Carton with a locking mechanism

Abstract

A carton comprising an inner structure having a plurality of inner panels that at least partially extend around a first interior, and an inner locking tab foldably connected to at least one of the inner panels. The outer structure comprises a plurality of outer panels that at least partially extend around a second interior. The outer structure comprises an outer locking tab foldably connected to at least one of the outer panels, and the inner locking tab and the outer locking tab cooperate to limit movement between the inner structure and the outer structure. The carton also comprises an engagement feature having a cover panel that is at least partially separable from at least one of the outer panels. The inner locking tab of the inner structure extends along the engagement feature of the outer structure and, when the cover panel is at least partially removed, the inner locking tab can be engaged to facilitate movement of the inner structure and the outer structure relative to each other.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of German Utility Model Application No. 202022103827.9, filed Jul. 7, 2022.

[0002] [Incorporation by Reference] The disclosure of German Utility Model Application No. 202022103827.9, filed Jul. 7, 2022, is hereby incorporated by reference in its entirety for all purposes as if fully set forth herein.

[0003] [Background of the Disclosure] The present disclosure generally relates to a carton / box for holding one or more products. More specifically, the present disclosure relates to a carton having an inner structure at least partially received within an outer structure and a locking mechanism for selectively restricting and / or preventing relative movement between the structures of the carton.

[0004] Cartons / boxes having a locking mechanism can be used for a wide variety of different products such as dishwashing detergents, pharmaceuticals, household detergents, candles, cosmetics, tobacco, and other products that should be kept out of reach of children because children may put the products in their mouths, swallow them, or use them in other dangerous ways. For example, there may be cases where a particular product is desired to be out of reach of infants, toddlers, kindergarten children, and pre - school age children, i.e., children up to about 6 years old, for example.

Summary of the Invention

Means for Solving the Problems

[0005] Generally, one aspect of the present disclosure relates to a carton comprising an inner structure having a plurality of inner panels that at least partially extend around a first interior of the inner structure. The inner structure can comprise an inner locking tab foldably connected to at least one of the plurality of inner panels. The carton can further comprise an outer structure having a plurality of outer panels that at least partially extend around a second interior of the outer structure. The inner structure can be at least partially received within the second interior of the outer structure. The outer structure can comprise 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 can cooperate to limit movement between the inner structure and the outer structure. The carton can also comprise an engagement feature extending on at least one outer panel of the outer structure. The engagement feature can comprise a cover panel that is at least partially separable from the at least one outer panel to form an engagement hole in the at least one outer panel. The inner locking tab of the inner structure extends along the engagement feature of the outer structure, and when the cover panel is at least partially removed, the inner locking tab can be engaged through the engagement hole to move the inner locking tab relative to the outer locking tab, facilitating movement of the inner structure and the outer structure from a closed configuration relative to each other to an open configuration.

[0006] In another aspect, the present disclosure generally relates to a combination of a first blank and a second blank for cooperatively forming a carton at least in part. The first blank can 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 can be for forming an inner structure. The second blank can 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 can be for forming an outer structure for at least partially receiving the inner structure formed from the first blank when the carton is formed from the first and second blanks, and the inner and outer locking tabs can be configured to selectively cooperate to restrict movement between the inner structure formed from the first blank and the outer structure formed from the second blank when the carton is formed from the first and second blanks. The engagement feature extends within at least one outer panel of the second blank and includes a cover panel that is at least partially separable from the at least one outer panel to form an engagement hole within the at least one outer panel. The engagement feature can facilitate engagement of the inner locking tab with respect to the outer locking tab when the carton is formed from the first and second blanks.

[0007] In another aspect, the present disclosure generally relates to a method of forming a carton. The method can include obtaining a first blank comprising a plurality of inner panels and an inner locking tab foldably connected to at least one of the plurality of inner panels, and forming an inner structure from the first blank by at least partially folding the plurality of inner panels around a first interior of the inner structure. The method can further include 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 can extend within at least one of the outer panels and can comprise a cover panel at least partially separable from the at least one outer panel to form an engagement hole within the at least one outer panel. The method can further include forming an outer structure from the second blank by at least partially folding the plurality of outer panels around a second interior of the outer structure, and assembling the carton with at least one of the inner structure and the outer structure moved relative to the other such that the inner structure is at least partially received within 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 can extend along an engagement feature of the outer structure such that when the cover panel is at least partially removed, the inner locking tab is engaged through the engagement hole to move the inner locking tab relative to the outer locking tab and facilitate movement of the inner structure and the outer structure from a closed configuration to an open configuration relative to each other.

