels  923 - 926 ; perforations  927 - 930  (which may be replaced by straight cuts); top side closure flaps  931 - 934 ; fold lines  935 - 938 ; first overlap panels  940 - 943 ; fold lines  944 - 947 ; second overlap panels  948 - 951 ; fold lines  952 - 955 ; and knock-outs  956 ,  957 , formed by perforations  958 ,  959 . 
     Carton  900  is substantially similar to carton  700 , but for the addition of second overlap panels  948 - 951 , which are adhered to the outside surfaces of side panels  907 ,  908 . 
       FIGS. 49-50  illustrate the steps in a method for setting up a carton, such as may be fabricated from the blank of  FIGS. 21-22 . These methods may be performed using suitably modified carton forming machinery such as are known in the art, and such modifications may be readily accomplished by one of ordinary skill in the art, having the present disclosure before them. The steps are as follows: 
     I. A flat blank is indexed into a forming station from the top of a stack of blanks. 
     II. The blank is indexed laterally as adhesive is applied to the inside surfaces of panels  903 ,  904 ,  948 - 951  and  940 - 943 , particularly in a series of parallel glue lines, extending in a direction parallel to the direction of the flutes (as shown by the double arrow). In panels  903 ,  904 , the glue lines may be placed near the top and bottom of those panels (as observed in  FIG. 21 ), but not along the mid-regions of those panels, if desired. 
     III. A mandrel pushes the blank down through a forming chamber into a compression section. 
     IV. At a secondary forming station, the top panels and first overlap panels are folded down while the second overlap panels are articulated and glued. 
     V. As a new carton is received in the forming chamber, the just-formed carton is discharged from the compression section onto a powered take-away conveyor. 
     VI. Formed cartons are pushed down a chute from a case erecting room located on an upper floor to a production floor of a production facility. 
     VII. Cartons are moved laterally, e.g., at shoulder height, on a powered belt conveyor, past manual packing stations. 
     VIII. A worker selects an empty carton from the belt conveyor, and positions the carton at the worker&#39;s pack station, e.g., at waist or thigh height. 
     IX. The top panels are pulled up (breaking perforations as necessary) to open the carton for packing. 
     X. Product, such as Cryovac™ wrapped meat cuts are packed into the open carton. 
     XI. The filled carton is pushed forward onto a take-away conveyor to a sealing device, such as an Elliott Top &amp; Side Sealer, a Pearson side flange sealer or a Smurfit-Stone Container Corporation side flange sealer. 
     XII. The top panels are plowed down and the top side closure flaps are sealed with hot melt adhesive. 
     XIII. Sealed cartons are then transported, e.g., by roller conveyor to a manual palletizing area. Pallet Loads are built, transferred by lift trucks to temporary storage, and then shipped to customers as required. 
     In the embodiment of  FIGS. 23, 24 , carton  1000  is formed by blank  1001 , to create a single top panel carton. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 23 . Blank  1001  includes bottom panel  1002 ; (front) end panel  1003 ; (rear) end panel  1004 ; fold lines  1005 ,  1006 ; side panels  1007 ,  1008 ; fold lines  1009 ,  1010 ; gusset panels  1011 - 1014 ; fold lines  1015 - 1018 ; minor flaps  1019 - 1022 ; fold lines  1024 - 1027 ; top panel  1028 ; fold line  1029 ; top side closure flaps  1030 ,  1031 ; fold lines (or perforation lines)  1032 ,  1033 ; cutouts  1034 ,  1035 ; top corner panels  1036 ,  1037 ; perforations or through-cuts  1038 ,  1039 ; first overlap panels  1040 ,  1041 ; fold lines  1059 ,  1060 ; perforations  1042 ,  1043 ; top front closure flap  1044 ; fold line  1045 ; second overlap panels  1046 - 1049 ; fold lines  1050 - 1053 ; hand holes  1054 ,  1056 ; and vent apertures  1057 ,  1058 . 
