Carton with locking feature

Abstract

A carton includes an inner structure including a plurality of inner panels extending at least partially around a first interior and an inner locking tab foldably connected to at least one of the inner panels. The outer structural member may include a plurality of outer panels extending at least partially around the second interior. The outer structural member may include an outer locking plate foldably connected to the at least one outer panel, and the inner locking plate and the outer locking plate may cooperate to limit movement between the inner structural member and the outer structural member. The carton may also include an engagement feature including a cover panel that is at least partially separable from the at least one outer panel. An inner locking plate of the inner structure may extend along an engagement feature in the outer structure such that the inner locking plate may engage when the cover plate is at least partially removed to facilitate movement of the inner and outer structures relative to each other.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of German utility model application No. 202022103827.9 filed on July 7, 2022. Incorporated by Reference

[0002] The disclosure content of German Utility Model Application No. 202022103827.9 filed on July 7, 2022 is hereby incorporated by reference for all purposes as if fully presented herein. Technical Field

[0003] The present disclosure generally relates to cartons / boxes for containing one or more products. More specifically, the present disclosure relates to a carton having an inner structure at least partially housed within an outer structure and having a locking feature for selectively limiting and / or resisting relative movement between the carton structures. Background Art

[0004] Cartons / boxes with locking features can be used for a variety of different products, such as dishwashing detergents, medicines, household cleaners, candles, cosmetics, tobacco, and other products that should be kept out of the reach of children (because they might put the product in their mouths, swallow it, or use it in other dangerous ways). For example, it may be desirable to keep certain products out of the reach of, for example, infants, toddlers, kindergarteners, and preschoolers (i.e., up to about six years of age). Summary of the invention

[0005] In general, one aspect of the present invention relates to a carton, which includes an inner structure, the inner structure includes a plurality of inner panels extending at least partially around a first interior of the inner structure. The inner structure may include an inner locking tab foldably connected to at least one of the plurality of inner panels. The carton may also include an outer structure, the outer structure includes a plurality of outer panels extending at least partially around a second interior of the outer structure. The inner structure may be at least partially accommodated in the second interior of the outer structure. The outer structure may include an outer locking tab foldably connected to at least one of the plurality of outer panels, and the inner locking tab and the outer locking tab may cooperate to limit movement between the inner structure and the outer structure. The carton may also include an engagement feature extending in the at least one outer panel of the outer structure. The engagement feature may include a cover plate, which may be at least partially separated from the at least one outer panel so as to form an engagement hole in the at least one outer panel. The inner locking tab of the inner structure may extend along an engagement feature in the outer structure such that when the cover is at least partially removed, the inner locking tab may engage through the engagement aperture to move the inner locking tab relative to the outer locking tab, thereby facilitating movement of the inner and outer structures relative to each other from a closed configuration to an open configuration.

[0006] In another aspect, the present invention generally relates to a combination of a first blank and a second blank for cooperating to at least partially form a carton. The first blank may include a plurality of inner panels and an inner locking tab foldably connected to at least one of the plurality of inner panels. The first blank may be used to form an inner structure. The second blank may include a plurality of outer panels and an outer locking tab foldably connected to at least one of the plurality of outer panels. The second blank may be used to form an outer structure for at least partially accommodating the inner structure formed by the first blank when the carton is formed by the first blank and the second blank, and the inner locking tab and the outer locking tab may be configured to selectively cooperate to limit movement between the inner structure formed by the first blank and the outer structure formed by the second blank when the carton is formed by the first blank and the second blank. An engagement feature may extend in the at least one outer panel of the second blank, the engagement feature including a cover plate that may be at least partially separated from the at least one outer panel so as to form an engagement hole in the at least one outer panel. The engagement feature may facilitate engaging the inner locking tab to move the inner locking tab relative to the outer locking tab when the carton is formed from the first blank and the second blank.

[0007] In another aspect, the present invention generally relates to a method of forming a carton. The method may include obtaining a first blank including a plurality of inner panels and an inner locking tab foldably connected to at least one of the plurality of inner panels, forming an inner structure from the first blank by folding the plurality of inner panels at least partially around a first interior of the inner structure, and obtaining a second blank including a plurality of outer panels and an outer locking tab foldably connected to at least one of the plurality of outer panels. An engagement feature may extend in the at least one outer panel, and the engagement feature may include a cover that is at least partially separable from the at least one outer panel so as to form an engagement hole in the at least one outer panel. The method may also include forming an outer structure by folding the plurality of outer panels at least partially around a second interior of the outer structure, and moving at least one of the inner structure and the outer structure relative to the other so as to assemble the carton by at least partially housing the inner structure in the second interior of the outer structure. The inner locking tab and the outer locking tab can cooperate to limit movement between the inner structure and the outer structure, and the inner locking tab of the inner structure extends along the engagement feature in the outer structure, so that the inner locking tab can be engaged through the engagement hole when the cover plate is at least partially removed to move the inner locking tab relative to the outer locking tab to facilitate the inner structure and the outer structure to move relative to each other from the closed configuration to the open configuration.

[0008] Those skilled in the art will appreciate the above-mentioned advantages and other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the below-listed drawing figures. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. The sizes of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present disclosure.

[0010] Figure 1 is a plan view of a first blank for forming an inner structure according to an exemplary embodiment of the present disclosure.

[0011] Figure 2 According to an exemplary embodiment of the present disclosure, Figure 1 Side view of an inner structure formed from a first blank.

[0012] Figure 3 is a plan view of a second blank for forming an outer structure according to an exemplary embodiment of the present disclosure.

[0013] Figure 4 According to an exemplary embodiment of the present disclosure, Figure 3 A side view of an outer structure formed from a second blank.

[0014] Figure 5A are arranged relative to each other when the outer structure is being moved onto the inner structure and / or after the inner structure is removed from the outer structure according to an exemplary embodiment of the present disclosure Figure 2 The internal structure and Figure 4 A three-dimensional view of the external structure.

[0015] Figure 5B Yes Figure 5A A perspective view of an arranged inner structure member and an outer structure member, showing hidden structures of the inner structure member and the outer structure member according to an exemplary embodiment of the present disclosure in dotted lines.

