Stackable carton and blank and method of forming same

Abstract

A carton (100) includes a bottom wall (104), a plurality of side walls (140, 142, 144, 146) connected to the bottom wall, and a top wall (106) releasably coupled to one of the side walls. The carton further includes a handle (112) formed by at least a portion of the top wall. The carton further includes a planar surface (114) formed at least in part by the handle (114) and the top wall (106).

Description

Technical Field

[0001] This disclosure generally relates to product packaging, and more particularly, to cardboard boxes for packaging products, blanks for forming cardboard boxes, and methods for forming cardboard boxes from blanks. More particularly, but not exclusively, this disclosure relates to cardboard boxes including an integral handle and configured for stacking. Background Technology

[0002] In the packaging industry, and more specifically in the fresh food packaging industry, products are typically packaged in outer containers. For example, products such as fresh fruits and vegetables can be packaged in cardboard boxes (C). Figure 1 ) or bag B ( Figure 2 This type of container is desirable for transportation and distribution, product protection, and displaying product labeling or promotional information.

[0003] It is also expected that end consumers will use the container as a product carrier when the product is sold. For example, many product containers include handles (H). Figure 1 and 2 The handle provides consumers with the ability to carry the product. Typically, the handle H is located at the top of the container and extends outward from the top of the container.

[0004] It is also expected that product containers can be stacked for transport (e.g., on pallets), storage (e.g., in warehouses), or display (e.g., on storage shelves). However, typical containers may be difficult or impossible to stack due to the lack of structural integrity of containers (e.g., bag B) or due to the configuration of the handles H of containers (e.g., cardboard box C).

[0005] For reasons of transportation, product protection, and consumer carrying, it is also desirable to ensure that the container has appropriate strength to hold and transport the product. For cost and environmental considerations, it is also desirable that the container be made with as little material as possible, resulting in minimal material waste. For cost and process considerations, it is also desirable that the container be formed through the simplest possible set of operations to facilitate automation of the container forming and loading process.

[0006] Therefore, those skilled in the art continue to conduct research and development in the field of product packaging. Summary of the Invention

[0007] Disclosed are cardboard boxes for packaging products, blanks for forming the disclosed cardboard boxes, methods for forming the disclosed cardboard boxes from the disclosed blanks, and methods for packaging products using the disclosed cardboard boxes. The following is a non-exhaustive list of examples of the subject matter of this disclosure, which may or may not be claimed.

[0008] In one example, the disclosed cardboard box includes a bottom wall, a plurality of side walls connected to the bottom wall, and a top wall releasably coupled to one of the side walls. The cardboard box also includes a handle formed by at least a portion of the top wall. The cardboard box also includes a planar surface formed by at least a portion of the handle and the top wall.

[0009] In one example, the disclosed cardboard box includes a plurality of panels forming the internal volume, handles, and flat surfaces of the cardboard box. The plurality of panels includes a first side panel, a second side panel foldably connected to the first side panel, a third side panel foldably connected to the second side panel, and a fourth side panel foldably connected to the third side panel. The plurality of panels also includes a first handle panel foldably connected to the first side panel and releasably connected to the second and fourth side panels. The plurality of panels also includes a second handle panel foldably connected to the third side panel and releasably connected to the second and fourth side panels. At least a portion of the first handle panel overlaps with the second handle panel, such that the first handle panel and the second handle panel form at least a portion of the handle and the flat surface.

[0010] In one example, the disclosed blank includes a first side panel, a second side panel foldably connected to the first side panel, a third side panel foldably connected to the second side panel, and a fourth side panel foldably connected to the third side panel. The blank also includes a first handle plate foldably connected to the first side panel and a second handle plate foldably connected to the third side panel. The blank further includes a first portion of a locking mechanism on each of the first and second handle plates, and a second portion of a locking mechanism on each of the second and fourth side panels. When a carton is formed from the blank, the first and second portions of the locking mechanism cooperate to attach the first and second handle plates to the second and fourth side panels. When the carton is formed from the blank, the first and second handle plates form the handles and planar surfaces of the carton.

[0011] In one example, the disclosed method includes the steps of: (1) providing a blank comprising a plurality of plates; and (2) manipulating the blank such that the plurality of plates form a bottom wall, a top wall, a plurality of side walls, and a handle of a cardboard box. The top wall is releasably coupled to an opposing pair of the plurality of side walls. The handle is formed by at least a portion of the top wall. The handle and the top wall form a planar surface of the cardboard box.

[0012] In one example, the disclosed method includes the following steps: (1) erecting the cardboard box such that the side walls are detached from the top wall; (2) loading the product into the internal volume of the cardboard box; and (3) further erecting the cardboard box such that the side walls are connected to the top wall.

[0013] Other examples of the disclosed cardboard boxes, blanks, and methods will become apparent from the following detailed description, accompanying drawings, and appended claims. Attached Figure Description

[0014] Figure 1 This is a schematic perspective view of an example of a conventional product packaging container in the form of a cardboard box;

[0015] Figure 2 This is a schematic perspective view of another example of a conventional product packaging container in the form of a bag;

[0016] Figure 3 This is a schematic perspective side view of an example of a cardboard box used for packaging products;

[0017] Figure 4 yes Figure 3 A schematic perspective end view of an example cardboard box shown;

[0018] Figure 5 This is a schematic perspective side view of an example of multiple cardboard boxes arranged in a stacked manner;

[0019] Figure 6 This is a schematic perspective top view of an example cardboard box;

[0020] Figure 7 yes Figure 6 A schematic perspective view of an example cardboard box shown;

[0021] Figure 8 yes Figure 6 A schematic perspective view of an example cardboard box shown, wherein the cardboard box is depicted as having end panels separated from a pair of top panels;

[0022] Figure 9 This is a schematic perspective top view of another example of a cardboard box;

[0023] Figure 10 yes Figure 9 A schematic perspective view of an example cardboard box shown;

[0024] Figure 11 yes Figure 9 A schematic perspective view of an example cardboard box shown, wherein the cardboard box is depicted as having end panels separated from a pair of top panels;

[0025] Figure 12 This is a schematic side view of a portion of an example of a cardboard box, depicting an example of the locking mechanism of the cardboard box;

[0026] Figure 13 This is a schematic side view of a portion of an example of a cardboard box, depicting another example of the locking mechanism of the cardboard box;

[0027] Figure 14 This is a schematic side view of a portion of an example of a cardboard box, depicting another example of the locking mechanism of the cardboard box;

[0028] Figure 15 This is a schematic plan view of an example blank used to form a cardboard box;

[0029] Figure 16 This is a schematic plan view of another example of a blank used to form a cardboard box;

[0030] Figure 17 This is a schematic plan view of another example of a blank used to form a cardboard box; and

[0031] Figure 18 This is a schematic plan view of another example of a blank used to form a cardboard box. Detailed Implementation

[0032] The following detailed description refers to the accompanying drawings, which illustrate specific examples of the disclosed cardboard boxes and blanks described herein. It will be understood that the disclosed examples are merely exemplary embodiments of how certain aspects of the invention can be implemented and do not represent an exhaustive list of all ways in which the invention can be implemented. Other examples with different structures and operations do not depart from the scope of this disclosure. In different drawings, the same reference numerals may refer to the same features, elements, or parts. The drawings are not necessarily drawn to scale, and some features may be exaggerated or minimized to show detail of particular parts. Throughout this disclosure, any one of a plurality of items may be referred to individually as an item, and a plurality of items may be collectively referred to as an item. Furthermore, as used herein, features, elements, parts, or steps beginning with the word “a” or “an” should be understood to not exclude multiple features, elements, parts, or steps unless such exclusion is expressly stated.