     Carton  1000  is formed by placing side panels  1007 ,  1008  perpendicular to bottom panel  1002 . Minor flaps  1019 - 1022  are affixed to inside surfaces of (front) end panel  1003  and (rear) end panel  1004 . Closure of carton  1000  is accomplished by folding top panel  1028  to a position parallel to bottom panel  1002 . At this point, top panel  1028  is still attached along perforations  1042  and  1043  to first overlap panels  1040 ,  1041 . First overlap panels  1040 ,  1041  are affixed to outside surfaces of side panels  1007 ,  1008  with second overlap panels  1046 - 1049  being affixed to outside surfaces of (front) end panel  1003  and (rear) end panel  1004 . Top front closure flap  1044  is affixed to an outer surface of (front) end panel  1003 . In addition, top side closure panels  1030  and  1031  are adhered to outside surfaces of side panels  1007  and  1008 . Opening of carton  1000  is accomplished by peeling back top front closure panel  1044 , and top side closure panels  1030  and  1031  (or tearing along their respective fold lines/perforations), and tearing along perforations  1042  and  1043 . 
     The embodiment of  FIGS. 25-26  is a carton  1100  provided with a two-panel top, and is formed from blank  1101  (preferably bilaterally symmetrical). For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 25 . Blank  1101  includes bottom panel  1102 , end panels  1103 ,  1104 ; fold lines  1105 ,  1106 ; side panels  1107 ,  1108 ; fold lines  1109 ,  1110 ; gusset panels  1111 - 1114 ; fold lines  1115 - 1118 ; minor panels  1119 - 1122 ; fold lines  1123 - 1126 ; top panels  1127 ,  1128 ; fold lines  1129 ,  1130 ; first overlap panels  1131 - 1134 ; perforations  1135 - 1138 ; top side closure flaps  1139 - 1142 ; cuts  1143 - 1146 ; fold lines  1147 - 1150 ; second overlap panels  1151 - 1154 ; and hand holes  1155 ,  1156 . 
     In carton  1100 , minor panels  1119 - 1122  are adhered to inside surfaces of side panels  1103 ,  1104 , so that gusset panels  1111 - 1114  extend diagonally across the corners of the interior of carton  1100  to provide vertical stacking strength. First overlap panels  1131 - 1134  are adhered to outside surfaces of side panels  1107 ,  1108 . Top panels  1128 ,  1127  are pulled up, tearing perforations  1135 - 1138  where the top panels are joined to first overlap panels  1131 - 1134 , to permit the top panels to be raised for loading. After loading, top side closure flaps  1139 - 1142  are folded down and glued in place, later to be separated from the top panels along the perforations to enable access to the interior of carton  1100 . 
     Carton  1200  of  FIGS. 27-28  is formed from blank  1201 . For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 27 . Blank  1201  includes bottom panel  1202 ; (front) end panel  1203 ; (rear) end panel  1204 ; fold lines  1205 ,  1206 ; side panels  1207 ,  1208 ; fold lines  1209 ,  1210 ; gusset panels  1211 - 1214 ; fold lines  1215 - 1218 ; minor flaps  1219 - 1222 ; fold lines  1223 - 1226 ; top panel  1227 ; fold line  1228 ; top side closure flaps  1229 ,  1230 ; fold lines  1231 ,  1232 ; top front closure flap  1233 ; fold line  1234 ; first overlap panels  1235 ,  1236 ; perforations  1237 - 1240 ; second overlap panels flaps  1241 - 1244 ; fold lines  1245 - 1248 ; hand holes  1249 ,  1250 ; and vent holes  1251 ,  1252 . 
     Carton  1200  is formed from a blank  1201 , which is similar to carton  1000  previously described, the primary difference being that the blank of carton  1200  is not provided with the top corner panels along the rear panel of the blank as in the embodiment of carton  1000 . 
