Patent Description:
According to one aspect of the disclosure, a carton for holding at least one article comprises a base comprising a first plurality of panels and a lid comprising a second plurality of panels. The lid is foldably connected to the base such that the base and the lid at least partially surround an interior of the carton. A shoulder is attached to the base, the shoulder comprising at least one holder for holding at least one accessory for the at least one article.

According to another aspect of the disclosure, a blank for forming a carton for holding at least one article comprises a first plurality of panels for forming a base of the carton formed from the blank and a second plurality of panels for forming a lid of the carton formed from the blank. The first plurality of panels is foldably connected to the second plurality of panels such that the base and the lid at least partially surround an interior of the carton formed from the blank. The blank further comprises panels for forming a shoulder attached to the base of the carton formed from the blank. The panels for forming the shoulder comprise at least one holder for holding at least one accessory for the at least one article in the carton formed from the blank.

According to another aspect of the disclosure, a method of forming a carton for holding at least one article comprises obtaining a blank comprising a first plurality of panels, a second plurality of panels foldably connected to the first plurality of panels, and shoulder panels. The method further comprises at least partially folding the first plurality of panels to form a base of the carton, and at least partially folding the second plurality of panels to form a lid of the carton such that the base and the lid at least partially surround an interior of the carton. The method further comprises at least partially folding the shoulder panels to form a shoulder attached to the base, the shoulder comprising at least one holder for holding at least one accessory for the at least one article.

In the prior art, cartons, blanks for forming cartons and methods of forming cartons are known from <CIT>, <CIT> and <CIT>.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.

Cartons according to the present disclosure can accommodate containers of numerous different shapes. In this specification, the terms "lower," "bottom," "upper," "top," "front," and "back" indicate orientations determined in relation to fully erected cartons. As described herein, cartons may be formed by multiple overlapping panels, end flaps, and/or other portions. Such panels, end flaps, and/or other portions may be designated in relative terms to one another, e.g., "first", "second", "third", etc., in sequential or non-sequential reference, without departing from the disclosure.

<FIG> shows an exterior surface <NUM> of a blank <NUM> for forming a carton <NUM> (<FIG>) according to a first exemplary embodiment of the disclosure. As described herein, the carton <NUM> includes a tray or base <NUM> and a reclosable lid <NUM> foldably connected to the base <NUM> such that the base <NUM> and the lid <NUM> at least partially surround an interior <NUM> of the carton <NUM>. Such an arrangement can be commonly referred to as a "clamshell" carton. The illustrated carton <NUM> can be useful for holding one or more articles such as food products F (<FIG>) that may be provided in discrete portions, for example, chicken nuggets, chicken strips, French fries, chips, and/or other food items that can commonly be referred to as finger foods. Other types of articles that can include food products and/or nonfood products can be placed in the carton <NUM> for service to a customer without departing from the disclosure. Such products can be contained in additional packaging and then placed in the carton <NUM>. As described further herein, the carton <NUM> includes a shoulder <NUM> attached to the base <NUM> and defining at least one holder <NUM> (<FIG>) within which an accessory for one or more food products F can be held, for example, a container C for a condiment, for example, a sauce or dressing (e.g., ketchup, mustard, barbeque sauce, etc.) and/or another condiment. The carton <NUM> could be otherwise shaped and arranged and could be used to hold other products and/or articles in similar or different environments without departing from the disclosure.

As shown in <FIG>, the blank <NUM> has a longitudinal axis L1 extending generally in the direction of the length of the blank <NUM> and a lateral axis L2 extending generally in the direction of the width of the blank <NUM>. In one embodiment, the blank <NUM> comprises a front extension flap <NUM>, a front extension panel <NUM>, a front panel <NUM>, a bottom panel <NUM>, a first back panel <NUM>, a second back panel <NUM>, and a top panel <NUM>, and a lid panel <NUM>. As illustrated, the front extension flap <NUM> is foldably connected to the front extension panel <NUM> at a lateral fold line <NUM>, the front extension panel <NUM> is foldably connected to the front panel <NUM> at a lateral fold line <NUM>, the front panel <NUM> is foldably connected to the bottom panel <NUM> at a lateral fold line <NUM>, the bottom panel <NUM> is foldably connected to the first back panel <NUM> at a lateral fold line <NUM>, the first back panel <NUM> is foldably connected to the second back panel <NUM> at a lateral fold line <NUM>, the second back panel <NUM> is foldably connected to the top panel <NUM> at a lateral fold line <NUM>, and the top panel <NUM> is foldably connected to the lid panel <NUM> at a lateral fold line <NUM>. In one embodiment, the first back panel <NUM>, the bottom panel <NUM>, and the front panel <NUM> can be a first plurality of panels at least partially forming the base <NUM> of the carton <NUM>, the second back panel <NUM>, the top panel <NUM>, the lid panel <NUM> can be a second plurality of panels foldably connected to the first plurality of panels and for at least partially forming the lid <NUM> of the carton <NUM>, and a portion of the bottom panel <NUM>, the front panel <NUM>, the front extension panel <NUM>, and the front extension flap <NUM> can be shoulder panels that at least partially form the shoulder <NUM> of the carton <NUM>.