[0033] The following are illustrative, non-exhaustive examples of the subject matter of this disclosure, which may, but are not necessarily, claimed. Reference to “example” herein means that one or more features, structures, elements, components, characteristics, and / or operating steps described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter of this disclosure. Therefore, the phrases “example,” “another example,” “one or more examples,” and similar language throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, the subject matter characterizing any example may, but does not necessarily include the subject matter characterizing any other example. Moreover, the subject matter characterizing any example may, but does not necessarily, combine with the subject matter characterizing any other example.

[0034] refer to Figure 3-14As an example, this disclosure relates to a cardboard box 100 for packaging products. The cardboard box 100 facilitates the packaging, transportation, and display of products. In other words, the cardboard box 100 provides or serves as an outer packaging container for products. The cardboard box 100 also provides or serves as a carrier for products, for example, after a consumer purchases them. The cardboard box 100 also provides or serves as a support structure for stacking one cardboard box 100 on top of another cardboard box 100.

[0035] Cardboard box 100 can be made of any suitable packaging material. Examples of suitable packaging materials include cardboard, corrugated cardboard, hardboard, plastic, combinations thereof, and any other suitable materials known to those skilled in the art and guided by the teachings provided herein.

[0036] The product can be any of a variety of primary products packaged in cardboard box 100. In one or more examples, the product is fresh food, such as fresh fruit or fresh vegetables. Cardboard box 100 can be configured to a suitable size and shape to accommodate any reasonable quantity of product. Therefore, throughout this disclosure, the term "product" refers to one or more products.

[0037] refer to Figure 3 and Figure 4 In one or more examples, cardboard box 100 includes a bottom wall 104, multiple side walls 104, and a top wall 106. The bottom wall 104, top wall 106, and side walls 108 form the internal volume 110 of cardboard box 100. The bottom wall 104, top wall 106, and multiple side walls 108 encapsulate the product for transport and display.

[0038] exist Figure 1-3 In the example shown, the cardboard box 100 includes four side walls 108. For example, the cardboard box 100 includes a first side wall 116 (e.g., a front wall), a second side wall 118 (e.g., a right end wall) connected to the first side wall 116, a third side wall 120 (e.g., a rear wall) connected to the second side wall 118 opposite to the first side wall 116, and a fourth side wall 122 (e.g., a left end wall) connected to the third side wall 120 and the first side wall 116 opposite to the second side wall. In other examples, the cardboard box 100 may include fewer than four or more side walls.

[0039] In one or more examples, a plurality of sidewalls 108 connect to the bottom wall 104. In one or more examples, each of the first sidewall 116, the second sidewall 118, the third sidewall 120, and the fourth sidewall 122 connects to the bottom wall 104. The top wall 106 is opposite to the bottom wall 104. In one or more examples, the top wall 106 is approximately parallel to the bottom wall 104.

[0040] The top wall 106 is releasably coupled to one of the side walls 108 (e.g., detachable from it). In one or more examples, the top wall 106 is releasably coupled to more than one of the side walls 108. In one or more examples, the top wall 106 is releasably coupled to a first pair of opposing side walls 108 (e.g., a second side wall 118 and a fourth side wall 122). In one or more examples, the top wall 106 is connected (e.g., inseparably connected) to a second pair of opposing side walls 108 (e.g., a first side wall 116 and a third side wall 120). When the top wall 106 is coupled to the first pair of opposing side walls 108, the top wall 106 is configured to hold the carton 100 in a constructed (e.g., upright) configuration and to keep the carton 100 closed around the product.

[0041] The cardboard box 100 also includes a handle 112. The handle 112 facilitates carrying the cardboard box 100. The handle 112 is integral with the top wall 106. For example, the handle 112 is formed by at least a portion of the top wall 106. Alternatively, at least a portion of the top wall 106 is formed by the handle 112.

[0042] The cardboard box 100 also includes a planar surface 114. The planar surface 114 is at least partially formed by a handle 112 and a top wall 106. For example, the handle 112 and the top wall 106 are approximately parallel to the bottom wall 104. For example, when the handle 112 forms part of the top wall 106, the handle 112 is parallel to the bottom wall 104. As another example, when the handle 112 is formed from a portion of the top wall 106, the handle 112 and the top wall 106 are coplanar and parallel to the bottom wall 104.

[0043] In one or more examples, a portion of the end 132 of at least one of the first pair of opposing sidewalls 108 (e.g., the second sidewall 118 and / or the fourth sidewall 122) extends beyond the top wall 106 and forms a portion of the planar surface 114 of the cardboard box 100. In one or more examples, a portion of the end 132 of each of the first pair of opposing sidewalls 108 (e.g., the second sidewall 118 and the fourth sidewall 122) extends beyond the top wall 106 and forms a portion of the planar surface 114 of the cardboard box 100.

[0044] Reference Figure 5 The cardboard box 100 is self-supporting and easy to stack, such as during transport, storage, or display. The top wall 106 and handle 112 are supported by a plurality of side walls 108 in a near-horizontal and planar orientation. Thus, the planar surface 114 formed by the handle 112 and the top wall 106 allows the cardboard box 100 to be stacked vertically on top of another cardboard box 100. For example, in Figure 5The diagram shows multiple cardboard boxes 100, each cardboard box 100 stacked on top of another cardboard box 100 such that the bottom wall 104 of the upper cardboard box 100 is substantially flush with (e.g., substantially coplanar) the handle 112 and top wall 106 of the lower cardboard box 100. When multiple cardboard boxes 100 are stacked, the interconnection of the top wall 106 and the first pair of opposing side walls 108 provides structural integrity to the cardboard boxes 100.

[0045] Refer again Figure 3 and Figure 4 In one or more examples, the cardboard box 100 includes a locking mechanism 124. The locking mechanism 124 connects one of the top wall 106 and the side wall 108 together. For example, the locking mechanism 124 connects the top wall 106 to each of a first pair of opposing side walls 108 (e.g., a second side wall 118 and a fourth side wall 122). For example, the cardboard box 100 includes a pair of opposing locking mechanisms 124. Each of these locking mechanisms 124 connects one end of the top wall 106 to one of a pair of opposing side walls 108.

[0046] Locking mechanism 124 may include any suitable mechanical locking mechanism known to those skilled in the art and guided by the teachings provided herein. In one or more examples, locking mechanism 124 includes a convex portion forming a first part of the complementary locking mechanism and a concave portion forming a second part of the complementary locking mechanism.

[0047] In one or more examples, the locking mechanism 124 includes a locking tab 126 (e.g., a convex portion) and a corresponding locking groove 128 (e.g., a concave portion). The locking tab 126 is received by and secured within the locking groove 128. In one or more examples, such as Figure 3 and 4 As shown, the locking tab 126 and locking groove 128 associated with the top wall 106 are associated with one of the side walls 108 (e.g., the second side wall 118 or the fourth side wall 122). Alternatively, in one or more examples, the locking groove 128 is associated with the top wall 106, and the locking tab 126 is associated with one of the side walls 108 (e.g., the second side wall 118 or the fourth side wall 122).

