Patent Description:
The present disclosure generally relates to cartons for holding and dispensing food products.

<CIT> already discloses a carton for holding at least one food product, the carton comprising a plurality of panels extending at least partially around an interior of the carton, the plurality of panels comprising a bottom panel, a front panel and a back panel, and at least one side end flap foldably connected to one of the front panel and the back panel, the front panel, the back panel, and the at least one side end flap cooperate to form an open top of the carton for accessing the interior of the carton, wherein the at least one side end flap has a first male locking feature and the other of the front panel and the back panel has a second female locking feature, engagement of the first locking feature and the second locking feature secures the at least one side end flap to the other of the front panel and the back panel. <CIT> and <CIT> disclose similar cartons. The cartons according to the aforementioned prior art references, however, still leave room for improvement.

According to one aspect, the subject invention relates to a carton for holding at least one food product as per claim <NUM>.

According to another aspect, the subject invention also relates to a blank for forming a carton for holding at least one food product as per claim <NUM>.

According to another aspect, the subject invention further relates to a method of forming a carton for holding at least one food product as per claim <NUM>.

Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims.

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.

The present disclosure generally relates to cartons (e.g., carriers) with features for containing and facilitating dispensing articles such as food products, cooked food products, fried food products, hot and/or moist articles, etc. The articles can include, but are not limited to, fast food products, take-out products, meal leftovers, and the like, or any combination thereof. Examples of such products include, but are not limited to, fish, chicken (such as chicken nuggets, chicken strips, chicken fingers, etc.), popcorn, peanuts, candy, French fries (such as waffle fries, steak fries, shoestring fries, curly fries, etc.), French toast sticks, sandwich, pizza, calzone, turnover, burrito, or any other food product that may be packaged for consumption by a consumer. In this specification, the terms "inner," "interior," "outer," "exterior," "lower," "bottom," "upper," and "top" indicate orientations determined in relation to fully erected and upright cartons.

As described herein, cartons may be formed by multiple overlapping panels, end flaps, and/or other portions of blanks. Such panels, end flaps, and/or other portions of the blanks can 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> is a plan view of an exterior surface <NUM> of a blank, generally indicated at <NUM>, used to form a carton <NUM> (<FIG>) according to one exemplary embodiment of the disclosure. The carton <NUM> has an open top <NUM> that provides access to an interior <NUM> of the carton <NUM> such that carton <NUM> can be used to hold a food product, for example a fast food product (e.g., French fries) in an interior <NUM> of the carton <NUM>. In one embodiment, the carton <NUM> can be sized to fit in a hand of a customer and/or can have a generally tapered configuration. In one embodiment, the carton <NUM> can be used for holding, packaging, and/or serving cooked/fried food products from a fast food or quick service restaurant, but the carton <NUM> could hold other types of food products or other non-food products without departing from the disclosure.

In the illustrated embodiment, the blank <NUM> has a longitudinal axis L1 and a lateral axis L2. The blank <NUM> includes a bottom panel <NUM> foldably connected to a back panel <NUM> at a fold line <NUM> and a front panel <NUM> foldably connected to the bottom panel <NUM> at a fold line <NUM>. As shown in <FIG>, the fold lines <NUM>, <NUM> connecting the bottom panel <NUM> to the respective panels <NUM>, <NUM> are generally arcuate, curved, or crescent-shaped so that the bottom panel <NUM> is curved toward the interior <NUM> of the carton <NUM> (e.g., concave) when the carton <NUM> is formed, as described further herein.

As also shown, the back panel <NUM> has a free edge <NUM> that is curved and generally convex relative to a generally central axis or centerline C of the blank <NUM> that is collinear with a lateral fold line <NUM> that extends through the bottom panel <NUM> such that the curved free edge <NUM> of the back panel <NUM> extends from its respective endpoints away from the axis C. Further, the front panel <NUM> has a free edge <NUM> that is curved and generally concave relative to the generally central axis C such that the curved free edge <NUM> of the front panel <NUM> extends from its respective endpoints toward the axis C. The bottom panel <NUM> has free edges <NUM>, <NUM> that extend between the respective endpoints of the fold lines <NUM>, <NUM>.

Still referring to <FIG>, a first front side end flap <NUM> (broadly, "first side end flap" or "third side end flap") is foldably connected to the front panel <NUM> at a longitudinal fold line <NUM> (broadly, "first fold line"). A second front side end flap <NUM> (broadly "first side end flap" or "third side end flap") is foldably connected to the front panel <NUM> at a longitudinal fold line <NUM> (broadly, "first fold line"). The front side end flaps <NUM>, <NUM> define respective upper free edges <NUM>, <NUM>.