In the illustrated embodiment, a first end flap <NUM> and a second end flap <NUM> are foldably connected to the front panel <NUM> at respective oblique fold lines <NUM>, <NUM>, a first end flap <NUM> and a second end flap <NUM> are foldably connected to the bottom panel <NUM> at respective longitudinal fold lines <NUM>, <NUM>, a first end flap <NUM> and a second end flap <NUM> are foldably connected to the first back panel <NUM> at respective oblique fold lines <NUM>, <NUM>, a first end flap <NUM> and a second end flap <NUM> are foldably connected to the second back panel <NUM> at respective oblique fold lines <NUM>, <NUM>, a first end flap <NUM> and a second end flap <NUM> are foldably connected to the top panel <NUM> at respective longitudinal fold lines <NUM>, <NUM>, and a first end flap <NUM> and a second end flap <NUM> are foldably connected to the lid panel <NUM> at respective oblique fold lines <NUM>, <NUM>. As shown, the end flaps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> extend along a first marginal area of the blank <NUM> and the end flaps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> extend along a second marginal area of the blank <NUM>. As described herein, when the carton <NUM> (<FIG>) is erected, the end flaps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> at least partially close a first lateral side <NUM> (<FIG>) of the carton <NUM>, and the end flaps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> at least partially close a second lateral side <NUM> of the carton <NUM>. Different flap arrangements can be used for closing the sides of the carton <NUM> without departing from the disclosure.

Still referring to <FIG>, two pairs of retention flaps <NUM>, <NUM> are foldably connected to the front extension panel <NUM> at respective fold lines <NUM>, <NUM>. The retention flaps <NUM>, <NUM> are at least partially defined by respective cuts <NUM>, <NUM> and <NUM>, <NUM> in the front extension panel <NUM> that interrupt the respective lateral fold lines <NUM>, <NUM>, and are separated by a respective cut <NUM> that may have an at least partially curved, e.g., wave-shaped or sinusoidal, configuration. As described herein, the retention flaps <NUM>, <NUM> can be deflected away (e.g., downwardly) from the front extension panel <NUM> to form holders <NUM> (<FIG>) in the carton <NUM>, for example, to receive one or more accessories, such as the container C, for the one or more food products F.

As shown, the blank <NUM> comprises locking features which includes a tab <NUM> protruding from the front extension flap <NUM> into a portion of the front extension panel <NUM> adjacent a cut <NUM> extending between portions of the lateral fold line <NUM>. In one embodiment, the cut <NUM> is curved or semicircular, but the cut <NUM> and the tab <NUM> could be otherwise shaped, arranged, and/or configured without departing from the disclosure. As described further herein, the tab <NUM> can be deflected away from the front extension panel <NUM> upon formation of the carton <NUM> to provide an opening <NUM> (<FIG>) for receiving a lock <NUM> extending from a free edge of the lid panel <NUM> to maintain closure of the carton <NUM>. As shown, the lock <NUM> includes a head <NUM> defined by a pair of notches <NUM> adjacent the free edge of the lid panel <NUM>. The head <NUM> can have a trapezoidal profile, as shown, or in embodiments, may have a different configuration, for example, square or rectangular, triangular, pentagonal, heptagonal, or octagonal, or any other suitable shape. The locking features may also include extensions <NUM>, <NUM> protruding from the respective end flaps <NUM>, <NUM> and respective ledges <NUM>, <NUM> defined at lateral end portions of the front extension panel <NUM>. The extensions <NUM>, <NUM> can engage the respective ledges <NUM>, <NUM> upon closure of the carton <NUM>, as described further herein. The locking features can have a different configuration without departing from the disclosure.

As also shown in <FIG>, the blank <NUM> comprises interengaging features to effect formation of the carton <NUM> (<FIG>) that include openings <NUM> in the respective end flaps <NUM>, <NUM> that receive tabs <NUM> extending from respective lateral edge portions of the front extension flap <NUM>. A pair of cuts <NUM>, <NUM>, as shown, can extend from each opening <NUM> into the respective end flaps <NUM>, <NUM> to provide relief portions that are activable, for example, during formation, use, and/or other manipulation of the carton <NUM>.