[0048] In the illustrated example, the cardboard box 100 includes a pair of opposing locking mechanisms 124. As an example, the top wall 106 includes a pair of opposing locking tabs 126, and each of the first pair of opposing side walls 108 (e.g., the second side wall 118 or the fourth side wall 122) includes a locking groove 128. As another example, the top wall 106 includes a pair of opposing locking grooves 128, and each of the first pair of opposing side walls 108 (e.g., the second side wall 118 or the fourth side wall 122) includes a locking tab 126. As yet another example, the top wall 106 includes locking tabs 126 and opposing locking grooves 128, one of the first pair of opposing side walls 108 (e.g., the second side wall 118) includes a locking groove 128 corresponding to the locking tab 126 of the top wall 106, and the other of the first pair of opposing side walls 108 (e.g., the fourth side wall 122) includes a locking tab 126 corresponding to the locking groove 128 of the top wall 106.

[0049] The top wall 106, and therefore the handle 112, can have a double-walled or double-layered construction. In one or more examples, the top wall 106 includes or is formed by a first handle plate 136 and a second handle plate 138 that overlap each other. The first handle plate 136 and the second handle plate 138 are releasably coupled to at least one of the side walls 108, such as a first pair of opposing side walls 108, by a locking mechanism 124. The top wall 106 having a double-layered construction formed by the first and second handle plates 136 and 138 provides additional reinforcement and structural integrity to the cardboard box 100.

[0050] In one or more examples, the cardboard box 100 includes at least one opening 208 formed through at least one of the sidewalls 108. For example, the opening 208 may be formed through one or more of the first sidewall 116, the second sidewall 118, the third sidewall 120, and the fourth sidewall 122. The opening 208 may have any suitable shape and size. The opening 208 provides visual access to the internal volume 110 of the cardboard box 100, and thus provides visual access to the product contained within the cardboard box 100. The opening 208 also facilitates the circulation of air through the internal volume 110 of the cardboard box 100, which can help keep the product fresh.

[0051] Now for reference Figure 6-11 The illustration schematically shows an example of a cardboard box 100. In one or more examples, the cardboard box 100 includes a plurality of panels 134 that form the internal volume 110, handles 112, and flat surfaces 114 of the cardboard box 100. Typically, the plurality of panels 134 form the walls of the cardboard box 100. Figure 3-5 ).

[0052] In one or more examples, the plurality of plates 134 include a first side plate 140. When constructed, the first side plate 140 may form a first sidewall 116. Figure 3-5 The plurality of plates 134 include a second side plate 142 that is foldably (e.g., hingedly or movably) connected to the first side plate 140. When constructed, the second side plate 140 may form a second sidewall 118. Figure 3-5 The plurality of plates 134 includes a third side plate 144 foldably connected to the second side plate 142. When constructed, the third side plate 144 can form a third sidewall 120. Figure 3-5 The plurality of plates 134 includes a fourth side plate 146 foldably connected to the third side plate 144. When constructed, the fourth side plate 146 can form a fourth sidewall 122. Figure 3-5 The plurality of panels 134 include a first handle panel 136, which is foldably connected to a first side panel 140 and releasably connected to a second side panel 142 and a fourth side panel 146. The plurality of panels 134 also include a second handle panel 138, which is foldably connected to a third side panel 144 and releasably connected to a second side panel 142 and a fourth side panel 146. When constructed, the first handle panel 136 and the second handle panel 138 form the top wall 106 of the cardboard box 100. Figure 3-5 ) and handle 112, and thus form at least a portion of the planar surface 114 of the cardboard box 100.

[0053] In one or more examples, the first handle plate 136 overlaps with at least a portion of the second handle plate 138. In one or more examples, the first handle plate 136 overlaps with the entire second handle plate 138. In one or more examples, the first handle plate 136 and the second handle plate 138 have substantially the same shape, such that a handle 112 is formed when portions of the first and second handle plates 136 and 138 overlap.

[0054] In one or more examples, locking mechanism 124 connects first handle plate 136 and second handle plate 138 to second side plate 142 and fourth side plate 146. In one or more embodiments, first handle plate 136 and second handle plate 138 extend between second side plate 142 and fourth side plate 146 and interlock with second side plate 142 and fourth side plate 146, such that first handle plate 136 and second handle plate 138 provide or function as retaining straps that hold carton 100 in a constructed and closed configuration.

[0055] like Figure 6-8As shown in Figure 12, in one or more examples, the locking mechanism 124 includes a handle locking tab 148 and a wall locking groove 150. The handle locking tab 148 protrudes from each end 130 of each of the first handle plate 136 and the second handle plate 138. The wall locking groove 150 is formed through each of the second side plate 142 and the fourth side plate 146. When the carton 100 is constructed, the handle locking tab 148 is received by the wall locking groove 150 and engages with a corresponding one of the second side plate 142 and the fourth side plate 146. The mating engagement of the handle locking tab 148 and the wall locking groove 150 locks the first handle plate 136 and the second handle plate 138 to the second side plate 142 and the fourth side plate 146.

[0056] like Figure 12 As shown, in one or more examples, a portion of the end 132 of the second side panel 142 and the fourth side panel 146 extends beyond the handle 112 and can be folded to form a portion of the planar surface 114.

[0057] like Figure 9-11 As shown in 13 and 14, in one or more examples, the locking mechanism 124 includes a wall-locking tab 152 and a handle-locking slot 154. The wall-locking tab 152 protrudes from end 132 of each of the second side panel 142 and the fourth side panel 146. The handle-locking slot 154 is formed through each end 130 of each of the first handle plate 136 and the second handle plate 138. When the carton 100 is constructed, the wall-locking tab 152 is received by the handle-locking slot 154 and engages the handle 112. The mating engagement of the wall-locking tab 152 and the handle-locking slot 154 locks the first handle plate 136 and the second handle plate 138 to the second side panel 142 and the fourth side panel 146.

[0058] like Figure 13 and 14 As shown, in one or more examples, a portion of the end 132 of each of the second side plate 142 and the fourth side plate 146 forms a portion of the planar surface 114.

[0059] Refer again Figure 6-11 In one or more examples, the cardboard box 100 includes at least one opening 208 formed through at least one of a plurality of boards 134. In one or more examples, such as Figure 9-11As shown in 13 and 14, each of the second side panel 142 and the fourth side panel 146 includes an opening 210 positioned near the end 132 of the respective second side panel 142 and the fourth side panel 146. When the first and second handle plates 136 and 138 are engaged to the second and fourth side panels 142 and 146 by the locking mechanism 124, the opening 210 allows the ends 130 of the first handle plate 136 and the second handle plate 138 to extend through the respective second side panel 142 and the fourth side panel 146.

[0060] Now for reference Figure 15-18 This disclosure also relates to blanks of sheet material, generally referred to herein as "blanks" 102. Blanks 102 are used to form (e.g., manufacture, erect, or otherwise construct) cardboard boxes 100. As an example, Figure 3-8 The cardboard box 100 shown in Figure 12 can be made of Figure 15 and 18 The blank 102 shown is formed. As another example, Figure 9-11 The cardboard box 100 shown in Figure 13 can be made of Figure 16 The blank 102 shown is formed. As another example, Figure 14 The cardboard box 100 shown can be made of Figure 17 The blank 102 shown is formed.

[0061] The blank 102 can be made from a suitable raw material sheet. The blank 102 can be cut (e.g., punched) from the raw material sheet. Suitable raw materials include all forms of foldable sheet materials. In one or more examples, the raw material is a cellulose material, such as cardboard (e.g., solid bleached sulfate cardboard), hardboard, or other heavy-duty paper-based materials. In one or more examples, the raw material is a polymer material, such as plastic sheets (e.g., plastic hardboard) or sheet plastic. In one or more examples, the raw material is made from corrugated cardboard (e.g., cellulose or polymer), such as a grooved corrugated cardboard material comprising two inner liner sheets and sandwiched between and attached to the inner liner sheets.