     Carton  1300  of  FIGS. 29-30  is formed from blank  1301 . For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 29 . Blank  1301  includes bottom panel  1302 ; end panels  1303 ,  1304 ; fold lines  1305 ,  1306 ; top panels  1307 ,  1308 ; fold line  1309  interrupted by die-cut stacking tabs  1311 ,  1312 ; fold line  1310  interrupted by die-cut stacking tabs  1313 ,  1314 ; top side closure flaps  1315 - 1318 ; fold lines  1319 - 1322 ; top corner panels  1323 - 1326 ; through-cuts  1327 - 1330  (which could be replaced by perforations); fold lines  1331 - 1334 ; first overlap panels  1333 - 1336 ; second overlap panels  1337 - 1340 ; fold lines  1341 - 1344 ; outer side panels  1345 ,  1346 ; fold lines  1347 - 1348 ; double fold lines  1349 ,  1350 ; inner side panels  1351 ,  1352 ; outer side panel minor flaps  1353 - 1356 ; fold lines  1357 - 1360 ; V-shaped gusset panels  1361 - 1364 ; fold lines  1365 - 1372 ; inner side panel minor flaps  1373 - 1376 ; vent openings  1377 ,  1379 ; die-cut stacking slots  1380 - 1383 . 
     Carton  1300 , shown in  FIGS. 29-30 , is, except for the proportions, substantially similar in the structure and mode of operation to carton  300 . In addition, top side closure flaps  1315 - 1318  extend from end edges of the top panels and are adhered to outside surfaces of side panels  1345 ,  1346 . 
     Carton  1400 , shown in  FIGS. 31-32 , is a two top panel carton, but based on an asymmetrical blank  1401 . For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 31 . Blank  1401  includes bottom panel  1402 ; end panels  1403 ,  1404 ; fold lines  1405 ,  1406 ; side panels  1407 ,  1408 ; fold lines  1409 ,  1410 ; gusset panels  1411 - 1414 ; fold lines  1415 - 1418 ; minor flaps  1419 - 1422 ; fold lines  1423 - 1426 ; top panels  1427 ,  1428 ; fold lines  1429 ,  1430 ; top corner panels  1431 - 1434 ; through-cuts  1435 - 1438  (which could be replaced by perforations); first overlap panels  1439 - 1442 ; fold lines  1443 - 1446 ; second overlap panels  1447 - 1450 ; fold lines  1451 - 1454 ; top side closure flaps  1455 ,  1456 ; fold lines  1457 ,  1458 ; locking flaps  1459 ,  1460 ; fold lines  1461 ,  1462 ; tabs  1463 ,  1464 ; hand holes  1465 ,  1466 . 
     In the embodiment shown in  FIGS. 31, 32 , tabs  1463 ,  1464  are set off by separate score lines  1467 - 1470  that extend perpendicular to fold lines  1471 ,  1472  that extend across locking flaps  1459 ,  1460 . In an alternative embodiment of the invention, score lines  1467 - 1470  may be omitted. 
     In carton  1400 , minor flaps  1419 - 1422  are adhered to inside surfaces of end panels  1403 ,  1404 . First overlap panels  1439 - 1442  are adhered to outside surfaces of side panels  1407 ,  1408  and/or second overlap panels  1447 - 1450  are adhered to outside surfaces of end panels  1403 ,  1402 . To maintain closure panel  1427  in place over bottom panel  1402 , closure flaps  1455 ,  1456  are folded down over the outer surfaces of side panels  1407 ,  1408 , while tabs  1464 ,  1463  or locking flaps  1459 ,  1460  are inserted and received through hand holes  1465 ,  1466 , locking the top flaps  1427 ,  1428  down in place. 
       FIGS. 33-34  illustrate a covered carton with self-locking top panels. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 33 . Carton  1500  is formed from blank  1500 , which includes bottom panel  1502 ; outer side panels  1503 ,  1504 ; fold line  1505 , interrupted by stacking notches  1506 ,  1507 ; fold line  1508  interrupted by stacking notches  1509 ,  1510 ; end panels  1511 ,  1512 ; fold lines  1513 ,  1514 ; top panels  1516 ,  1517 ; fold lines  1518 ,  1519 ; top corner panels  1520 - 1523 ; through-cuts  1524 - 1527  (which may be replaced by perforations); locking tabs  1528 - 1531 ; first overlap panels  1532 - 1535 ; fold lines  1536 - 1539 ; second overlap panels  1540 - 1543 ; inner side panels  1544 ,  1545 ; web fold lines  1546 - 1549 ; outer side panel stacking tabs  1550 - 1553 ; inner side panel stacking tabs  1554 - 1557 ; minor flaps  1560 - 1563 ; fold lines  1563 ′- 1566 ; minor flaps  1567 - 1570 ; fold lines  1571 - 1574 ; and stacking notches  1575 - 1578 . 