In the illustrated embodiment of <FIG>, the first back panel <NUM> comprises cuts <NUM> and second back panel <NUM> comprises cuts <NUM>. As shown, the cuts <NUM>, <NUM> intersect to form an X-shaped configuration and define relief portions <NUM>, <NUM> in the back panels <NUM>, <NUM>. The relief portions <NUM>, <NUM> can, for example, minimize, inhibit, and/or prevent the back panels <NUM>, <NUM> from buckling when the carton <NUM> is opened, closed, or otherwise manipulated. The relief portions <NUM>, <NUM> could be otherwise shaped, arranged, configured, and/or omitted without departing from the scope of the disclosure.

Referring additionally to <FIG>, in one exemplary embodiment of forming the blank <NUM> into the carton <NUM>, the base <NUM> of the carton <NUM> can be formed by folding the front panel <NUM> upwardly relative to the bottom panel <NUM> at the fold line <NUM>, folding the first back panel <NUM> upwardly relative to the bottom panel <NUM> at the fold line <NUM>, and folding the end flaps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> upwardly at respective fold lines <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, as shown. The base <NUM> can be arranged such that the end flaps <NUM>, <NUM> are in at least partial face-to-face contact with the end flap <NUM> and the end flaps <NUM>, <NUM> are in at least partial face-to-face contact with the end flap <NUM>. As described herein, the flaps <NUM>, <NUM> and the flaps <NUM>, <NUM> can be positioned on an external surface or an internal surface of the respective end flaps <NUM>, <NUM>.

As shown, the lid <NUM> of the carton <NUM> can be formed by folding the second back panel <NUM> upwardly relative to the top panel <NUM> at the fold line <NUM>, folding the lid panel <NUM> upwardly relative to the top panel <NUM> at the fold line <NUM>, and folding the end flaps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> upwardly at respective fold lines <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, as shown. The lid <NUM> can be arranged such that the end flaps <NUM>, <NUM> are in at least partial face-to-face contact with the end flap <NUM> and the end flaps <NUM>, <NUM> are in at least partial face-to-face contact with the end flap <NUM>. As described herein, the flaps <NUM>, <NUM> and the flaps <NUM>, <NUM> can be positioned on an external surface or an internal surface of the respective end flaps <NUM>, <NUM>.

As shown in <FIG> and <FIG>, the shoulder <NUM> can be formed by folding the front extension panel <NUM> at the fold line <NUM> into substantially parallel planar relation with the bottom panel <NUM> and folding the front extension flap <NUM> at the fold line <NUM> downwardly toward the bottom panel <NUM> and into general parallel relation with the front panel <NUM>. The tabs <NUM> of the front extension flap <NUM> can then be inserted through the openings <NUM> in the respective end flaps <NUM>, <NUM> such that and an interior chamber <NUM> is formed in the shoulder <NUM> and such that the above-described configuration of the shoulder <NUM> is maintained. The above-described arrangement of overlapping portions of the blank <NUM> to form the carton <NUM> can be maintained through the use of an adhesive such as glue.

Still referring to <FIG> and <FIG>, the carton <NUM> is shown in an open configuration in which the lid <NUM> is foldably attached to but otherwise disengaged from the base <NUM> such that an interior <NUM> of the carton <NUM> is accessible. In such a configuration of the carton <NUM>, one or more food products F can be placed in the interior <NUM>, for example, for transport, storage, and/or serving.

Referring additionally to <FIG>, in order to close the carton <NUM>, the lid <NUM> can be folded at the fold line <NUM> toward the base <NUM>, which may include at least partial camming or deflection of the extensions <NUM>, <NUM> about the respective ledges <NUM>, <NUM>. Upon alignment of the lid <NUM> with the base <NUM>, the lock <NUM> enters the opening <NUM> such that the carton <NUM> is maintained in the above-described closed configuration. In particular, the notches <NUM> of the lock <NUM> can become disposed between the head <NUM> and the front extension panel <NUM> adjacent the opening <NUM> to maintain closure of the carton <NUM>. As also shown, the disposition of the extensions <NUM>, <NUM> disposed beneath the respective ledges <NUM>, <NUM> can assist in inhibiting or preventing opening of the carton <NUM> absent purposeful manipulation by a user.