As shown, the front side end flap <NUM> includes a base portion <NUM> foldably connected to the front panel <NUM> at the fold line <NUM>, and a distal portion <NUM> foldably connected to the base portion <NUM> at an oblique fold line <NUM>. Similarly, the front side end flap <NUM> includes a base portion <NUM> foldably connected to the front panel <NUM> at the fold line <NUM>, and a distal portion <NUM> foldably connected to the base portion <NUM> at an oblique fold line <NUM>. In this regard, the side end flaps <NUM>, <NUM> are generally bisected at the respective fold lines <NUM>, <NUM>.

As also shown, a pair of male locking features or locking tabs <NUM> (broadly, "first locking feature" or "second locking feature" or "first male locking feature") is formed on a distal edge of the distal portion <NUM> of the end flap <NUM>. Further, a pair of spaced cuts <NUM> (broadly, "first locking feature" or "second locking feature" or "second female locking feature") is collinear with the fold line <NUM> to form a pair of female locking features between the distal portion <NUM> and the base portion <NUM> of the end flap <NUM>.

Similarly, a pair of the locking tabs <NUM> is formed on a distal edge of the distal portion <NUM> of the end flap <NUM>, and a pair of the cuts <NUM> are collinear with the fold line <NUM> to form a pair of female locking features between the distal portion <NUM> and the base portion <NUM> of the end flap <NUM>. In this regard, the front panel <NUM> is provided with female locking features due to the placement of the cuts <NUM>.

The blank <NUM> also has a first back side end flap <NUM> (broadly, "second side end flap" or "fourth side end flap") foldably connected to the back panel <NUM> at a longitudinal fold line <NUM> (broadly, "second fold line"). Similarly, a second back side end flap <NUM> (broadly, "second side end flap" or "fourth side end flap") is foldably connected to the back panel <NUM> at a longitudinal fold line <NUM> (broadly, "second fold line"). The back side end flaps <NUM>, <NUM> define respective upper free edges <NUM>, <NUM>.

The front side end flap <NUM>, as shown, includes a pair of male locking features or locking tabs <NUM> (broadly, "first locking feature" or "second locking feature" or "second male locking feature") defined along a free edge of the front side end flap <NUM>.

Similarly, a pair of the locking tabs <NUM> are defined along a free edge of the front side end flap <NUM>. Further, the back panel <NUM> has a pair of spaced cuts <NUM> (broadly, "first locking feature" or "second locking feature" or "first female locking feature") that is collinear with the fold line <NUM> to form a pair of female locking features adjacent the side end flap <NUM>, and a pair of the cuts <NUM> is collinear with the fold line <NUM> to form a pair of female locking features adjacent the side end flap <NUM>.

One or more of the locking tabs <NUM>, <NUM> can be configured with features for enhanced engagement with the respective cuts <NUM>, <NUM>, for example, hooks, barbs, notches, slits, etc. While the cuts <NUM>, <NUM> are shown as having curved and/or angled portions, one or more of the cuts <NUM>, <NUM> could have a different configuration without departing from the disclosure.

As also shown, the bottom panel <NUM> includes a first portion <NUM> foldably connected to the front panel <NUM> at the fold line <NUM>, and a second portion <NUM> that is foldably connected to the back panel <NUM> at the fold line <NUM>. The first portion <NUM> of the bottom panel <NUM> is foldably connected to the second portion <NUM> at the lateral fold line <NUM> such that the bottom panel <NUM> is generally bisected at the fold line <NUM>.

As described herein, the respective locking tabs <NUM> are configured for at least partial insertion through the respective cuts <NUM> such that the locking tabs <NUM> and cuts <NUM> can be considered as a set of first locking features of the carton <NUM>. Similarly, the respective locking tabs <NUM> are configured for at least partial insertion through the respective cuts <NUM> such that the locking tabs <NUM> and cuts <NUM> can be considered a set of second locking features of the carton <NUM>.

It will be understood that one or more of the bottom panel <NUM>, the front panel <NUM>, the back panel <NUM>, and the side end flaps <NUM>, <NUM>, <NUM>, <NUM> could be otherwise shaped, arranged, positioned, and/or configured without departing from the invention as defined in the claims.

Referring additionally to <FIG>, formation of the carton <NUM> from the blank <NUM> according to one exemplary embodiment of the disclosure is illustrated. It will be understood that the blank <NUM> can be folded about edges/surfaces of a folding body such as a mandrel, can be folded manually, and/or can be folded with specialized or generalized machinery.