     In the carton  1500 , minor flaps  1560 - 1563  are affixed to inside surfaces of end panels  1511 ,  1512  and minor flaps  1567 - 1570  are affixed to inside surfaces of minor flaps  1560 - 1563 . In addition, second overlap panels  1540 - 1543  are affixed to outside surfaces of end panels  1511 ,  1512 . The stacking tab structures  1554 - 1557  also serve to help keep the lid closed or re-closeable by being provided with notches that receive locking tabs  1528 ,  1531  as indicated in  FIG. 34 . 
     Carton  1600  of  FIGS. 35-36  is formed from blank  1601 , and has bottom panel  1602 ; outer side panels  1603 ,  1604 ; fold line  1605 , interrupted by stacking openings  1606 ,  1607 ; fold line  1608 , interrupted by stacking openings  1609 ,  1610 ; end panels  1611 ,  1612 ; fold lines  1613 ,  1614 ; top panels  1615 ,  1616 ; fold lines  1617 ,  1618 ; top corner panels  1619 - 1622 ; through-cuts  1623 - 1626  (which may be replaced by perforations); locking tabs  1627 - 1630 ; first overlap panels  1631 - 1634 ; fold lines  1635 - 1638 ; second overlap panels  1639 - 1642 ; inner side panels  1643 ,  1644 ; web double fold lines  1645 - 1648 ; outer side panel stacking tabs  1649 - 1652 ; notched inner side panel stacking tabs  1653 - 1656 ; minor flaps  1658 - 1661 ; fold lines  1662 - 1664 ; minor flaps  1665 - 1668 ; double fold lines  1669 - 1672 ; and stacking notches  1673 - 1680 . For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 35 . 
     In carton  1600 , the structure mode of operation and manner of affixation of certain panels to other panels is substantially similar to that of the embodiment of carton  1500 , except that the panels emanating from the ends of the inner side panels are elongated so as to be folded back upon outwardly facing surfaces of the inner side panels. Thus, panels  1665 ,  1666  are captured between panels  1603  and  1643 , and panels  1667  and  1668  are captured between panels  1604  and  1664 . This sandwiching of panels is evidenced in  FIG. 36 , particularly on the left end of the carton where outer side panel  1603  and inner side panel  1643  capture between them panels  1665  and  1666 . 
     Carton  1700  is illustrated in  FIGS. 37-38 . For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 37 . Blank  1701  includes bottom panel  1702 ; outer side panels  1703 ,  1704 ; fold line  1705  interrupted by stacking openings  1706 ,  1707 ; fold line  1708  interrupted by stacking openings  1709 ,  1710 ; end panels  1711 ,  1712 ; fold lines  1713 ,  1714 ; top panels  1715 ,  1716 ; fold lines  1717 ,  1718 ; top corner panels  1719 - 1722 ; through-cuts  1786 - 1789 ; first overlap panels  1723 - 1726 ; fold lines  1727 - 1730 ; second overlap panels  1731 - 1734 ; fold lines  1735 - 1738 ; minor flaps  1739 - 1742 ; fold lines  1743 - 1746 ; web fold lines  1747 - 1750 ; outer side panel stacking tabs  1751 - 1754 ; inner side panel stacking tabs  1755 - 1758 ; inner side panels  1759 ,  1760 ; minor flaps  1761 - 1764 ; gusset panels  1765 - 1768 ; fold lines  1769 - 1776 ; stacking notches  1778 - 1781 ; and locking tabs  1782 - 1785 . 