[0062] The blank 102 comprises a series of plates connected one after another by corresponding fold lines. Any fold line and / or hinge line described herein may include any suitable predetermined or pre-formed weakening line and / or dividing line known to those skilled in the art and guided by the teachings provided herein, such as creases, notches, perforations, etc. Typically, fold lines transform the blank 102 into multiple independent but integral plates, folded plates, tabs, etc.

[0063] For clarity, it should be recognized that the first surface of the blank 102 is exposed (e.g., protruding toward the observer), and Figure 15-18 As shown in the figure. For example, the first surface of the blank 102 can become the inner surface 156 of the cardboard box 100. Figure 3 and 4 The blank 102 also includes a corresponding second surface (e.g., a lower surface), which is not visible until the cardboard box 100 is formed from the blank 102. For example, the second surface of the blank 102 may become the outer surface 158 of the cardboard box 100. Figure 3 and 4 ).

[0064] In one or more examples, the second surface of the outer surface 158 of the blank 102 forming the cardboard box 100 is coated (e.g., including an outer surface coating). The outer surface coating may be a waterproof coating, a protective coating, an aesthetic coating, etc. In one or more examples, at least a portion of the second surface of the outer surface 158 of the blank 102 forming the cardboard box 100 is printed with various product information about the product. For example, the outer surface 158 of the cardboard box 100 may include trademarks or other product markings that are easily visible to consumers when the cardboard box 100 is displayed.

[0065] In one or more examples, a first surface of the inner surface 156 of the forming cardboard box 100 of the blank 102 is coated (e.g., including an inner surface coating). The inner surface coating may be a waterproof coating, a protective coating, an aesthetic coating, etc. For example, the inner surface 156 of the cardboard box 100 may be pleated to resist weakening or damage to the cardboard box 100 by liquids or moisture from the product.

[0066] In one or more examples, blank 102 includes a first side panel 140, a second side panel 142, a third side panel 144, a fourth side panel 146, a first handle panel 136, and a second handle panel 138. In one or more examples, when cardboard box 100 is formed from blank 102, the first side panel 140 forms a first side wall 116 of cardboard box 100. In one or more examples, when cardboard box 100 is formed from blank 102, the second side panel 142 forms a second side wall 118 of cardboard box 100. In one or more examples, when cardboard box 100 is formed from blank 102, the third side panel 144 forms a third side wall 120 of cardboard box 100. In one or more examples, when cardboard box 100 is formed from blank 102, the fourth side panel 146 forms a fourth side wall 122 of cardboard box 100. In one or more examples, when the cardboard box 100 is formed from the blank 102, the first handle plate 136 and the second handle plate 138 together form the top wall 106 and the handle 112 of the cardboard box 100.

[0067] Each of the side panels 140, 142, 144, and 146 can have any suitable two-dimensional shape and / or any desired size. In the illustrated example, each of the side panels 140, 142, 144, and 146 has an approximately rectangular shape. Thus, when the cardboard box 100 is formed from the blank 102, the side walls 116, 118, 120, and 122 of the cardboard box 100 can have any suitable or desired shape, such as an approximately rectangular shape.

[0068] In one or more examples, a first side plate 140, a second side plate 142, a third side plate 144, and a fourth side plate 146 are linearly connected in series along the longitudinal axis of the blank 102. The second side plate 142 extends from the first side plate 140 and is foldably connected to the first side plate 140 along a fold line 160 (e.g., the first side plate fold line). The fold line 160 extends laterally and separates the second side plate 142 from the first side plate 140. The third side plate 144 extends from the second side plate 142 and is foldably connected to the second side plate 142 opposite to the first side plate 140 along a fold line 162 (e.g., the second side plate fold line). The fold line 162 extends laterally approximately parallel to the fold line 160 and separates the third side plate 144 from the second side plate 142. The fourth side plate 146 extends from the third side plate 144 and is foldably connected to the third side plate 144 opposite to the second side plate 142 along a fold line 164 (e.g., the third side plate fold line). The fold line 164 extends laterally approximately parallel to the fold line 162, separating the fourth side plate 146 from the third side plate 144.

[0069] The second side plate 142 is hingedly movable (e.g., foldable) relative to the first side plate 140 about the fold line 160, such that it can be oriented from the orientation shown in the flat configuration (e.g., as shown in the figure). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11 (As shown). The third side plate 144 is hinged relative to the second side plate 142 about the fold line 162, such that it can be oriented from the orientation shown in the flat configuration (e.g., as shown). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11 (As shown). The fourth side plate 146 is hinged relative to the third side plate 144 about the fold line 164, so that it can be oriented from the orientation shown in the flat configuration (e.g., as shown). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11 (As shown).

[0070] In one or more examples, blank 102 includes at least one opening 208 formed through at least one of the plurality of plates 134. The opening 208 may be formed (e.g., cut out) during the formation of blank 102. In one or more examples, the opening 208 may interrupt the fold line, thereby making blank 102 easier to fold during the erection of cardboard box 100.

[0071] In one or more examples, one or more of the side panels 140, 142, 144, and 146 may include a lower portion 192 and an upper portion 194. As an example, the lower portion 192 of each of the side panels 140, 142, 144, and 146 is foldably connected to the lower portion 192 of an adjacent side panel 140, 142, 144, and 146 along corresponding fold lines 160, 162, and 164. The upper portion 194 extends from the lower portion 192 and is foldably connected to the lower portion 192 along a fold line 196. The fold line 196 extends longitudinally, approximately perpendicular to the corresponding fold lines 160, 162, and 164, and separates the upper portion 194 from the lower portion 192.

[0072] The upper portion 194 is hinged relative to the lower portion 192 about the fold line 196 (e.g., foldable), such that it can be oriented from the orientation shown in the flat configuration (e.g., as shown in the figure). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11 (As shown).

[0073] Each of the lower portion 192 and upper portion 194 of the corresponding side panels 140, 142, 144, and 146 can have any suitable two-dimensional shape and / or any desired size. In the illustrated example, the lower portion 192 has an approximately rectangular shape, and the upper portion 194 has an approximately trapezoidal shape. Thus, when the carton 100 is formed from the blank 102, one or more of the side walls 116, 118, 120, and 122 of the carton 100 can have a lower portion with any suitable or desired shape (such as an approximately rectangular shape) and an upper portion with any suitable or desired shape (such as an approximately trapezoidal shape).

[0074] like Figure 3-11As shown, in one or more examples, when the cardboard box 100 is formed from the blank 102, the lower portions 192 of the respective side panels 140, 142, 144, and 146 are folded such that the lower portions of the respective side walls 116, 118, 120, and 122 are oriented approximately vertically (e.g., approximately perpendicular to the bottom wall 104). The upper portions 194 of the respective side panels 140, 142, 144, and 146 are folded at an oblique angle relative to the lower portions 192 such that the upper portions of the respective side walls 116, 118, 120, and 122 are oblique relative to the lower portions of the respective side walls 116, 118, 120, and 122.

[0075] refer to Figure 15-17 In one or more examples, the upper portion of each of the side plates 140, 142, 144, and 146 is not connected to the upper portion 194 of an adjacent pair of side plates 140, 142, 144, and 146 (e.g., not foldably connected). For example, a “V” shaped cut may be formed in the blank 102 between the upper portions 194 of an adjacent pair of side plates 140, 142, 144, and 146 to separate each upper portion 194 from the adjacent upper portion 194.