As shown in <FIG>, the blank <NUM> can be positioned with the exterior surface <NUM> facing down and an interior surface <NUM> facing up, and the back panel <NUM> and the second portion <NUM> of the bottom panel <NUM> can together be folded at the fold line <NUM> in the direction of the arrows A1 into at least partial face-to-face contact with the respective first portion <NUM> of the bottom panel <NUM> and the front panel <NUM>. In such an arrangement, an upper portion of the back panel <NUM> defined by the curved edge <NUM> protrudes past an upper portion of the front panel <NUM> defined by the curved edge <NUM>.

As shown in <FIG>, the respective side end flaps <NUM>, <NUM> can be folded at the respective fold lines <NUM>, <NUM> in the direction of the respective arrows A2, A3. Such folding of the side end flaps <NUM>, <NUM> can have the effect of urging the respective base portions <NUM>, <NUM> of the respective side end flaps <NUM>, <NUM> to fold at the respective fold lines <NUM>, <NUM> in the direction of the respective arrows A2, A3.

Simultaneously or thereafter, the respective distal portions <NUM>, <NUM> of the respective side end flaps <NUM>, <NUM> can be folded upwardly at the respective fold lines <NUM>, <NUM> in the direction of the respective arrows A4, A5 into at least partial face-to-face contact with the respective side end flaps <NUM>, <NUM> such that the side end flap <NUM> is disposed between and in at least partial face-to-face contact with each of the base portion <NUM> and the distal portion <NUM> of the side end flap <NUM>, and the side end flap <NUM> is disposed between and in at least partial face-to-face contact with each of the base portion <NUM> and the distal portion <NUM> of the side end flap <NUM>.

This configuration also positions the respective locking tabs <NUM> to at least partially extend through the respective cuts <NUM>. In this regard, the cuts <NUM> at least partially receive the respective locking tabs <NUM> in a locking engagement that secures the end flaps <NUM>, <NUM> to the front panel <NUM>.

Referring additionally to <FIG>, the respective distal portions <NUM>, <NUM> and the respective base portions <NUM>, <NUM> of the respective side end flaps <NUM>, <NUM> can be maintained in substantially planar and parallel relation as the respective base portions <NUM>, <NUM> are folded upwardly at the respective fold lines <NUM>, <NUM> in the direction of the respective arrows A6, A7. In such an arrangement, the respective folded side end flaps <NUM>, <NUM> are positioned in substantially planar relation to the front panel <NUM> and back panel <NUM>, and are positioned such that the respective locking tabs <NUM> protruding from the respective distal portions <NUM>, <NUM> of the respective side end flaps <NUM>, <NUM> extend at least partially through the respective cuts <NUM> into the interior <NUM> of the carton <NUM>. In this regard, the cuts <NUM> at least partially receive the respective locking tabs <NUM> to provide a locking engagement that secures the end flaps <NUM>, <NUM> to the back panel <NUM>.

As shown in <FIG> and <FIG>, the aforementioned folded configuration of the carton <NUM> can be expanded to at least partially surround the interior <NUM> of the carton <NUM>, e.g., such that the respective portions <NUM>, <NUM> of the bottom panel <NUM> fold at the respective fold lines <NUM>, <NUM> and further at the fold line <NUM> into an arrangement that forms a curved or angled bottom <NUM> of the carton <NUM>.

Such expansion of the carton <NUM> also at least partially unfolds the arrangement of the side end flaps <NUM>, <NUM>, <NUM>, <NUM>, e.g., such that the side end flap <NUM> is in at least partial face-to-face contact with the distal portion <NUM> of the side end flap <NUM>, and the side end flap <NUM> and the distal portion <NUM> of the side end flap <NUM> are together obliquely disposed relative to the base portion <NUM> of the side end flap <NUM>. Similarly, the side end flap <NUM> is positioned in at least partial face-to-face contact with the distal portion <NUM> of the side end flap <NUM>, and the side end flap <NUM> and the distal portion <NUM> of the side end flap <NUM> are together obliquely disposed relative to the base portion <NUM> of the side end flap <NUM>.

Expansion of the carton <NUM> can also cause the front panel <NUM> and/or the back panel <NUM> to bow/flex/curve between the respective fold lines <NUM>, <NUM> and fold lines <NUM>, <NUM>. In this regard, the front panel <NUM>, the back panel <NUM>, and the side end flaps <NUM>, <NUM>, <NUM>, <NUM> cooperate to form the open top <NUM> of the carton <NUM> through which the interior <NUM> of the carton <NUM> can be accessed. In particular, the free edge <NUM> of the front panel <NUM>, the free edge <NUM> of the back panel <NUM>, the free edge <NUM> of the front side end flap <NUM>, the free edge <NUM> of the front side end flap <NUM>, the free edge <NUM> of the back side end flap <NUM> and the free edge <NUM> of the back side end flap <NUM> define the open top <NUM> of the carton <NUM>.