[0008] Those skilled in the art will understand the above and other advantages and other advantages and benefits of various additional embodiments upon reading the following detailed description of the embodiments with reference to the drawings listed below.

[0009] By convention, the various features of the drawings described below are not necessarily drawn to scale. The dimensions of the various features and elements in the drawings may be enlarged or reduced to more clearly illustrate embodiments of the present disclosure.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 6

Figure 7A

Figure 7B

[0011] Corresponding parts are designated by corresponding reference numerals throughout the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0012] The present disclosure generally relates to structures, boxes, cartons, carriers, trays, etc. for holding one or more products or articles, such as those that should be kept out of reach of children (e.g., for safety reasons), and packages. The product(s) can be cleaning products such as dishwashing detergents, household cleaners, soaps, pharmaceuticals, cosmetics, candles, tobacco, objects that can pose a choking hazard, any other suitable product or material, or combinations thereof.

[0013] The structures according to the present disclosure can accommodate products or articles of any shape. As used herein, the terms "inner", "interior", "outer", "exterior", "lower", "bottom", "upper", and "top" refer to the orientation determined with respect to a fully assembled and upright structure and carton. As described herein, the structure can be formed from a blank by being adhered with a plurality of panels, parts, tabs, and / or flaps, which can be designated in terms of each other, e.g., "first", "second", "third", etc. in continuous or discontinuous reference, without departing from the present disclosure herein.

[0014] According to FIG. 1, the first blank 1 is used to form an inner portion or inner structure 17 (FIGS. 2 and 5A-7B) having a first opening 18 according to an exemplary embodiment of the present disclosure. The inner structure 17 can be a container used to hold one or more products (not shown). FIG. 3 shows a second blank 21 used to form an outer portion or outer structure 49 (e.g., cover 49) (FIGS. 4-7B) having a second opening 52 according to an exemplary embodiment of the present disclosure. In an embodiment, the inner (internal) structure 17 and the outer (external) structure 49 cooperate to form a carton 55 (FIGS. 6 and 7), and the outer structure 49 extends at least partially around the inner structure 17, and the inner structure is selectively movable within the outer structure between a closed configuration or a first position (FIGS. 6-7B) and an open configuration or a second position (FIGS. 5A and 5B), as will be described in more detail below. In the illustrated embodiment, the inner structure 17 and the outer structure 49 can include locking and stopping features for cooperating to resist and / or limit the movement of the inner structure 17 relative to the outer structure 49, as will be described in more detail below. In an exemplary embodiment, the blanks 1, 21 can be made of cardboard, paperboard, corrugated paperboard, or other suitable materials.

[0015] As shown in FIG. 1, the first blank 1 has a longitudinal direction L1 and a transverse direction L2. In the illustrated embodiment, the first blank 1 can have a bottom wall or panel 2 that is foldably connected to four first side walls or inner panels 3, 4, 5, 6 along respective fold lines 2.1, 2.2, 2.3, 2.4 at its edges. For example, the bottom panel 2 can be foldably connected to the respective first inner side panel 3 and the second inner side panel 5 along respective transverse fold lines 2.1, 2.3, and the bottom panel 2 can be foldably connected to the respective first inner end panel 4 and the second inner end panel 6 along respective longitudinal fold lines 2.2, 2.4. As shown in FIG. 1, at least the bottom panel 2 and the inner end panels 4, 6 can be rectangular. Any of the bottom panel 2 and / or the inner panels 3, 4, 5, 6 may be omitted or otherwise shaped, arranged, and / or configured without departing from the present disclosure.

[0016] In the illustrated embodiment, the inner side panels 3, 5 can be foldably connected to respective first or inner locking tabs 9, 10 along respective transverse fold lines 7, 8 at opposing edges of the inner side panels 3, 5. As shown in FIG. 1, each of the inner locking tabs 9, 10 can include respective proximal portions 9.1, 10.1 (e.g., inner or first proximal portions) and respective distal portions 9.2, 10.2 (e.g., inner or first distal portions). In an embodiment, the proximal portions 9.1, 10.1 are foldably connected (e.g., directly foldably connected) to the respective inner side panels 3, 5 along respective transverse fold lines 7, 8 and are foldably connected to the respective distal portions 9.2, 10.2 along respective transverse fold lines 11, 12. In the illustrated embodiment, the proximal portions 9.1, 10.1 can be trapezoidal (e.g., such that the fold lines 11, 12 are shorter than the fold lines 7, 8 and the free edges of the proximal portions 9.1, 10.1 are angled), and the distal portions 9.2, 10.2 can be rectangular. Alternatively, the portions 9.1, 9.2, 10.1, 10.2 can have any suitable shape.