[0016] Figure 6 By assembling Figure 5A and 5B A side view of a carton formed by inner and outer structural members, showing in phantom the engaged locking tabs of these structural members according to an exemplary embodiment of the present disclosure.

[0017] Fig. 7A yes Figure 6 Three-dimensional image of a carton.

[0018] Figure 7B yes Figure 6 and 7A 0026] A three-dimensional view of a carton of FIG. 1 shows hidden structures of inner and outer structural members according to an exemplary embodiment of the present disclosure in dotted lines.

[0019] Corresponding parts are indicated by corresponding reference numerals throughout the drawings. DETAILED DESCRIPTION

[0020] The present disclosure generally relates to structures, boxes, cartons, carriers, trays, or the like, and packaging for containing one or more products or articles, such as those that should be child-proof (e.g., for safety reasons). The one or more products may be cleaning products, such as dishwashing detergent, household cleaner, soap, or the like; pharmaceuticals; cosmetics; candles; tobacco; objects that may pose a choking hazard; any other suitable products or materials; or combinations thereof.

[0021] A structural member according to the present disclosure may accommodate products or articles of any shape. In this specification, the terms "inner," "interior," "exterior," "outer," "lower," "bottom," "upper," and "top" indicate orientations determined relative to a fully erected and upright structural member and carton. As described herein, without departing from the present disclosure, a structural member may be formed from a blank by bonding with a plurality of panels, portions, tabs, and / or flaps, which may be named herein with respect to each other by terms (e.g., "first," "second," "third," etc.) in a sequential or non-sequential manner.

[0022] according to Figure 1 According to an exemplary embodiment of the present disclosure, the first blank 1 is used to form an inner member or inner structure 17 ( Figure 2 and 5A -7B). The inner structure 17 may be a container for containing one or more products (not shown). Figure 3 FIG. 4 shows an exemplary embodiment of the present disclosure for forming an outer member or outer structure 49 (eg, a cover 49) having a second opening 52 ( Figure 4-7B ) of the second blank 21. In some embodiments, the inner (internal) structural member 17 and the outer (external) structural member 49 cooperate to form a carton 55 ( Figure 6 and 7), wherein the outer structure 49 extends at least partially around the inner structure 17 and the inner structure is selectively movable within the outer structure in a closed configuration or first position ( Figure 6-7B ) and the open configuration or second position ( Figure 5A and 5B ), as described in more detail below. In the illustrated embodiment, the inner structure 17 and the outer structure 49 may include locking and stop features for cooperating to resist and / or limit movement of the inner structure 17 relative to the outer structure 49, as described in more detail below. In some exemplary embodiments, the blanks 1, 21 may be made of paperboard, cardboard, corrugated cardboard or other suitable materials.

[0023] like Figure 1As shown, the first blank 1 has a longitudinal direction L1 and a transverse direction L2. In the embodiment shown, the first blank 1 may have a bottom wall or panel 2, which is foldably connected to four first side walls or inner panels 3, 4, 5, 6 along respective folding lines 2.1, 2.2, 2.3, 2.4 at the edges. For example, the bottom panel 2 may be foldably connected to the respective first inner side panel 3 and the second inner side panel 5 along respective transverse folding lines 2.1, 2.3, and the bottom panel 2 may be foldably connected to the respective first inner end panel 4 and the second inner end panel 6 along respective longitudinal folding lines 2.2, 2.4. Figure 1 As shown, at least the bottom plate 2 and the inner end plates 4, 6 may be rectangular. Without departing from the present disclosure, any of the bottom plate 2 and / or the inner plates 3, 4, 5, 6 may be omitted or may be otherwise shaped, arranged and / or constructed.

[0024] In the embodiment shown, the inner panels 3, 5 may be foldably connected to respective first or inner locking tabs 9, 10 along respective transverse fold lines 7, 8 at opposite edges of the inner panels 3, 5. Figure 1 As shown, each inner locking tab 9, 10 may include a respective proximal segment 9.1, 10.1 (e.g., an inner or first proximal segment) and a respective distal segment 9.2, 10.2 (e.g., an inner or first distal segment). In some embodiments, the proximal segments 9.1, 10.1 are foldably connected (e.g., directly foldably connected) to the respective inner panels 3, 5 along respective transverse fold lines 7, 8, and are foldably connected to the respective distal segments 9.2, 10.2 along respective transverse fold lines 11, 12. In the illustrated embodiment, the proximal segments 9.1, 10.1 may be trapezoidal (e.g., such that the fold lines 11, 12 are shorter than the fold lines 7, 8, and such that the free edges of the proximal segments 9.1, 10.1 are inclined), and the distal segments 9.2, 10.2 may be rectangular. Alternatively, the segments 9.1, 9.2, 10.1, 10.2 may have any suitable shape.

[0025] like Figure 1As shown, the first inner panel 3 is foldably connected to the corresponding inner dust flap or inner end flap 13, 14 along the corresponding longitudinal folding lines 3.1, 3.3. Similarly, the second inner panel 5 is foldably connected to the corresponding inner dust flap or inner end flap 15, 16 along the corresponding longitudinal folding lines 5.1, 5.3. In some embodiments, the longitudinal folding lines 3.1, 3.3 and 5.1, 5.3 may extend along the rectangular section of the corresponding inner panel 3, 5. Further, the inclined free edge 3.2, 5.2 of the corresponding inner panel 3, 5 may extend from the corresponding longitudinal folding lines 3.1, 3.3 and 5.1, 5.3 to the corresponding end of the corresponding transverse folding line 7, 8 to at least partially define the corresponding trapezoidal section of the corresponding inner panel 3, 5. In the illustrated embodiment, each free edge of the proximal section 9.1, 10.1 of the inner locking tabs 9, 10 may extend as a continuation of the corresponding inclined free edge 3.2, 5.2 of the inner side panels 3, 5. Without departing from the present disclosure, any of the inner locking tabs 9, 10, the inner end flaps 13, 14, 15, 16 and / or the inner side panels 3, 5 may be omitted or may be otherwise shaped, arranged and / or constructed.

[0026] The blank 1 may be otherwise shaped, arranged and / or configured without departing from the present disclosure.