[0076] refer to Figure 18 In one or more examples, the upper portion of each of side panels 140, 142, 144, and 146 is foldably connected to the upper portion 194 of an adjacent side panel 140, 142, 144, and 146. As an example, blank 102 may include a gusset plate 198 foldably connected to the upper portion 194 of the respective side panels 140, 142, 144, and 146. When carton 100 is formed from blank 102, the gusset plate 198 provides increased structural integrity to carton 100.

[0077] In one or more examples, the gusset 198 includes a pair of fold-in plates. For example, a first fold-in plate extends from the upper portion 194 of one of the side panels 140, 142, 144, and 146 and is foldably connected to that upper portion along a fold line, and a second fold-in plate extends from the upper portion 194 of one of the directly adjacent side panels 140, 142, 144, and 146 and is foldably connected to that upper portion along a fold line. The first and second fold-in plates are foldably connected along the fold line. When the carton 100 is formed from the blank 102, the gusset 198 folds inward (e.g., within the internal volume 110 of the carton 100), thereby holding the upper portion 194 of a corresponding side panel 140, 142, 144, and 146, and thus the upper portion of a corresponding side wall 116, 118, 120, and 122, in the constructed configuration (e.g., as shown in the image). Figure 3-11 (As shown).

[0078] In one or more examples, the first and second folding plates of the corresponding gusset plates 198 connecting the upper portion 194 of the first side plate 140 and the upper portion 194 of the fourth side plate 146 are initially separate (e.g., when in a flat configuration of the blank 102) and are joined (e.g., adhesively joined) together when the carton 100 is formed from the blank 102. For example, a folding plate 200 can extend from and be foldably attached to the first folding plate. When the carton 100 is formed from the blank 102, the folding plate 200 can be attached to the second folding plate.

[0079] Refer again Figure 15-18 A first handle plate 136 extends from a first side plate 140 and is foldably connected to the first side plate 140 along a fold line 166 (e.g., a first handle plate fold line). The fold line 166 extends longitudinally and separates the first handle plate 136 from the first side plate 140. A second handle plate 138 extends from a third side plate 144 and is foldably connected to the third side plate 144 along a fold line 168 (e.g., a second handle plate fold line). The fold line 168 extends longitudinally and separates the second handle plate 138 from the third side plate 144.

[0080] In one or more examples, a first handle plate 136 extends from the upper portion 194 of a first side plate 140 and is foldably connected to the upper portion 194 along a fold line 166. The fold line 166 extends approximately parallel to the longitudinal direction of the fold line 196 and separates the first handle plate 136 from the upper portion 194 of the first side plate 140. A second handle plate 138 extends from the upper portion 194 of a third side plate 144 and is foldably connected to the upper portion 194 along a fold line 168. The fold line 168 extends approximately parallel to the longitudinal direction of the fold line 196 and separates the second handle plate 138 from the upper portion 194 of the third side plate 144.

[0081] The first handle plate 136 is hinged (e.g., foldable) relative to the first side plate 140 about the fold line 166, such that it can be moved from the orientation shown in the flat configuration (e.g., as shown in the image). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11 (As shown). The second handle plate 138 is hinged relative to the first side plate 140 about the fold line 168 (e.g., foldable), so that it can be positioned from the orientation shown in the flat configuration (e.g., as shown). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11 (As shown).

[0082] In one or more examples, blank 102 includes a cut or opening formed between the first side plate 140 and the first handle plate 136, and a cut or opening formed between the third side plate 144 and the second handle plate 138. For example, the cut may be positioned or interrupted along or along the respective fold lines 166 and 168. The cut provides a defined edge on one side of the respective first handle plate 136 and second handle plate 138, thereby forming a handle 112, and thus forming a handle portion of the top wall 106.

[0083] In one or more examples, blank 102 includes at least one base plate extending from and foldably connected to at least one of side plates 140, 142, 144, and 146. When cardboard box 100 is formed from blank 102, the at least one base plate forms the bottom wall 104 of cardboard box 100.

[0084] In the illustrated example, blank 102 includes a first base plate 170, a second base plate 172, a third base plate 174, and a fourth base plate 176. The first base plate 170 extends from the first side plate 140 and is foldably connected to the first side plate 140 along a fold line 178 (e.g., a first base plate fold line). The fold line 178 extends longitudinally, is approximately parallel to fold line 166 and approximately perpendicular to fold line 160, and separates the first base plate 170 from the first side plate 140. The second base plate 172 extends from the second side plate 142 and is foldably connected to the second side plate 142 along a fold line 180 (e.g., a second base plate fold line). The eighth fold line 180 extends longitudinally, is approximately collinear with fold line 166 and approximately perpendicular to fold lines 160 and 162, and separates the second base plate 172 from the second side plate 142. A third base plate 174 extends from the third side plate 144 and is foldably connected to the third side plate 144 along a fold line 182 (e.g., a fold line of the third base plate). Fold line 182 extends longitudinally, is approximately collinear with fold line 180, approximately parallel to fold line 168, and approximately perpendicular to fold lines 162 and 164, separating the third base plate 174 from the third side plate 144. A fourth base plate 176 extends from the fourth side plate 146 and is foldably connected to the fourth side plate 146 along a fold line 184 (e.g., a fold line of the fourth base plate). Fold line 184 extends longitudinally, is approximately collinear with fold line 180, and approximately perpendicular to fold line 164, separating the fourth base plate 176 from the fourth side plate 146.

[0085] Each of the base plates 170, 172, 174, and 176 is hinged (e.g., foldable) relative to the corresponding side plates 140, 142, 144, and 146 about the corresponding fold lines 178, 180, 182, and 184, such that it can be moved (e.g., foldable) from the orientation shown in the flat configuration (e.g., as shown in the flat configuration). Figure 15-18 (as shown) move to the orientation shown in the constructed configuration (e.g., as shown) Figure 3-11(As shown).

[0086] In other examples, blank 102 may include a different number (e.g., less than four) of base plates and / or base plates of different configurations. Thus, the illustrated example of the base plate forming the bottom wall 104 of the cardboard box 100 should not be considered a limiting factor.

[0087] Each of the base plates 170, 172, 174, and 176 can have any suitable two-dimensional shape and / or any desired size. In the example shown, one or more of the base plates 170, 172, 174, and 176 have a rectangular or trapezoidal shape. Thus, when the cardboard box 100 is formed from the blank 102, the bottom wall 104 of the cardboard box 100 can have any suitable or desired shape, such as an approximately rectangular shape.

[0088] One or more of the base plates 170, 172, 174, and 176 may be coupled to the other or more of the base plates 170, 172, 174, and 176 by any suitable technique known to those skilled in the art and guided by the teachings provided herein. For example, one or more of the base plates 170, 172, 174, and 176 may be interlocked with each other, glued together, adhesively bonded to each other, or combined with each other.

[0089] In one or more examples, such as when base plates 170, 172, 174 and 176 are joined together using an adhesive, at least a portion of at least one of base plates 170, 172, 174 and 176 may include an uncoated area 186 that facilitates adhesive bonding.

[0090] In one or more examples, one or more of the base plates 170, 172, 174, and 176 may include a fold 188 extending from a corresponding one of the base plates 170, 172, 174, and 176. The fold 188 may facilitate the joining of a corresponding pair of base plates 170, 172, 174, and 176. For example, when the cardboard box 100 is formed from the blank 102, the fold 188 of one of the base plates 170, 172, 174, and 176 may be joined and adhesively attached to the uncoated area 186 of a corresponding one of the base plates 170, 172, 174, and 176.