[0017] As shown in FIG. 1, the first inner side panel 3 is foldably connected to the respective inner dust flaps or inner side end flaps 13, 14 along the respective longitudinal fold lines 3.1, 3.3. Similarly, the second inner side panel 5 is foldably connected to the respective inner dust flaps or inner side end flaps 15, 16 along the respective longitudinal fold lines 5.1, 5.3. In an embodiment, the longitudinal fold lines 3.1, 3.3 and 5.1, 5.3 can extend along the rectangular portions of the respective inner side panels 3, 5. Further, the diagonal free edges 3.2, 5.2 of the respective inner side panels 3, 5 can extend from the respective longitudinal fold lines 3.1, 3.3 and 5.1, 5.3 to the respective ends of the respective transverse fold lines 7, 8 to at least partially define the respective trapezoidal portions of the respective inner side panels 3, 5. In the illustrated embodiment, each of the free edges of the proximal portions 9.1, 10.1 of the inner locking tabs 9, 10 can extend as an extension of the respective diagonal free edges 3.2, 5.2 of the inner side panels 3, 5. Any of the inner locking tabs 9, 10, the inner side end flaps 13, 14, 15, 16, and / or the inner side panels 3, 5 may be omitted or otherwise shaped, arranged, and / or configured without departing from the present disclosure.

[0018] The blank 1 can be of other shapes, arrangements, and / or configurations without departing from the present disclosure.

[0019] In a first processing step for forming the inner structure 17 (Figs. 2, 5A, and 5B) from the first blank 1, the distal portions 9.2, 10.2 of the inner locking tabs 9, 10 can be folded and fixed (e.g., adhesively joined) relative to the outside of the respective proximal portions 9.1, 10.1 of the inner locking tabs 9, 10, and the proximal portions 9.1, 10.1 can be folded and fixed (e.g., adhesively joined) relative to the outside of the respective inner side panels 3, 5. In an embodiment, the distal portions 9.2, 10.2 can be fixed between the respective proximal portions 9.1, 10.1 and the respective inner side panels 3, 5. Alternatively, the proximal portions 9.1, 10.1 can be disposed between the respective inner side panels 3, 5 and the respective distal portions 9.2, 10.2. In an exemplary embodiment, the locking tabs 9, 10 are folded (e.g., by a packaging manufacturer) and adhered to the respective inner side panels 3, 5 and then can be stored and / or transported (e.g., to a packer) in a flat adhered blank configuration (not shown), such as a stack with other similar or identical blanks.

[0020] As shown in FIGS. 2, 5A, and 5B, the assembled inner structure 17 is formed from a flat pasted blank (e.g., by a folder gluing system, a packer, etc.) by folding the inner side panels 3, 5 along the horizontal fold lines 2.1, 2.3 to extend upward from the bottom panel 2, folding the inner end flaps 13, 16, and 14, 15 over the respective ends of the inner structure 17 along the respective vertical fold lines 3.1, 5.3, and 3.3, 5.1, and folding the inner end panels 6, 4 over the respective ends of the inner structure 17 along the respective vertical fold lines 2.4, 2.2. In the illustrated embodiment, the inner end flaps 13, 14, 15, 16 can be folded to extend between the inner side panels 3, 5 perpendicular to the inner side panels 3, 5. In an embodiment, the first inner end panel 4 can overlap and be fixed (e.g., adhered) to the inner end flaps 14, 15 to form the first inner end wall, and the second inner end panel 6 can overlap and be fixed (e.g., adhered) to the inner end flaps 13, 16 to form the second inner end wall. As shown in FIGS. 2, 5A, and 5B, the bottom panel 2, the inner panels 3, 4, 5, 6, and the inner end flaps 13, 14, 15, 16 can at least partially extend around the first interior of the inner structure 17 to receive an article within the inner structure 17. In the illustrated embodiment, the assembled inner structure 17 can 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 a product into and removing a product from the inner structure 17). As shown in FIGS. 2, 5A, and 5B, the folded inner locking tabs 9, 10 form first or inner locking edges 19, 20 along the respective horizontal fold lines 11, 12. In the illustrated embodiment, the first locking edges 19, 20 can face away from the inner opening 18 and toward the bottom panel 2 and be spaced from the inner opening 18 and the bottom panel 2. The inner structure 17 can be formed in other ways without departing from the present disclosure.