[0027] When forming the inner structural member 17 ( Figure 2 , 5A In the first processing step of the inner locking pieces 9, 10 (see FIGS. 1 and 5B), the distal sections 9.2, 10.2 of the inner locking pieces 9, 10 may be folded and fixed (e.g., adhesively bonded) to the outer sides of the corresponding proximal sections 9.1, 10.1 of the inner locking pieces 9, 10, and the proximal sections 9.1, 10.1 may be folded and fixed (e.g., adhesively bonded) to the outer sides of the corresponding inner panels 3, 5. In some embodiments, the distal sections 9.2, 10.2 may be fixed between the corresponding proximal sections 9.1, 10.1 and the corresponding inner panels 3, 5. Alternatively, the proximal sections 9.1, 10.1 may be disposed between the corresponding inner panels 3, 5 and the corresponding distal sections 9.2, 10.2. In some exemplary embodiments, the locking tabs 9, 10 may be folded and glued to the respective inner side panels 3, 5 (e.g., by a packaging manufacturer) and then stored and / or transported (e.g., to a packaging machine) in a flat, glued blank configuration (not shown), such as in a stack with other similar or identical blanks.

[0028] like Figure 2 , 5AAs shown in Figures 5B and 5B, the erected inner structure 17 can be formed from a flat glued blank (e.g., by a folder-gluer system, a packaging machine, etc.) by folding the inner side panels 3, 5 along the transverse fold lines 2.1, 2.3 to extend upward from the bottom panel 2, folding the inner end flaps 13, 16 and 14, 15 along the corresponding longitudinal fold lines 3.1, 5.3 and 3.3, 5.1 onto the corresponding ends of the inner structure 17, and folding the inner end panels 6, 4 along the corresponding longitudinal fold lines 2.4, 2.2 onto the corresponding ends of the inner structure 17. In the illustrated embodiment, the inner end flaps 13, 14, 15, 16 can be folded to extend perpendicularly to the inner side panels 3, 5 between the inner side panels 3, 5. In some embodiments, the first inner end panel 4 may be stacked and may be fixed (e.g., adhered) to the inner end wing panels 14, 15 to form a first inner end wall, and the second inner end panel 6 may be stacked and may be fixed (e.g., adhered) to the inner end wing panels 13, 16 to form a second inner end wall. Figure 2 , 5A As shown in FIGS. 5B and 5B , the bottom panel 2, the inner panels 3, 4, 5, 6, and the inner end wings 13, 14, 15, 16 may extend at least partially around a first interior portion of the inner structure 17 for receiving items in the inner structure 17. In the illustrated embodiment, the erected inner structure 17 may have a first or inner opening 18 defined between the inner panels 3, 4, 5, 6 relative to the bottom panel 2 (e.g., for inserting products into and removing products from the inner structure 17). Figure 2 , 5A 5B, the folded inner locking tabs 9, 10 form first or inner locking edges 19, 20 along respective transverse fold lines 11, 12. In the illustrated embodiment, the first locking edges 19, 20 may face away from the inner opening 18 and toward the bottom panel 2, and may be spaced apart from the inner opening 18 and the bottom panel 2. The inner structure 17 may be formed in other ways without departing from the present disclosure.

[0029] like Figure 3As shown, the second blank 21 for the outer member / outer structure 49 can have a longitudinal direction L1 and a transverse direction L2. In the embodiment shown, the second blank 21 can include a top wall or panel 22, which is foldably connected to four second side walls or outer panels 23, 24, 25, 26 along respective fold lines 22.1, 22.2, 22.3, 22.4 at the edges. For example, the top panel 22 can be foldably connected to the respective first outer side panels 23 and second outer side panels 25 along respective transverse fold lines 22.1, 22.3, and the top panel 22 can be foldably connected to the respective first outer end panels 24 and second outer end panels 26 along respective longitudinal fold lines 22.2, 22.4. In some embodiments, each of the top wall 22 and the outer panels 23, 24, 25, 26 can be rectangular. The top panel 22 and / or any of the outer panels 23 , 24 , 25 , 26 may be omitted or may be otherwise shaped, arranged and / or configured without departing from the present disclosure.

[0030] In the illustrated embodiment, the first outer side panel 23 can be foldably connected to the respective outer dust flap or outer side end flaps 27, 28 along respective longitudinal fold lines 23.1, 23.2. Similarly, the second outer side panel 25 can be foldably connected to the respective outer dust flap or outer side end flaps 29, 30 along respective longitudinal fold lines 25.1, 25.2. Without departing from the invention, any of the outer side end flaps 27, 28, 29, 30 and / or the outer side panels 23, 25 can be omitted or can be otherwise shaped, arranged and / or constructed.

[0031] like Figure 3As shown, the outer side panels 23, 25 can be foldably connected to the respective second or outer locking tabs 33, 34 along respective transverse fold lines 31, 32 at the opposite edges of the outer side panels 23, 25. In the illustrated embodiment, each outer locking tab 33, 34 can include a respective proximal section 33.1, 34.1 (e.g., an outer or second proximal section) and a respective distal section 33.2, 34.2 (e.g., an outer or second distal section). In some embodiments, the proximal sections 33.1, 34.1 are foldably connected (e.g., directly foldably connected) to the respective outer side panels 23, 25 along the respective transverse fold lines 31, 32, and are foldably connected to the respective distal sections 33.2, 34.2 along the respective transverse fold lines 35, 36 opposite to the respective transverse fold lines 31, 32. In some exemplary embodiments, each proximal segment 33.1, 34.1 may have two parts, wherein a first part 33.11, 34.11 adjoins the respective transverse fold lines 31, 32 and may be rectangular (e.g., may be defined by a free edge extending in the longitudinal direction L1). In some embodiments, a second part 33.12, 34.12 adjoins the respective transverse fold lines 35, 36 and is trapezoidal (e.g., may be defined by an inclined free edge), wherein the respective second part 33.12, 34.12 widens toward the respective first part 33.11, 34.11. In some exemplary embodiments, the distal segments 33.2, 34.2 may be rectangular and may be foldably connected to the short edges of the proximal segments 33.1, 34.1 along the transverse fold lines 35, 36. Alternatively, the segments 33.1, 33.2, 34.1, 34.2 may have any suitable shape.