[0091] In one or more examples, fold plate 188 may be foldably connected to a corresponding one of the base plates 170, 172, 174, and 176 along a fold line 190 (e.g., a fold plate fold line). Fold plate 188 may be hingedly movable (e.g., foldable) relative to a corresponding one of the base plates 170, 172, 174, and 176 about the fold line 190, such that fold plate 188 may be movable during the construction of cardboard box 100 from blank 102. In one or more examples, the fold line 190 may include discontinuous cuts or perforations that facilitate folding of fold plate 188 during construction.

[0092] The blank 102 includes at least one locking mechanism 124 for interlocking the first handle plate 136 and the second handle plate 138 to the second side plate 142 and the fourth side plate 146 when the cardboard box 100 is formed from the blank 102.

[0093] In one or more examples, blank 102 includes a first portion of locking mechanism 124 on each of the first handle plate 136 and the second handle plate 138 (e.g., as shown in the image). Figure 15 and 18 The convex portion shown or as Figure 16 and 17 (The concave portion shown). The blank 102 includes a second portion of the locking mechanism 124 on each of the second side plate 142 and the fourth side plate 146 (e.g., as shown). Figure 15 and 18 The concave portion shown or Figure 16 and 17 (The convex portion shown). When the cardboard box 100 is formed from the blank 102, the first and second portions of the locking mechanism 124 cooperate to connect the first handle plate 136 and the second handle plate 138 to the second side plate 142 and the fourth side plate 146. When the cardboard box 100 is formed from the blank 102, the first handle plate 136 and the second handle plate 138 form the handle 112, the top wall 106 and the flat surface 114 of the cardboard box 100.

[0094] refer to Figure 15 and 18 In one or more examples, the first portion of the locking mechanism 124 includes a handle locking tab 148. The handle locking tab 148 is an example of the locking tab 126 (e.g., as shown in...). Figure 3-5 (As shown). A handle locking tab 148 protrudes from each end 130 of each of the first handle plate 136 and the second handle plate 138. A second portion of the locking mechanism 124 includes a wall locking groove 150. The wall locking groove 150 is an example of the locking groove 128 (e.g., as shown). Figure 3-5(As shown). A wall locking groove 150 is formed through each of the second side plate 142 and the fourth side plate 146. A handle locking tab 148 is configured to be received by the wall locking groove 150 when the cardboard box 100 is formed from the blank 102, and to engage a corresponding one of the second side plate 142 and the fourth side plate 146 to connect the first handle plate 136 and the second handle plate 138, as well as the second side plate 142 and the fourth side plate 146 together.

[0095] Typically, the wall locking groove 150 is positioned near (e.g., at or near) the end 132 of a corresponding one of the second side panel 142 and the fourth side panel 146. In one or more examples, the wall locking groove 150 is spaced apart from the end edge of a corresponding one of the second side panel 142 and the fourth side panel 146, such that when the carton 100 is formed from the blank 102, a portion of the end 132 of each of the second side panel 142 and the fourth side panel 146 extends beyond the overlapping first handle plate 136 and second handle plate 138 (e.g., as shown in the image). Figure 6-8 (as shown in Figure 12). Thus, a portion of each end 132 of the second sidewall 118 and the fourth sidewall 122 extends beyond the top wall 106 (e.g., as shown in Figure 12). Figure 3-5 (As shown).

[0096] In one or more examples, each of the second side panel 142 and the fourth side panel 146 includes a hinge plate 202 positioned at an end 132 of the respective side panel 142 and the fourth side panel 146. The hinge plate 202 extends from the respective side panel 142 and the fourth side panel 146 and is foldably connected to the respective side panel along a fold line 204 (e.g., a hinge plate fold line). For example, the hinge plate 202 extends from an upper portion 194 of the respective side panel 142 and the fourth side panel 146 and is foldably connected to the upper portion 194 along a fold line 204. The fold line 204 extends longitudinally, approximately parallel to the respective fold line 196, and separates the hinge plate 202 from the respective side panel 142 and the fourth side panel 146.

[0097] The hinge plate 202 is hinged (e.g., foldable) relative to one of the second side plates 142 and the fourth side plates 146 about the fold line 204, such that when the second cardboard box 100 is stacked on top of the cardboard box 100, the hinge plate 202 is movable to be approximately coplanar with the first handle plate 136 and the second handle plate 138, and thus forms part of the planar surface 114.

[0098] In one or more examples, the fold line 204 may include discontinuous cuts or perforations that make the hinge plate 202 easier to fold during stacking. In one or more examples, the wall locking slot 150 interrupts or is positioned along the fold line 204, thereby making the hinge plate 202 easier to fold during stacking and positioning the hinge plate 202 directly over the overlapping first handle plate 136 and second handle plate 138.

[0099] refer to Figure 16 and 17 In one or more examples, the first portion of the locking mechanism 124 includes a handle locking slot 154. The handle locking slot 154 is an example of a locking slot 128 (e.g., as shown in...). Figure 3-5 (As shown). A handle locking groove 154 is formed through each end 130 of each of the first handle plate 136 and the second handle plate 138. A second portion of the locking mechanism 124 includes a wall locking tab 152. The wall locking tab 152 is an example of the locking tab 126 (e.g., as shown). Figure 3-5 (As shown). The wall locking tab 152 protrudes from the end 132 (e.g., end edge) of each of the second side panel 142 and the fourth side panel 146. When the carton 100 is formed from the blank 102, the wall locking tab 152 is configured to be received by the handle locking slot 154 and engage the handle 112 to connect the first handle plate 136 and the second handle plate 138, as well as the second side panel 142 and the fourth side panel 146 together.

[0100] Typically, the handle locking groove 154 is located near (e.g., at or near) each opposite end 130 of the corresponding one of the first handle plate 136 and the second handle plate 138. In one or more examples, the handle locking groove 154 is spaced apart from the edge of each opposite end of the corresponding one of the first handle plate 136 and the second handle plate 138.

[0101] In one or more examples, a wall locking tab 152 extends from the hinge plate 202 of a corresponding one of the second side plate 142 and the fourth side plate 146 and is foldably connected to the hinge plate 202 along a fold line 206 (e.g., a locking tab fold line). The fold line 206 extends longitudinally and is approximately parallel to the corresponding fold line 204. The wall locking tab 152 is hingedly movable (e.g., foldable) relative to the hinge plate 202 about the fold line 206, such that it can be moved during insertion of the corresponding handle locking slot 154 when the carton 100 is formed from the blank 102. In one or more examples, the fold line 206 may include discontinuous cuts or perforations that make it easier for the hinge plate 202 to fold during stacking.

[0102] In one or more examples, hinge plate 202 is hingedly movable (e.g., foldable) relative to a respective one of the second side plate 142 and the fourth side plate 146 about fold line 204, such that when wall locking tab 152 is received by handle locking slot 154, hinge plate 202 is movable to be substantially coplanar with the first handle plate 136 and the second handle plate 138, and thus forms part of planar surface 114 (e.g., as shown in the image). Figure 13 (As shown).

[0103] In one or more examples, the opening 210 interrupts or is positioned along the fold line 204, thereby allowing the hinge plate 202 to fold during the insertion of the wall locking tab 152 into the handle locking slot 154. During the insertion of the wall locking tab 152 into the handle locking slot 154, the opening 210 also allows the end 130 of each of the first and second handle plates 136 and 138 to extend through a corresponding one of the second and fourth side plates 142 and 146 (e.g., as shown in the image). Figure 13 and 14 (As shown).

[0104] refer to Figure 17 In one or more examples, the first portion of the locking mechanism 124 includes a pair of handle locking slots 154. These handle locking slots 154 are examples of locking slots 128 (e.g., as shown in...). Figure 3-5 (As shown). The pair of handle locking grooves 154 are formed through each end 130 of each of the first handle plate 136 and the second handle plate 138.