Such an arrangement provides a first side panel <NUM> (broadly, "first closed end of the carton" or "second closed end of the carton") and a second side panel <NUM> (broadly, "first closed end of the carton" or "second closed end of the carton") that each include an at least partial multi-ply, e.g., two-ply, configuration. The first side panel <NUM> includes the side end flap <NUM> in at least partial face-to-face contact with distal portion <NUM> of the side end flap <NUM>, and with the base portion <NUM> of the side end flap <NUM> extending obliquely therefrom. Similarly, the side panel <NUM> includes the side end flap <NUM> in at least partial face-to-face contact with the distal portion <NUM> of the side end flap <NUM>, and with the base portion <NUM> of the side end flap <NUM> extending obliquely therefrom.

Furthermore, the oblique arrangement of the respective portions of the side panels <NUM>, <NUM> present respective angled surfaces that extend between the respective front and back panels <NUM>, <NUM>, for example, to provide a comfortable/ergonomic gripping surface for a customer that is convenient, comfortable, and secure.

In addition, bottom free edges <NUM>, <NUM> of the respective side end flaps <NUM>, <NUM> protrude below the bottom panel <NUM> and the respective front and back panels <NUM>, <NUM> to define respective angled supports or angled legs <NUM>, <NUM> upon which the carton <NUM> can rest in an upright configuration. The legs <NUM>, <NUM> can provide a stable surface that inhibits or prevents tipping or tilting of the carton <NUM> in the upright configuration, e.g., so that a customer can retrieve food products from the interior <NUM> of the carton <NUM> without the need to manually position or maintain the carton <NUM> in an upright position.

In this regard, the disclosed carton <NUM> includes side panels <NUM>, <NUM> to provide a robust structure for holding one or more food products at least partially in the interior <NUM> thereof. In addition, the set of first locking features provided by the respective tabs <NUM> and respective cuts <NUM> and the set of second locking features provided by the respective tabs <NUM> and the respective cuts <NUM> provides a secure engagement among the panels <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> to maintain the carton <NUM> in an erected configuration through the arrangement of interlocking structures. Such an arrangement can obviate the need for additional materials to maintain the carton <NUM> in the erected configuration, for example, adhesives such as glue. In this regard, the carton <NUM> can be formed from a unitary piece of material that is devoid of adhesives such as glue, and without the need to incorporate additional securing materials such that material can be selected for the blank <NUM>/carton <NUM> with desired properties, e.g., recyclability and/or biodegradability. In one embodiment, such unitary material can be paperboard.

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

In accordance with the above-described embodiments of the present disclosure, 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 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.

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 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 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 spaced apart slits to be replaced with a continuous slit, a continuous score, 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. Also, a tear line can be a series of cut scores passing completely, or partially, through the material, that are separated by nicks.

The term "glue" is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

Claim 1:
A carton (<NUM>) for holding at least one food product, the carton comprising:
a plurality of panels (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) extending at least partially around an interior (<NUM>) of the carton, the plurality of panels comprising a bottom panel (<NUM>), a front panel (<NUM>), and a back panel (<NUM>); and
at least one side end flap (<NUM>, <NUM>, <NUM>, <NUM>) foldably connected to one of the front panel and the back panel, the front panel, the back panel, and the at least one side end flap cooperate to form an open top (<NUM>) of the carton for accessing the interior of the carton,
the at least one side end flap has a first locking feature (<NUM>, <NUM>, <NUM>, <NUM>) and the other of the front panel and the back panel has a second locking feature (<NUM>, <NUM>, <NUM>, <NUM>), engagement of the first locking feature and the second locking feature secures the at least one side end flap to the other of the front panel and the back panel,
the first locking feature is a male locking feature (<NUM>, <NUM>) and the second locking feature is a female locking feature (<NUM>, <NUM>),
the at least one side end flap is a first side end flap (<NUM>, <NUM>) foldably connected to the front panel (<NUM>), the male locking feature is a first male locking feature (<NUM>), and the female locking feature is a first female locking feature (<NUM>) in the back panel (<NUM>), characterized in that
the carton further comprises
a second side end flap (<NUM>, <NUM>) foldably connected to the back panel (<NUM>), the second side end flap comprises a second male locking feature (<NUM>) and the carton further comprises a second female locking feature (<NUM>) in the front panel, the first side end flap (<NUM>, <NUM>) and the second side end flap (<NUM>, <NUM>) are in at least partial face-to-face contact to form a side panel (<NUM>, <NUM>)of the carton.