[0032] In the embodiment shown, the second blank 21 may include engagement means or features 37, 38 extending in the respective outer panels 23, 25. Figure 3 As shown, the engagement means 37, 38 may be closer to the top panel 22 than to the respective outer locking tabs 33, 34, and may have an oval shape. In some embodiments, the engagement means 37, 38 may include respective weakened lines 39, 40 (e.g., cut or tear lines) that at least partially define respective engagement covers or cover panels 41, 42. In some exemplary embodiments, the weakened lines 39, 40 may be formed by mutually offset score lines in the outer and inner surfaces of the outer panels 23, 24. Figure 3As shown, the engagement means 37, 38 may include respective access openings 43, 44 (e.g., in the shape of a lens) extending along the edge of the respective weakened line 39, 40 (e.g., near the top panel 22). Alternatively, the access openings 43, 44 may be located along any portion of the respective cover panels 41, 42, or may be omitted. In some embodiments, the cover panels 41, 42 may be removed by tearing along the weakened lines 39, 40 to form respective engagement holes 45, 46 ( Fig. 7A and 7B In some embodiments, the joining means 37, 38 may include folding lines (not shown), wherein respective weakening lines 39, 40 extend from ends of the respective folding lines, so that the covers 41, 42 are partially removed from the respective outer panels 23, 25 along the respective weakening lines 39, 40 and folded outwardly along the respective folding lines (not shown).

[0033] like Figure 3 As shown, the second blank 21 may also include engagement openings 47, 48 (e.g., in an oval shape). In some embodiments, the opening 47 may extend in the proximal portion 33.1 of the first outer panel 23 and the first outer locking tab 33 (e.g., with half in the outer panel 23 and half in the proximal portion 33.1 arranged symmetrically with respect to the transverse fold line 31). In addition, the engagement opening 48 extends in the proximal portion 34.1 of the second outer panel 25 and the second outer locking tab 34 (e.g., with half in the outer panel 25 and half in the proximal portion 34.1 arranged symmetrically with respect to the transverse fold line 32). Without departing from the present disclosure, any of the engagement features 37, 38, 47, 48 may be omitted, or may be otherwise shaped, arranged and / or constructed. For example, the engagement features may have any suitable shape. In another example, the covers 41, 42 may be omitted so that the engagement features 37, 38 are openings in the outer panels 23, 25. Further, at least partially removable panels (not shown) (e.g. similar to cover panels 41 , 42 ) may be included in the first blank 1 and may be removed by tearing along weakening lines (not shown) (e.g. similar to weakening lines 39 , 40 ) to form engagement openings 47 , 48 .

[0034] When the outer structural member 49 ( Figure 4-7B), the distal sections 33.2, 34.2 of the outer locking tabs 33, 34 may be folded and fixed (e.g., adhesively bonded) to the inner sides of the respective proximal sections 33.1, 34.1 of the outer locking tabs 33, 34. Further, the outer proximal sections 33.1, 34.1 may be folded on the inner sides of the respective outer panels 23, 25, and the distal sections 33.2, 34.2 may be fixed (e.g., adhesively bonded) to the inner sides of the outer panels 23, 25. Accordingly, the distal sections 33.2, 34.2 may be fixed between the respective proximal sections 33.1, 34.1 and the respective outer panels 23, 25. Alternatively, the proximal sections 33.3, 34.1 may be disposed between the respective outer panels 23, 25 and the respective distal sections 33.2, 34.2 and fixed to the outer panels 23, 25. In the embodiment shown, the folded outer locking tabs 33, 34 may form second or outer locking edges 50, 51 along respective transverse fold lines 35, 36 and are positioned between the engagement means 37, 38 and the respective transverse fold lines 31, 32 ( Figure 4 and 5B ).like Figure 4-7B As shown, when the outer locking tabs 33, 34 are folded over the inner sides of the outer side panels 23, 25, the engagement openings 47, 48 are formed as corresponding engagement recesses or cutouts 53, 54 in the outer structure 49. In some embodiments, the engagement recesses 53, 54 may have a semi-elliptical shape and may extend along the lower edge of the outer side panels 23, 25. In some exemplary embodiments, the outer locking tabs 33, 34 may be folded and glued to the corresponding outer side panels 23, 25 (e.g., by a packaging manufacturer) and then stored and / or transported (e.g., to a packaging machine) in a flat glued blank configuration (not shown), such as in a stack with other similar or identical blanks and / or with the first blank 1.

[0035] like Figure 4-7BAs shown, the erected outer structure 49 can be formed from a flat glued blank (e.g., by a folder-gluer system, a packaging machine, etc.) by folding the outer panels 23, 25 along transverse fold lines 22.1, 22.3 to extend downwardly from the top panel 22, folding the outer end flaps 27, 30 and 28, 29 along respective longitudinal fold lines 23.1, 25.2 and 23.2, 25.1 onto respective ends of the outer structure 49, and folding the outer end panels 26, 24 along respective longitudinal fold lines 22.4, 22.2 onto respective ends of the outer structure 49. In the embodiment shown, the outer end flaps 27, 28, 29, 30 can be folded to extend perpendicularly to the outer panels 23, 25 between the outer panels 23, 25. In some embodiments, the first outer end panel 24 may be stacked and may be fixed (e.g., adhered) to the outer end wing panels 28, 29 to form a first outer end wall, and the second outer end panel 26 may be stacked and may be fixed (e.g., adhered) to the outer end wing panels 27, 30 to form a second outer end wall. Figure 4-7B As shown, the top panel 22, outer panels 23, 24, 25, 26 and outer end flaps 27, 28, 29, 30 can extend at least partially around the second interior of the outer structure 49, wherein the inner structure 17 is at least partially received in the second interior of the outer structure 49 when the carton 55 is in its closed configuration. In the illustrated embodiment, the erected outer structure 49 can have a second or outer opening 52, and the inner structure 17 can be moved into or out of the second interior of the outer structure 49 through the second opening when the locking tabs are disengaged from each other, as described in more detail below. Figure 4 and Figure 5B As shown, the second locking edges 50, 51 may face away from the outer opening 52 and toward the top panel 22, and may be spaced apart from the outer opening 52 and the top panel 22. The outer structure 49 may be formed in other ways without departing from the present disclosure.