     Carton  1700  is substantially similar to cartons  1600 , except that gusset panels are provided adjacent inside side panels  1759  and  1760  with minor flaps  1739 - 1742  being adhered to inside surfaces of end panels  1711 ,  1712  and minor flaps  1761 - 1764  being affixed to inside minor flaps  1739 - 1742 . The closure mechanism for carton  1700  is the same as it is for carton  1600 . 
     Carton  1800  ( FIGS. 39-40 ) includes self-locking top panels as well as interior corner supports. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 39 . Blank  1801  includes bottom panel  1802 ; end panels  1803 ,  1804 ; fold line  1805 , interrupted by stacking openings  1806 ,  1807 ; fold line  1808 , interrupted by stacking openings  1809 ,  1810 ; outer side panels  1811 ,  1812 ; fold line  1813 , interrupted by stacking openings  1814 ,  1815 ; fold line  1816 , interrupted by stacking openings  1817 ,  1818 ; notched stacking tabs  1819 - 1822 ; side end panels  1823 ,  1824 ; double fold lines  1825 ,  1826 ; stacking notches  1827 - 1830 ; gusset panels  1831 - 1834 ; fold lines  1835 - 1838 ; minor flaps  1839 - 1843 ; fold lines  1843 - 1846 ; minor flaps  1847 - 1850 ; fold lines  1851 - 1854 ; fold line  1855 , interrupted by die-cut stacking tabs  1856 ,  1857 ; fold line  1858 , interrupted by die-cut stacking tabs  1859 ,  1860 ; outer top panels  1861 ,  1862 ; top corner panels  1863 - 1866 ; through-cuts  1867 - 1870 ; overlap panels  1871 - 1874 ; fold lines  1875 - 1878 ; inner top panels  1879 ,  1880 ; fold lines  1881 ,  1882 ; locking tab receiving slots  1883 - 1886 ; and knock-outs  1887 - 1890  (surrounded by oval lines of perforations). 
     In carton  1801 , the stacking tab structures are incorporated into the side and end panel structures, especially upon folding over of the inner side panels to the positions inside the outer side panels exposes the hooked stacking and closure tabs  1819 - 1822 . Minor flaps  1847 - 1850  are affixed to inside surfaces of outer end panels  1803 ,  1804  and minor flaps  1839 - 1843  are affixed to minor flaps  1847 - 1850 , while support panels  1871 - 1874  are affixed to outside surfaces of outer side panels  1811 ,  1812 . 
       FIGS. 41-42  illustrate a covered tray with integral lid, and having stacking tabs. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 41 . Covered tray  1900  is formed from blank  1901  (preferably bilaterally symmetrical), which includes bottom panel  1902 , end panels  1903 ,  1904 ; fold lines  1905 ,  1906 ; outer side panels  1907 ,  1908 ; fold line  1909 , interrupted by vent/stacking holes  1910 ,  1911 ; fold line  1912 , interrupted by vent/stacking holes  1913 ,  1914 ; inner side panels  1915 ,  1916 ; double fold line  1917 , interrupted by T-tab structures  1920 ,  1921  including offset tab fold lines  1918 ,  1919 ; double fold line  1922 , interrupted by T-tab structures  1925 ,  1926  including offset tab fold lines  1923 ,  1924 ; outer side panel minor flaps  1927 - 1930 ; fold lines  1931 - 1934 ; inner side panel minor flaps  1935 - 1938 ; inner side panel notches  1943 - 1946 ; top panels  1947 ,  1948 ; fold lines  1949 ,  1950 ; top corner panels  1951 - 1954 ; first overlap panels  1955 - 1958 ; fold lines  1959 - 1962 ; second overlap panels  1963 - 1966 ; fold lines  1967 - 1970 ; top panel locking tabs  1971 - 1974 ,  671 - 674 . Blank  1901  also includes gusset panels  1975 - 1978 ; fold lines  1979 - 1986 ; and through-cuts  1987 - 1990  (which may be substituted by perforations). An alternative embodiment of this carton, carton  1900 ′, is shown in  FIGS. 43-44 , wherein blank  1901 ′ is nearly identical to blank  1900 , except that panels  1963 - 1966  have been omitted, and panels, corresponding to panels  1927 - 1930  in blank  1900 , have been lengthened. For a corrugated paperboard blank, the preferred direction of the flutes is indicated by the double arrow in  FIG. 43 . 