[0021] As shown in FIG. 3, the second blank 21 for the outer portion / structure 49 has a longitudinal direction L1 and a transverse direction L2. In the illustrated embodiment, the second blank 21 can have an upper wall or panel 22 that 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 its edges. For example, the upper panel 22 can be foldably connected to the respective first outer side panel 23 and the second outer side panel 25 along respective transverse fold lines 22.1, 22.3, and the upper panel 22 can be foldably connected to the respective first outer end panel 24 and the second outer end panel 26 along respective longitudinal fold lines 22.2, 22.4. In an embodiment, each of the upper wall 22 and the outer panels 23, 24, 25, 26 can be rectangular. Any one of the upper panel 22 and / or the outer panels 23, 24, 25, 26 may be omitted without departing from the present disclosure, or may be shaped, arranged, and / or configured otherwise.

[0022] In the illustrated embodiment, the first outer side panel 23 can be foldably connected to respective outer dust flaps 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 respective outer dust flaps or outer side end flaps 29, 30 along respective longitudinal fold lines 25.1, 25.2. Any one of the outer side end flaps 27, 28, 29, 30 and / or the outer side panels 23, 25 may be omitted without departing from the present disclosure, or may be shaped, arranged, and / or configured otherwise.

[0023] As shown in FIG. 3, the outer side panels 23, 25 can be foldably connected to their respective second or outer locking tabs 33, 34 along their respective lateral fold lines 31, 32 at the opposing edges of the outer side panels 23, 25. In the illustrated embodiment, each of the outer locking tabs 33, 34 can include their respective proximal portions 33.1, 34.1 (e.g., outer or second proximal portions) and their respective distal portions 33.2, 34.2 (e.g., outer or second distal portions). In an embodiment, the proximal portions 33.1, 34.1 are foldably connected (e.g., directly foldably connected) to their respective outer side panels 23, 25 along their respective lateral fold lines 31, 32 and are foldably connected to their respective distal portions 33.2, 34.2 along respective lateral fold lines 35, 36 on the opposite sides of their respective lateral fold lines 31, 32. In an exemplary embodiment, each of the proximal portions 33.1, 34.1 can have two parts, with the first parts 33.11, 34.11 adjacent to their respective lateral fold lines 31, 32 and can be rectangular (e.g., defined by a free edge extending in the longitudinal direction L1). In an embodiment, the second parts 33.12, 34.12 are adjacent to their respective lateral fold lines 35, 36 and are trapezoidal (e.g., defined by an oblique free edge), and each of the second parts 33.12, 34.12 widens towards their respective first parts 33.11, 34.11. In an exemplary embodiment, the distal portions 33.2, 34.2 can be rectangular and can be foldably connected to the short edges of the proximal portions 33.21, 34.1 along the lateral fold lines 35, 36. Alternatively, the parts 33.1, 33.2, 34.1, 34.2 can have any suitable shape.

[0024] In the illustrated embodiment, the second blank 21 can include engagement devices or engagement features 37, 38 that extend into respective outer side panels 23, 25. As shown in FIG. 3, the engagement devices 37, 38 can be disposed closer to the upper panel 22 than respective outer locking tabs 33, 34 and can have an elliptical shape. In an embodiment, the engagement devices 37, 38 can include respective weakened lines 39, 40 (e.g., cut lines or tear lines) that at least partially define respective engagement covers or cover panels 41, 42. In an exemplary embodiment, the weakened lines 39, 40 can be formed by scribed lines offset from each other on the outer and inner surfaces of the outer side panels 23, 24. As shown in FIG. 3, the engagement devices 37, 38 can include respective access openings 43, 44 (e.g., having a lens shape) that extend along the edges of respective weakened lines 39, 40 (e.g., proximate to the upper panel 22). Alternatively, the access openings 43, 44 can be disposed along any portion of respective cover panels 41, 42 or can be omitted. In an embodiment, the covers 41, 42 can be removed by tearing along the weakened lines 39, 40 to form respective engagement holes 45, 46 (FIGS. 7A and 7B) in respective outer side panels 23, 25. In some embodiments, the engagement devices 37, 38 can include fold lines (not shown), and respective weakened lines 39, 40 extend from the ends of respective fold lines such that covers 41, 42 are partially removed from respective outer panels 23, 25 along respective weakened lines 39, 40 and are folded outwardly along respective fold lines (not shown).