Referring to <FIG>, <FIG>, and <FIG>, when received by a user, the carton <NUM> can be opened by a customer by disengaging the lock <NUM> from the opening <NUM> and raising the lid <NUM> away from the base <NUM>, which may include camming or deflecting the extensions <NUM>, <NUM> about the respective ledges <NUM>, <NUM>. In the open configuration, one or more food products F can be retrieved by a user from the interior <NUM> of the carton <NUM>. In the course of using the carton <NUM>, it may be desired to position one or more accessories for one or more of the food products F nearby. Accordingly, a user can fold one or more of the pairs of retention flaps <NUM>, <NUM> downwardly relative to the front extension panel <NUM> at respective fold lines <NUM>, <NUM> into the interior chamber <NUM> such that one or more holders <NUM> that are at least partially defined by the shoulder <NUM> and that extend into the interior chamber <NUM> are accessible. As described herein, the holders <NUM> can include the retention flaps <NUM>, <NUM>, and can additionally include portions of the interior chamber <NUM>. As shown, the carton <NUM> includes a first holder <NUM> and a second holder <NUM>, though a different number of holders can be provided without departing from the disclosure. The holders <NUM> provide convenient locations for one or more accessories for the one or more food products F, for example, a container C. As shown, the containers C can be partially recessed within the respective holders <NUM> such that the containers C or other accessories are at least partially disposed in the interior chamber <NUM> of the shoulder <NUM>, and edge portions of the containers C, such as flanges or rims R, can rest upon the front extension panel <NUM> such that the containers C are suspended above the bottom panel <NUM> of the carton <NUM> for convenient access by a customer. In addition, the retention flaps <NUM>, <NUM> can be disposed adjacent and in generally parallel relation to the sides of the containers C, for example, to provide support and stability for the containers C. In this regard, a user can dip or scoop one or more of the food products F into one or more of the containers C prior to consuming or serving one or more of the food products F. Alternatively, one or both of the holders <NUM> can be configured as openings formed in the front extension panel <NUM>, such that one or both of the retention flaps <NUM>, <NUM> could be omitted without departing from the disclosure.

It will be understood that the carton <NUM> can be formed, closed, and/or opened by other alternative methods and steps without departing from the disclosure.

Referring to <FIG>, a blank <NUM> for forming a carton according to a third exemplary embodiment of the disclosure which is not part of the invention is illustrated. The blank <NUM> and the carton formed therefrom may have substantially similar features as the blank <NUM> and carton <NUM> (<FIG>, <FIG>) of the first exemplary embodiment of the disclosure, but the lid panel <NUM> may be devoid of a lock, such as the lock <NUM> of the first exemplary embodiment, and the front extension flap <NUM> may be devoid of a tab (such as the tab <NUM> of the first exemplary embodiment) for forming an opening for receiving a lock. In this regard, a carton formed from the blank <NUM> can maintain closure of the lid <NUM> relative to the base <NUM> via engagement of the respective ledges <NUM>, <NUM> with the respective extensions <NUM>, <NUM>, as described above.

Referring to <FIG>, a carton <NUM> according to a third exemplary embodiment of the disclosure which is not part of the invention is illustrated. The carton <NUM> may have substantially similar features as the blank <NUM> and the carton <NUM> (<FIG> and <FIG>) of the first exemplary embodiment described herein, but may have a single central holder <NUM> with retention flaps <NUM>, <NUM> formed in the shoulder <NUM>. It will be understood that a different number and/or arrangement of retention flaps and holders can be provided without departing from the disclosure.

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

As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.

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, and is not intended to exclude heat, chemical, or frequency bonding techniques.

Claim 1:
A carton (<NUM>) for holding at least one article (F), the carton (<NUM>) comprising:
a base (<NUM>) comprising a first plurality of panels, the first plurality of panels comprises a first back panel (<NUM>), a bottom panel (<NUM>), and a front panel (<NUM>);
a lid (<NUM>) comprising a second plurality of panels, the second plurality of panels comprises a second back panel (<NUM>), a top panel (<NUM>), and a lid panel (<NUM>), the lid (<NUM>) foldably connected to the base (<NUM>) such that the base (<NUM>) and the lid (<NUM>) at least partially surround an interior (<NUM>) of the carton (<NUM>);
a shoulder (<NUM>) attached to the base (<NUM>) and comprising a portion of the bottom panel (<NUM>), the front panel (<NUM>), and a front extension panel (<NUM>), the shoulder (<NUM>) comprising at least one holder (<NUM>) for holding at least one accessory (C) for the at least one article (F);
a plurality of end flaps foldably connected to a respective panel of the first plurality of panels and the second plurality of panels, wherein at least one end flap (<NUM>, <NUM>) of the plurality of end flaps is foldably connected to the top panel (<NUM>) and comprises at least one extension (<NUM>, <NUM>) for engagement with at least one ledge (<NUM>, <NUM>) of the front extension panel (<NUM>); and
locking features comprising a lock (<NUM>) extending from the lid panel (<NUM>) and an opening (<NUM>) for at least partially receiving the lock (<NUM>), the at least one extension (<NUM>, <NUM>), and the at least one ledge (<NUM>, <NUM>), the front extension panel (<NUM>) comprising the opening (<NUM>).