     Carton  1900  features T-shaped stacking tabs similar to the embodiment of carton  600 , with the notches for capturing locking tabs in the lid panels as in the embodiment of carton  1800 . In carton  1900 , inner side panel minor flaps  1927 - 1930  are adhered to inside surfaces of end panels  1903 ,  1904  and minor flaps  1935 - 1938  are adhered to outside minor flaps  1927 - 1930 , such that gusset panels  1975 - 1978  extend diagonally across the corners of the interior volume. Second overlap panels  1963 - 1966  are adhered to outside surfaces of end panels  1903 ,  1904 . As mentioned, top panels  1947 ,  1948  may be retained in place through the capture of locking tabs  1971 - 1974  which can be received in the notches in T-tab structures  1925 ,  1926 ,  1920  and  1921 . As mentioned, carton  1900 ′ is substantially identical in structure and mode of operation to carton  1900 . 
     Carton  1800 ′ of  FIGS. 45-46  is substantially identical to carton  1800  of  FIGS. 39-40 , except that blank  1801 ′ is provided with second overlap panels  1891 - 1894 , along fold lines  1895 - 1898 , and the shortening of panels  1847 ′- 1850 ′ as compared to panels  1847 - 1850  in blank  1801 . 
     Although processes for forming and packing the foregoing cartons are provided specifically for the embodiments of  FIGS. 1-2  and  FIGS. 21-22 , it is to be understood that one of ordinary skill in the art, having the present disclosure before them, would readily be able to modify existing carton forming equipment, using ordinary design and engineering skills, for the purposes of erecting, and subsequently sealing, the cartons, of each of the embodiments, without departing from the scope of the present invention, and without extensive experimentation. 
     The carton designs of the present invention permit the carton to be fully erected with all of the vertical inner and outer flaps and any attached flaps to be sealed and properly positioned for maximum stacking performance, but will allow a portion of the top flaps (horizontal) to be separated from the vertical outer end flaps so that access to the carton cavity can be accomplished for loading of product. Additional design features incorporated into the separated top flap feature allow the top flaps to be sealed or locked into position as desired after the product has been loaded. 
     As described herein, among the critical features that enable this invention to perform well is the strategic use of slits or perforations that separate the top horizontal panel (flap) from the end flaps of a tray or wrap design having full overlapping end flaps. These fully overlapping vertical end flaps may include additional (secondary) flaps which provide additional corner structures for added stack strength. Through the utilization of the slits or perforations (nicks), this permits the erecting machine to fully set up the carton&#39;s stacking features (inner and outer full overlapping flaps and inner and where applicable outer minor flaps), but allows the horizontal top flaps to remain free or only lightly attached (nicked) to the end flaps. 
     This allows user access to the carton cavity for loading of the products through either manual, man-machine interface, or automatic methods. In the situation in which a slit is used to separate the top and end structures, the carton can be effectively erected with the top flaps left in an upright position upon discharge from the erecting machine. In the situation in which nicks are used, keeping the top and end panels connected, the top flaps are in a horizontal or closed position upon discharge from the machine and opened, through the breaking of the nicks (either manually or mechanically) when desired. Final sealing or closure is accomplished with special features, such as slot and tab mechanisms, or through the use of additional material removed from the vertical end flaps and left attached to the horizontal top flaps (such as a flange), which is glued to the outer container walls to facilitate final closure when desired. These features, among others, permit this strategic use of the top flap panel, while protecting the important functions of the end flaps, can be applied to a number of container designs, as shown in the accompanying description and drawings. 
     The foregoing description and drawings merely explain and illustrate the invention, and the invention is not so limited as those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.

Technology Classification (CPC): 8