[0036] Figure 5A and 5B The structures 17, 49 are shown in a separated or open configuration (e.g., such that the first opening 18 of the inner structure 17 can be used to load items into the inner structure 17 and / or remove items from the inner structure 17). In the illustrated embodiment, the second opening 52 of the outer structure 49 is aligned with the first opening 18 of the inner structure 17 in preparation for assembling the carton 55 into its closed configuration ( Figure 6-7B ). In some embodiments, Figure 5B , 67B show in phantom the interior or other hidden aspects of the structures 17, 49. When the outer structure 49 is moved onto the inner structure 17 to assemble the carton 55 into its closed configuration, the second locking edges 50, 51 of the outer structure 49 are moved past the first locking edges 19, 20 of the inner structure so that the second locking edges 50, 51 are arranged below the first locking edges 19, 20 ( Figure 6 and Figure 7B ).like Figure 6 and Figure 7B As shown, when the carton 55 is in the closed configuration, the inner locking edges 19, 20 face away from and are spaced apart from the top panel 22 of the outer structure 49, and the outer locking edges 50, 51 face away from and are spaced apart from the bottom panel 2 of the inner structure 17. In some embodiments, the carton 55 can be assembled by moving the outer structure 49 onto the inner structure 17, moving the inner structure 17 into the outer structure 49, or moving the two structures 17, 49 together.

[0037] In the illustrated embodiment, the carton 55 can be locked in its closed configuration (e.g., due to the positioning of the second locking edges 50, 51 below the first locking edges 19, 20). For example, the second locking edges 50, 51 can face the first locking edges 19, 20, whereby attempting to move the structures 17, 49 relative to each other can result in the first locking edges 19, 20 and the corresponding outer locking edges 50, 51 engaging (e.g., contacting, abutting, interacting, etc.). In some embodiments, the abutment of the first locking edges 19, 20 against the corresponding second locking edges 50, 51 can limit or prevent relative movement between the structures 17, 49 to limit or prevent undesirable withdrawal of the inner structure 17 from the opening 52 of the outer structure 49. Therefore, in some embodiments, the inner locking tabs 9, 10 can engage the corresponding outer locking tabs 33, 34 (e.g., along the corresponding locking edges 19, 20 and 50, 51) so that the locking tabs 9, 10, 33, 34 cooperate to limit the movement of the inner structure 17 relative to the outer structure 49. The carton 55 may be formed and / or erected in other ways without departing from the present disclosure.

[0038] In an exemplary embodiment, the carton 55 can be manipulated to overcome the locking engagement of the inner locking tabs 9, 10 with the outer locking tabs 33, 34 so that the inner structure 17 can be moved from a first (e.g., closed) position (e.g., wherein the inner structure 17 is partially or completely contained within the outer structure 49, wherein the first opening 18 is covered by the outer structure 49) to a second (e.g., open) position (e.g., wherein the inner structure 17 is removed from the outer structure 17 through the opening 52, such that the first opening 18 can be accessed). For example, the covers 41, 42 of the engagement devices 37, 38 are separated from the respective outer side panels 23, 25 along the respective weakening lines 39, 40 (e.g., by grasping the covers 41, 42 at the access openings 43, 44). In some embodiments, removing the covers 41, 42 can provide first opening protection for the carton 55. In the illustrated embodiment, removal of the covers 41, 42 may form engagement holes (not shown) in the respective outer side panels 23, 25, so that the inner locking tabs 9, 10 of the inner structure 17 may be accessed through the opening formed by the respective engagement means 37, 38 in the outer structure 49. In the illustrated embodiment, a user may grasp the engagement holes formed by the engagement means 37, 38 (e.g., with the thumb and index finger of one hand) and press the inner locking tabs 9, 10 inwardly, thereby causing the first locking edges 19, 20 to move inwardly and away from (displaced from) the second locking edges 50, 51. When the inner locking tabs 9, 10 of the inner structure 17 are pressed inwardly in this manner, the second locking edges 50, 51 of the outer structure 49 are no longer blocked by the first locking edge of the inner structure 17.

[0039] When the inner locking tabs 9, 10 are engaged through the opening formed by the engagement means 37, 38, the user can grasp the inner structure 17 through the engagement recesses 53, 54 in the outer structure 17 (e.g., with the thumb and index finger of the other hand). The user can use both hands to pull the structures 17, 49 apart while pressing the inner locking tabs 9, 10 inwardly through the opening formed in the outer structure 49 by the engagement means 37, 38 and pulling the inner structure 17 through the engagement recesses 53, 54 in the outer structure 49. In some embodiments, it is difficult or impossible for a child to perform the unlocking and opening operation (e.g., due to hand size and / or dexterity limitations).

[0040] In the embodiment shown, once the structural members 17, 49 are separated (e.g., similar to Figure 5A and 5B As shown in the figure, the opening 18 of the inner structure 17 can be accessed to remove or add items. The carton 55 can be reclosed and / or reopened according to the assembly and unlocking / separation operations described above. In some embodiments, once the inner structure 17 is fully inserted into the outer structure 49, the reclosed carton 55 is again protected from unwanted opening (e.g., by a child) by the locking engagement of the inner locking tabs 9, 10 with the corresponding outer locking tabs 33, 34.

[0041] In some exemplary embodiments, the dimensions of the shortest distance between the engagement features 37, 38 and / or the engagement recesses 53, 54 along the outside of the carton 55 in the closed configuration of the carton 55 are designed to make it difficult or impossible for a child (e.g., under three years old, under four years old, under five years old, under six years old, etc.) to unlock the carton 55, and when in the locked configuration, it is difficult or impossible to pull the outer structure 49 and the inner structure 17 apart. In some embodiments, the dimensioning is based on the average body measurements of children in the corresponding age groups in the European Union or North America (regardless of gender), depending on the area where the erected box is intended to be used. In some examples, the distance between the outsides of the second side wall can be about 50 mm to about 120 mm, about 70 mm to about 100 mm, about 60 mm to about 90 mm, about 80 mm to about 90 mm, or about 70 mm to about 80 mm. This can help ensure that a child's hand cannot engage all the engagement holes at the same time to unlock the folded carton, while an adult (e.g., having a larger hand) can reach the locking features to unlock and open the carton 55.