[0105] In one or more examples, the pair of handle locking slots 154 are spaced apart from each other and parallel to each other. When the cardboard box 100 is formed from the blank 102, the wall locking tab 152 is inserted from a first direction through the first of the pair of handle locking slots 154, and then from a second direction opposite to the first direction through the second of the pair of handle locking slots 154, such that the wall locking tab 152 loops or wraps around the pair of handle locking slots 154 (e.g., as shown in the image). Figure 14 (As shown), thus providing a double locking arrangement. This double locking arrangement between the wall locking tab 152 and the pair of handle locking slots 154 provides a more robust interlock between the first and second handle plates 136 and 138 and the second and fourth side plates 142 and 146.

[0106] Typically, the locking tab 126 (e.g., handle locking tab 148 or wall locking tab 152) and the locking groove 128 (e.g., handle locking groove 154 or wall locking groove 150) have complementary and matching shapes that allow the locking tab 126 to pass through the locking groove 128 in one direction, but prevent the locking tab 126 from passing through the locking groove 128 in the opposite direction. As an example, the locking tab 126 may have a truncated arrowhead shape.

[0107] like Figure 15 and 18 As shown, in one or more examples, the handle locking tab 148 may include a main portion connected to and extending from the end 130 of the respective first handle plate 136 and second handle plate 138, and a pair of opposing anchoring portions connected to and extending outward from the main portion. A notch or groove may be formed between each of the anchoring portions and the end edges of the respective first handle plate 136 and second handle plate 138. When the handle locking tab 148 is received by the wall locking groove 150, a portion of a respective one of the second side plate 142 and fourth side plate 146 may be positioned within the notch, thereby retaining the handle locking tab 148 within the wall locking groove 150 by an interference fit.

[0108] In one or more examples, the anchoring portion of the handle locking tab 148 may flex or bend relative to the main portion during insertion into the wall locking groove 150. Once the handle locking tab 148 has passed the edge of the wall locking groove 150, the anchoring portion may spring back to a more planar state relative to the main portion (e.g., flattening due to the natural elasticity of the raw material of the blank 102), such that when tension is applied in the opposite direction to the locking direction, the edge of the anchoring portion abuts the inner surface of the corresponding one of the second side plate 142 and the fourth side plate 146.

[0109] In one or more examples, the wall locking groove 150 may have a first part and a second part, such as Figure 15 and 18 As shown. The first part is provided with a suitable size (e.g., larger than the handle locking tab 148) so that the handle locking tab 148 can be inserted through the first part. The second part is provided with a suitable size (e.g., smaller than the handle locking tab 148) to prevent the handle locking tab 148 from being removed through the second part.

[0110] like Figure 16 and 17 As shown, in one or more examples, the wall-locking tab 152 may include an end 132 connected to and extending from the respective second side plate 142 and fourth side plate 146, and a main portion connected to and extending outwardly from the main portion, and a pair of opposing anchoring portions. A notch or groove may be formed between each of the anchoring portions and the end edges of the respective second side plate 142 and fourth side plate 146. When the wall-locking tab 152 is received by the handle locking groove 154, a portion of the first handle plate 136 and the second handle plate 138 may be positioned within the notch, thereby retaining the wall-locking tab 152 within the handle locking groove 154 by an interference fit.

[0111] In one or more examples, the anchoring portion of the wall locking tab 152 may flex or bend relative to the main portion during insertion into the handle locking groove 154. Once the wall locking tab 152 has passed the edge of the handle locking groove 154, the anchoring portion may spring back to a more planar state relative to the main portion (e.g., flattening due to the natural elasticity of the raw material of the blank 102), such that when tension is applied in the opposite direction to the locking direction, the edge of the anchoring portion abuts the inner surface of the lower of the overlapping first and second handle plates 136 and 138.

[0112] In one or more examples, the handle locking slot 154 can be approximately linear (e.g., as shown in the image). Figure 17 As shown). In one or more examples, the handle locking slot 154 can be non-linear (e.g., as shown). Figure 16 As shown), it is thus configured to be able to insert the wall locking tab 152 when the anchor portion bends, but without requiring the same amount of springback at the edge of the anchor portion to abut the inner surface of the lower of the overlapping first and second handle plates 136 and 138.

[0113] This disclosure also relates to a method for forming a cardboard box 100 from a blank 102. The method may include a series of successive folding operations. The folding process is not limited to any particular folding process and may be varied according to specific manufacturing requirements.

[0114] In one or more examples, the method includes the step of providing a blank 102 comprising a plurality of plates 134. The method includes the step of manipulating the blank 102 such that the plurality of plates 134 form a bottom wall 104, a top wall 106, a plurality of side walls 108, a handle 112, and a planar surface 114 of a cardboard box 100. The top wall 106 is releasably coupled to an opposing pair of the plurality of side walls 108. The handle 112 is formed by at least a portion of the top wall 106. The handle 112 and the top wall 106 form the planar surface 114 of the cardboard box 100.

[0115] In one or more examples, the cardboard box 100 can be erected and formed around the product. In one or more embodiments, the cardboard box 100 can be partially erected and filled with the product. The erection and filling process can be performed manually, automatically using a machine, or a combination of both.

[0116] This disclosure also relates to a method of packaging a product within a cardboard box 100. The cardboard box 100 includes a bottom wall 104, a plurality of side walls 108, a top wall 106, a handle 112 formed by at least a portion of the top wall 106, and a planar surface 114 formed by at least a portion of the handle 112 and the top wall 106. In one or more examples, the method includes the step of erecting the cardboard box 100 such that one of the side walls 108 detaches from the top wall 106. The method includes the step of loading a product into an internal volume 110 of the cardboard box 100. The method includes the step of further erecting the cardboard box 100 such that one of the side walls 108 is attached to the top wall 106. In one or more examples, the cardboard box 100 is the first of a plurality of cardboard boxes 100. The method includes the step of stacking a second of the plurality of cardboard boxes 100 on the planar surface 114 of the first of the plurality of cardboard boxes 100 (e.g., as shown in the image). Figure 5 (As shown).

[0117] The disclosed cardboard box 100 provides a solution with minimal materials while offering performance comparable to conventional product containers (e.g., integrity and marketability). Various examples of the disclosed cardboard box 100 formed from the blank 102 include handles 112, enabling the cardboard box 100 to function as a product carrier. The handles 112 substantially form the top wall 106 of the cardboard box 100 and have a portion (convex or concave) of a locking mechanism 124 on its lateral end portion, which engages respectively with corresponding portions of locking mechanisms 124 positioned on the upper portions of each side wall 108, thereby forming the ends of the cardboard box 100. Thus, the handles 112 extend and engage between and with the side walls 108 (e.g., side panels) of the cardboard box 100, rather than with the top panel (e.g., similar to conventional product packaging), thereby providing increased structural integrity to the cardboard box 100. Furthermore, the handle 112 and thus the top wall 106 have a double-layered construction formed by two substantially identical handle plates 136 and 138, which provides additional reinforcement and structural integrity to the cardboard box 100. Additionally, the configuration of the side walls 108 (e.g., side panels), the top wall 106, and the handles 112 (e.g., handle plates 136, 138) provides a planar surface 114 on which second cardboard boxes can be stacked, thereby enabling stacking while providing the handle cardboard box 100.