[0042] In the carton 55 according to the present invention, when the inner structure 17 moves into the outer structure 49, the inner locking tabs 9, 10 and the outer locking tabs 33, 34 form an interlock. This is because the inner locking edges 19, 20 can abut against the outer locking edges 50, 51, so that they prevent the inner structure 17 from being pulled out of the outer structure 49. Pulling the inner structure 17 out of the outer structure 49 may, for example, require releasing the interlock between the outer part and the inner part. To this end, the user can engage the engagement openings 45, 46 with the thumb and index finger of one hand and slightly compress the inner locking tabs 9, 10 so that the outer locking edges 50, 51 no longer block the path of the inner locking edges 19, 20. Using the thumb and index finger of the other hand, the user can grab a portion of the inner structure 17 (e.g., along or adjacent to the bottom plate 2) through the second engagement opening / recess 53, 54 and pull the inner structure 17 and the outer structure 49 apart. In doing so, the inner locking tabs 9, 10 slide over the thumb and index finger of the user that engage with the first engagement openings 45, 46 and slightly compress the first locking tabs 9, 10. By designing the size of the carton so that children cannot engage in the engagement openings 45, 46 in the manner described due to the relatively small size of their hands, it is possible to prevent or make it difficult for children to unlock. For example, unlocking may require a certain understanding of the function of the lock, for example, children under the age of six generally do not have such understanding. Thus, according to the present disclosure, children are prevented from unlocking the carton 55 and are protected from the associated dangers. In addition, the carton 55 is protected from accidental opening, which may occur on an everting carton that does not include a locking feature, for example, if the carton is lifted at the outer structure without supporting the inner structure so that the inner structure slides out of the outer structure without the locking feature.

[0043] In embodiments of the carton 55 according to the present disclosure, the cover panels 41, 42 can provide initial opening protection, which can prevent or resist partial compression of the inner locking tabs 9, 10 so that the inner locking tabs 9, 10 do not disengage from the outer locking tabs 33, 34. For example, only by tearing along the weakening lines 39, 40 to at least partially remove the cover panels 41, 42 and form the engagement openings 45, 46, it is possible to compress the inner locking tabs 9, 10 to open the carton 55 for the first time. In some exemplary embodiments, the cover panels 41, 42 in the outer side panels 23, 25 of the outer structure 49 can be bonded to the inner structure 17 (e.g., the corresponding inner locking tabs 9, 10), which can also help resist or prevent the carton 55 from opening before the cover panels 41, 42 are separated from the outer side panels 23, 25. In addition, interested consumers are prevented from opening the package before purchase. For example, tearing the lines of weakness 39, 40 and / or otherwise tearing the carton 55 due to an attempt to force open the carton can provide an indication to a potential purchaser that the package has been entered or tampered with (e.g., where product may have been removed from the carton 55 and / or other objects may have been inserted into the carton 55).

[0044] In some exemplary embodiments, the carton 55 may have tolerances during its formation, for example, when the packager forms the structural members 17, 49 from the flat glued blanks 1, 21. These tolerances may cause slight variations in the relative sizes of the structural members 17, 49. However, the two-layer thickness of the inner locking tabs 9, 10 and the outer locking tabs 33, 34 (e.g., their respective proximal and distal portions are in overlapping relationship) can help compensate for such tolerances and variations that may occur during the production of the blanks and the erection and bonding of the inner and / or outer structural members. This can also facilitate secure locking of the carton despite the tolerances.

[0045] The blank according to any embodiment of the present disclosure can be formed, for example, by coated paperboard and similar materials. For example, the inside and / or outside of the blank can be coated with a clay coating. Then, the clay coating can be printed with products, advertisements, price codes and other information or images. Then, the blank can be coated with a varnish to protect any information printed on the blank. The blank can also be coated with, for example, a moisture barrier on one or both sides of the blank. According to the above-mentioned embodiment, the blank can be composed of paperboard with a certain thickness (caliper), making it heavier and harder than ordinary paper. The blank can also be composed of other materials, such as paperboard, cardboard or any other material with a characteristic suitable for making the carton at least roughly as described herein work. The blank can also be laminated or coated with one or more sheet materials at a selected board or board section.

[0046] According to exemplary embodiments of the present disclosure, a fold line may be any substantially linear weakening form (but not necessarily straight) that facilitates folding along it. More specifically, but not to narrow the scope of the present disclosure, a fold line includes: a score line, such as a line formed with a blunt scoring knife, which produces a depressed or recessed portion in the material along the desired weakened line; a cut extending partially into the material along the desired weakened line, and / or a series of cuts extending partially into the material and / or completely through the material along the desired weakened line; and various combinations of these features. Where a cut is used to create a fold line, the cut is typically not so large as to cause a reasonable user to mistakenly perceive the fold line as a tear line.

[0047] As an example, a tear line may include: a slit extending partially into the material along a desired line of weakness, and / or a series of spaced apart slits extending partially into the material along a desired line of weakness and / or extending completely through the material, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced apart slits extending completely through the material, wherein adjacent slits are slightly spaced apart so that a notch (e.g., a small piece of slightly bridged material) is defined between adjacent slits, typically used to temporarily connect the materials on the tear line. During tearing along the tear line, the notch breaks. The notch typically accounts for a relatively small percentage of the tear line, and alternatively the notch may be omitted or torn from the tear line, making the tear line a continuous cut line. That is, it is also within the scope of the present disclosure to replace each tear line with a continuous slit, etc. For example, without departing from the present disclosure, the cut line may be a continuous slit or may be wider than a slit.

[0048] The above embodiments may be described as one or more panels being bonded together by glue during erection of the carton embodiment. The term "glue" is intended to encompass various adhesives commonly used to secure carton panels in place.

[0049] The above description of the present disclosure shows and describes various embodiments. Since various changes can be made to the above-mentioned structural parts without departing from the scope of the present disclosure, it is intended that all content contained in the above description or shown in the accompanying drawings be interpreted as illustrative rather than restrictive. In addition, the scope of the present disclosure covers various modifications, combinations, changes, etc. of the above-mentioned embodiments. In addition, the present disclosure only shows and describes selected embodiments, but various other combinations, modifications, and environments are within the scope of the present disclosure expressed herein, commensurate with the above-mentioned teachings, and / or within the scope of the technology or knowledge of the relevant field. In addition, certain features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure.

Claims

1. A carton, comprising: an inner structure comprising a plurality of inner panels extending at least partially around a first interior portion of the inner structure, wherein the inner structure comprises an inner locking tab foldably connected to at least one inner panel of the plurality of inner panels; and an outer structure comprising a plurality of outer panels extending at least partially around a second interior portion of the outer structure, the inner structure being at least partially housed within the second interior portion of the outer structure, wherein the outer structure comprises an outer locking tab foldably connected to at least one of the plurality of outer panels, and the inner locking tab and the outer locking tab cooperate to restrict movement between the inner structure and the outer structure; and an engagement feature extending in the at least one outer panel of the outer structure, the engagement feature comprising a cover plate that is at least partially separable from the at least one outer panel to form an engagement aperture in the at least one outer panel; The inner locking piece of the inner structure extends along the engagement feature in the outer structure, so that the inner locking piece can be engaged through the engagement hole when the cover plate is at least partially removed to move the inner locking piece relative to the outer locking piece, thereby facilitating the inner structure and the outer structure to move from a closed configuration to an open configuration relative to each other.

2. The carton according to claim 1, wherein: The cover panel is at least partially separable from the at least one outer panel along a weakening line.

3. The carton of claim 1 further comprising an engagement recess extending in the outer structure, wherein: At least a portion of the inner structure extends along at least a portion of the engagement recess in the outer structure such that the inner structure can be grasped by at least the engagement recess in the outer structure.

4. The carton according to claim 3, wherein: The engagement recess extends along at least a portion of the at least one outer panel and the outer locking tab.

5. The carton according to claim 3, wherein: The plurality of outer panels of the outer structure include a top panel foldably connected to at least one of the outer panels, the outer structure includes an opening opposite the top panel, the inner structure is selectively movable through the opening, and wherein the engagement feature is closer to the top panel than to the opening, and the engagement recess extends along the opening.

6. The carton according to claim 1, wherein: The inner locking tab is a first inner locking tab, the at least one inner panel includes a first inner panel, the outer locking tab is a first outer locking tab, the at least one outer panel includes a first outer panel, and the engagement feature is a first engagement feature, wherein the inner structure further includes a second locking tab foldably connected to a second inner panel of the plurality of inner panels, the outer structure further includes a second outer locking tab foldably connected to a second outer panel of the plurality of outer panels and a second engagement feature extending in the second outer panel, and the second inner locking tab and the second outer locking tab cooperate to limit movement between the inner structure and the outer structure.

7. The carton according to claim 6, wherein: The cover plate is a first cover plate, the engagement hole is a first engagement hole, wherein the second engagement feature includes a second cover plate that can be at least partially separated from the second outer plate to form a second engagement hole in the second outer plate, and wherein the second inner locking piece of the inner structure extends along the second engagement feature in the outer structure, so that the second inner locking piece can be engaged through the second engagement hole when the second cover plate is at least partially removed to move the second inner locking piece relative to the second outer locking piece.

8. The carton according to claim 6, wherein: Each of the first inner locking tab and the second inner locking tab has a first locking edge, and each of the first outer locking tab and the second outer locking tab has a second locking edge facing the corresponding first locking edge for limiting movement between the inner structure and the outer structure.

9. The carton of claim 1, wherein: the inner locking tab comprising an inner proximal section foldably connected to the at least one inner panel and an inner distal section foldably connected to the inner proximal section along a first fold line, the inner distal section folded along the first fold line into face-to-face contact with the inner proximal section, at least one of the inner proximal section and the inner distal section being attached to the at least one inner panel; the outer locking tab comprising an outer proximal section foldably connected to the at least one outer panel and an outer distal section foldably connected to the outer proximal section along a second fold line, the outer distal section folded along the second fold line into face-to-face contact with the outer proximal section, at least one of the outer proximal section and the outer distal section being attached to the at least one outer panel; and The first fold line of the inner locking tab and the second fold line of the outer locking tab engage with each other to resist movement between the inner structure and the outer structure.

10. The carton according to claim 9, wherein: The inner structure includes a first opening, the inner proximal section is foldably connected to the at least one inner panel along the first opening, the outer structure includes a second opening opposite the first opening of the inner structure, and the outer proximal section is foldably connected to the at least one outer panel along the second opening.

11. The carton of claim 1, wherein: The plurality of outer panels of the outer structure include a top panel foldably connected to at least one of the outer panels, the outer structure includes an opening opposite the top panel, the inner structure is movable through the opening, and wherein the engagement feature is closer to the top panel than to the opening.

12. The carton of claim 1, wherein: The inner structure includes an opening for inserting and / or removing items from the first interior, the opening in the inner structure being at least partially surrounded by the outer structure.

13. A combination of a first blank and a second blank for cooperation to at least partially form a carton, wherein: The first blank comprises a plurality of inner panels and an inner locking tab foldably connected to at least one inner panel of the plurality of inner panels, wherein the first blank is used to form an inner structural member; the second blank comprising a plurality of outer panels and an outer locking tab foldably connected to at least one of the plurality of outer panels, wherein the second blank is used to form an outer structure to at least partially accommodate the inner structure formed by the first blank when the carton is formed from the first blank and the second blank, and wherein the inner locking tab and the outer locking tab are configured to selectively cooperate to restrict movement between the inner structure formed by the first blank and the outer structure formed by the second blank when the carton is formed from the first blank and the second blank; and an engagement feature extending in the at least one outer panel of the second blank, the engagement feature including a cover panel that can be at least partially separated from the at least one outer panel to form an engagement hole in the at least one outer panel, wherein the engagement feature is used to facilitate engagement of the inner locking tab to move the inner locking tab relative to the outer locking tab when the carton is formed from the first blank and the second blank.