[0118] For the purposes of this disclosure, the terms “inner,” “outer,” “lower,” “upper,” “bottom,” “top,” “front,” “rear,” “side,” “end,” and similar terms or other forms of such terms are relative and refer to examples of spatial relationships between structures, elements, articles, parts, or features, or indicate orientations determined relative to fully upright and vertical cardboard boxes (e.g., as...). Figure 3-11(As shown). Similarly, the examples of cardboard box 100 and blank 102 described herein and illustrated in the accompanying drawings are not intended to be limited to any specific related terms used to describe any structure, element, item, component, or feature of cardboard box 100 or blank 102.

[0119] The foregoing has described in detail examples of the disclosed cardboard box 100 and the blank 102 used to manufacture the cardboard box 100. The blank 102 and the cardboard box 100 are not limited to the specific examples described herein, but rather components, elements, and / or features of the blank and / or container may be used independently of or separately from other components, elements, and / or features described herein. For example, the blank may also be used in conjunction with other types of products and is not limited to practice only with the articles described and illustrated herein. Rather, this exemplary embodiment can be implemented and utilized in conjunction with many other applications.

[0120] Unless otherwise indicated, the terms “first,” “second,” “third,” etc., are used merely as labels in this document and are not intended to impose any order, position, or rank on the items referred to by these terms. Furthermore, references to an item, such as “second,” do not require or exclude the existence of an item numbered, such as “first” or lower, and / or an item numbered, such as “third” or higher.

[0121] As used herein, when used with a list of items, the phrase “at least one of…” means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, “at least one of Item A, Item B, and Item C” can be, but is not limited to, Item A or Item A and Item B. This example could also include Item A, Item B, and Item C, or Item B and Item C. In other examples, “at least one of…” can be, for example, but not limited to, two of Item A, one of Item B, and ten of Item C; four of Item B and seven of Item C; and other suitable combinations.

[0122] For the purposes of this disclosure, the terms "coupled," "coupling," and similar terms refer to two or more elements being joined, linked, fastened, attached, connected, connected, or otherwise associated with each other. In various examples, elements may be directly or indirectly associated. As one example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. Therefore, in addition to those depicted in the figures, couplings may also exist.

[0123] As used herein, the term "substantially" means a condition that substantially performs the desired function or achieves the desired result. As used herein, the term "approximately" means a condition that is close to the stated condition, but not exactly the stated condition that still performs the desired function or achieves the desired result. However, the use of the terms "substantially" and "approximately" does not exclude conditions that are exactly the stated condition.

[0124] Those skilled in the art will understand that it is not Figure 1-18 All elements described and illustrated herein must be included in every example, and not all elements described herein must be depicted in every illustrative example. Unless otherwise expressly stated, Figure 1-18 The illustrative examples depicted are not intended to imply any structural limitations on the illustrative examples. On the contrary, while an illustrative structure is shown, it should be understood that this structure can be modified as appropriate. Furthermore, the illustrated structure may be modified, added to, and / or omitted.

[0125] Furthermore, references to features, advantages, or similar language used throughout this specification do not imply that all features and advantages that can be implemented with respect to the examples disclosed herein should be or exist in any single example. Rather, language relating to features and advantages is to be understood as meaning that a particular feature, advantage, or characteristic described in conjunction with the examples is included in at least one example. Therefore, the discussion of features, advantages, and similar language used throughout this disclosure may, but does not necessarily, refer to the same example.

[0126] The features, advantages, and characteristics described in one example can be combined in any suitable manner in one or more other examples. Those skilled in the art will recognize that the examples described herein can also be practiced even without one or more specific features or advantages of a particular example. In other cases, additional features and advantages that may not be present in all examples may be recognized in certain examples. Furthermore, although various examples of the cardboard box 100 and the blank 102 for forming the cardboard box 100, as well as the methods, have been shown and described, modifications will occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A cardboard box for packaging products, the cardboard box being formed from a blank of foldable sheet material, and the cardboard box comprising: Multiple plates forming the internal volume, handles, and flat surfaces of a cardboard box, said multiple plates including: First side panel; A second side plate that can be folded and connected to the first side plate; A third side plate that can be folded and connected to the second side plate; A fourth side plate that can be foldably connected to the third side plate; A first handle plate, which is foldably connected to the first side plate and releasably connected to the second and fourth side plates; and A second handle plate, which can be folded to the third side plate and can be releasably connected to both the second and fourth side plates, Wherein, at least a portion of the inner surface of the first handle plate overlaps with at least a portion of the outer surface of the second handle plate, such that the outer surfaces of the first and second handle plates face the outer side of the cardboard box, and that the first and second handle plates together form the handle and at least a portion of the planar surface. The locking mechanism connects the first handle plate and the second handle plate to the second side plate and the fourth side plate, respectively.

2. The cardboard box according to claim 1, wherein: The locking mechanism includes: A handle locking tab protruding from each end of each of the first and second handle plates; and A wall locking groove is formed through each of the second and fourth side plates; and The handle locking tab is received by the wall locking groove and engages with a corresponding one of the second side plate and the fourth side plate.

3. The cardboard box according to claim 2, wherein, A portion of the ends of the second and fourth side plates protrude above the handle and can be folded to form a portion of the planar surface.

4. The cardboard box according to claim 1, wherein: The locking mechanism includes: Wall locking tabs protruding from the ends of each of the second and fourth side plates; and A handle locking groove is formed through each end of each of the first handle plate and the second handle plate; and The wall locking tab is received by the handle locking groove and engages with the handle.

5. The cardboard box according to claim 4, wherein, A portion of the end of each of the second and fourth side plates forms part of the planar surface.

6. The cardboard box according to any one of claims 1-5, further comprising at least one opening formed through at least one of the plurality of boards.

7. The cardboard box according to any one of claims 1-5, wherein, The foldable sheet material includes cardboard or rigid cardboard; and Wherein, the inner surface includes a surface coating; and / or The outer surface includes a surface coating.

8. A blank of a foldable sheet material for forming a cardboard box, the blank comprising: First side panel; A second side plate that can be folded and connected to the first side plate; A third side plate that can be folded and connected to the second side plate; A fourth side plate that can be foldably connected to the third side plate; A first handle plate that can be folded and connected to the first side panel; A second handle plate that can be folded and connected to the third side plate; The first part of the locking mechanism on each of the first handle plate and the second handle plate; and The second part of the locking mechanism on each of the second and fourth side plates Wherein, when the cardboard box is formed from a blank: The inner surface of the first handle plate overlaps with at least a portion of the outer surface of the second handle plate, such that the outer surfaces of the first handle plate and the second handle plate face the outside of the cardboard box; The first and second portions of the locking mechanism cooperate to connect the first and second handle plates to the second and fourth side plates; and The first handle plate and the second handle plate form the handle and at least a portion of the flat surface of the cardboard box.

9. The blank according to claim 8, wherein: The first part of the locking mechanism includes a handle locking tab protruding from each end of each of the first handle plate and the second handle plate; The second part of the locking mechanism includes a wall locking groove formed through each of the second and fourth side plates; and The handle locking tab is configured to be received by the wall locking groove and engage with a corresponding one of the second and fourth side plates.

10. The blank according to claim 8, wherein: The first part of the locking mechanism includes a handle locking groove formed through each end of each of the first handle plate and the second handle plate; The second portion of the locking mechanism includes wall-locking tabs projecting from the ends of each of the second and fourth side plates; and The wall locking tab is configured to receive and engage the handle by the handle locking slot.

11. The blank according to claim 8, 9 or 10, further comprising at least one opening formed through at least one of the first side plate, the second side plate, the third side plate and the fourth side plate.

12. The blank according to any one of claims 8-10, wherein, The foldable sheet material includes cardboard or cardboard.

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