14. The combination according to claim 13, wherein: The cover panel is at least partially separable from the at least one outer panel along a weakening line.

15. The combination according to claim 13 further includes a joining opening extending in the second blank, which is used to form a joining recess when the outer structure is formed by the second blank, so as to facilitate grasping the inner structure formed by the first blank when the carton is formed by the first blank and the second blank.

16. The combination according to claim 15, wherein: The outer locking tab is foldably connected to the at least one outer panel along a fold line, and the engagement opening extends in at least a portion of the at least one outer panel and the outer locking tab along the fold line.

17. The combination according to claim 15, wherein: The plurality of outer panels of the second blank include a top panel that is opposite the outer locking tab and is foldably connected to the at least one outer panel, and wherein the engagement feature is closer to the top panel than to the outer locking tab, and the engagement opening extends in the at least one outer panel and the outer locking tab.

18. The combination according to claim 13, wherein: The inner locking tab is a first inner locking tab, the at least one inner panel includes a first inner panel, the outer locking tab is a first outer locking tab, the at least one outer panel includes a first outer panel, and the engagement feature is a first engagement feature, wherein the first blank further includes a second locking tab foldably connected to a second inner panel among the plurality of inner panels, the second blank further includes a second outer locking tab foldably connected to a second outer panel among the plurality of outer panels and a second engagement feature extending in the second outer panel, and the second inner locking tab and the second outer locking tab are configured to selectively cooperate to limit movement between the inner structure formed by the first blank and the outer structure formed by the second blank when the carton is formed by the first blank and the second blank.

19. The combination according to claim 18, wherein: The cover plate is a first cover plate and the engagement hole is a first engagement hole, wherein the second engagement feature comprises a second cover plate that is at least partially separable from the second outer panel to form a second engagement hole in the second outer panel.

20. The combination of claim 13, wherein: the inner locking tab comprising an inner proximal section foldably connected to the at least one inner panel and an inner distal section foldably connected to the inner proximal section along a first fold line, the inner distal section being adapted to be folded along the first fold line into face-to-face contact with the inner proximal section when the inner structure is formed from the first blank; the outer locking tab comprising an outer proximal section foldably connected to the at least one outer panel and an outer distal section foldably connected to the outer proximal section along a second fold line, the outer distal section being adapted to be folded along the second fold line into face-to-face contact with the outer proximal section when the outer structure is formed from the second blank; and When the carton is formed from the first and second blanks, the first fold line of the inner locking tab and the second fold line of the outer locking tab are configured to engage each other to resist movement between the inner structure formed from the first blank and the outer structure formed from the second blank.

21. The combination according to claim 13, wherein: The plurality of outer panels of the outer structure include a top panel opposite the outer locking tab and foldably connected to the at least one outer panel, and wherein the engagement feature is closer to the top panel than to the outer locking tab.

22. A method of forming a carton, the method comprising: obtaining a first blank comprising a plurality of inner panels and an inner locking tab foldably connected to at least one inner panel of the plurality of inner panels; forming an inner structure from the first blank by folding the plurality of inner panels at least partially around a first inner portion of the inner structure; obtaining a second blank comprising a plurality of exterior panels and an exterior locking tab foldably connected to at least one exterior panel of the plurality of exterior panels, an engagement feature extending in the at least one exterior panel, the engagement feature comprising a cover panel that is at least partially separable from the at least one exterior panel to form an engagement aperture in the at least one exterior panel; forming an outer structure from the second blank by folding the plurality of outer panels at least partially around a second inner portion of the outer structure; moving at least one of the inner structure and the outer structure relative to the other to assemble the carton by at least partially housing the inner structure within the second interior of the outer structure, wherein the inner locking tab and the outer locking tab cooperate to restrict movement between the inner structure and the outer structure; wherein the inner locking tab of the inner structure extends along the engagement feature in the outer structure such that the inner locking tab can be engaged through the engagement hole when the cover plate is at least partially removed so that the inner locking tab moves relative to the outer locking tab, thereby facilitating movement of the inner structure and the outer structure relative to each other from a closed configuration to an open configuration.

23. The method according to claim 22, wherein: The cover panel is at least partially separable from the at least one outer panel along a weakening line.

24. The method of claim 22, further comprising an engagement opening extending along at least a portion of the at least one outer panel and the outer locking tab in the second blank, wherein Forming the outer structure includes folding the outer locking tab into an overlapping relationship with the at least one outer panel, which forms the engagement opening into an engagement recess of the outer structure to facilitate grasping of the inner structure.

25. The method according to claim 24, wherein: The plurality of outer panels of the second blank include a top panel opposite the outer locking tab and foldably connected to the at least one outer panel, wherein the engagement feature is closer to the top panel in the second blank than to the outer locking tab.

26. The method of claim 22, wherein: The inner locking tab comprises an inner proximal section foldably connected to the at least one inner panel and an inner distal section foldably connected to the inner proximal section along a first fold line, wherein forming the inner structural member comprises: folding the inner distal section along the first fold line into face-to-face contact with the inner proximal section, folding the inner locking tab into an overlying relationship with the at least one inner panel, and attaching at least one of the inner proximal section and the inner distal section to the at least one inner panel; The outer locking tab comprises an outer proximal section foldably connected to the at least one outer panel and an outer distal section foldably connected to the outer proximal section along a second fold line, wherein forming the outer structural member comprises: folding the outer distal section along the second fold line into face-to-face contact with the outer proximal section, folding the outer locking tab into an overlapping relationship with the at least one outer panel, and attaching at least one of the outer proximal section and the outer distal section to the at least one outer panel; The first fold line of the inner locking tab and the second fold line of the outer locking tab engage with each other to resist movement between the inner structure and the outer structure.

27. The method according to claim 26, wherein: The inner structure includes a first opening, the inner proximal section is foldably connected to the at least one inner panel along the first opening, the outer structure includes a second opening opposite the first opening of the inner structure, and the outer proximal section is foldably connected to the at least one outer panel along the second opening.

28. The method of claim 22, wherein: The inner structure includes an opening for inserting and / or removing items from the first interior, the opening in the inner structure being at least partially surrounded by the outer structure.

Images