[0025] As shown in FIG. 3, the second blank 21 can further include engagement openings 47, 48 (e.g., elliptical). In an embodiment, the opening 47 can extend into the first outer side panel 23 and the proximal portion 33.1 of the first outer locking tab 33 (e.g., half within the outer side panel 23 and half within the proximal portion 33.1 are symmetrically arranged with respect to the transverse fold line 31). Further, the engagement opening 48 extends into the second outer side panel 25 and the proximal portion 34.1 of the second outer locking tab 34 (e.g., half within the outer side panel 25 and half within the proximal portion 34.1 are symmetrically arranged with respect to the transverse fold line 32). Any of the engagement features 37, 38, 47, 48 may be omitted without departing from the present disclosure, or may be otherwise shaped, arranged, and / or configured. For example, the engagement features can have any suitable shape. In another example, the covers 41, 42 can be omitted such that the engagement features 37, 38 are openings within the outer side panels 23, 25. Further, at least partially removable panels (not shown) (e.g., similar to the cover panels 41, 42) may be included in the first blank 1 and removed by tearing along weakened lines (not shown) (e.g., similar to the weakened lines 39, 40) to form the engagement openings 47, 48.

[0026] In a first processing step for forming the outer structure 49 (Figs. 4 - 7B) from the second blank 21, the distal portions 33.2, 34.2 of the outer locking tabs 33, 34 can be folded and fixed (e.g., adhesively joined) to the inside of the respective proximal portions 33.1, 34.1 of the outer locking tabs 33, 34. Further, the outer portions 33.1, 34.1 can be folded against the inside of the respective outer side panels 23, 25, and the distal portions 33.2, 34.2 can be fixed (e.g., adhesively joined) to the inside of the outer side panels 23, 25. Thus, the distal portions 33.2, 34.2 can be fixed between the respective proximal portions 33.1, 34.1 and the respective outer side panels 23, 25. Alternatively, the proximal portions 33.1, 34.1 can be disposed between the respective outer side panels 23, 25 and the respective distal portions 33.2, 34.2 and fixed to the outer side panels 23, 25. In the illustrated embodiment, the folded outer locking tabs 33, 34 can form second or outer locking edges 50, 51 disposed between the engaging devices 37, 38 and the respective lateral fold lines 31, 32 along the respective lateral fold lines 35, 36 (Figs. 4 and 5B). As shown in Figs. 4 - 7B, the engaging openings 47, 48 are formed in the respective engaging recesses or notches 53, 54 within the outer structure 49 when the outer locking tabs 33, 34 are folded against the inside of the outer side panels 23, 25. In an embodiment, the engaging recesses 53, 54 can have a semi - elliptical shape and can extend along the lower edge of the outer side panels 23, 25. In an exemplary embodiment, the outer locking tabs 33, 34 are folded (e.g., by a packaging manufacturer), adhered to the respective outer side panels 23, 25, and then can be stored and / or (e.g., transported to a packer) in a flat, adhered blank configuration (not shown), such as a stack with other similar or identical blanks and / or the first blank 1.

[0027] As shown in FIGS. 4 to 7B, the upright outer structure 49 folds the outer side panels 23, 25 along the lateral fold lines 22.1, 22.3 and extends them downward from the upper panel 22, and folds the outer end flaps 27, 30 and 28, 29 over the respective ends of the outer structure 49 along the respective vertical fold lines 23.1, 25.2 and 23.2, 25.1, and folds the outer end panels 26, 24 over the respective ends of the outer structure 49 along the respective vertical fold lines 22.4, 22.2, so as to be formed from a flat pasted blank (e.g., by a folder gluing system, a packer, etc.). In the illustrated embodiment, the outer end flaps 27, 28, 29, 30 can be bent to extend perpendicularly to the outer side panels 23, 25 and between the outer side panels 23, 25. In an embodiment, the first outer end panel 24 can overlap the outer end flaps 28, 29 to form the first outer end wall and can be fixed (e.g., adhered) thereto, and the second outer end panel 26 can overlap the outer end flaps 27, 30 to form the second outer end wall and can be fixed (e.g., adhered) thereto. As shown in FIGS. 4 to 7B, the upper panel 22, the outer panels 23, 24, 25, 26, and the outer end flaps 27, 28, 29, 30 can at least partially extend around the second interior of the outer structure 49, and 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 assembled outer structure 49 can have a second or outer opening 52, and the inner structure 17 can be movable in and out of the second interior of the outer structure 49 through the second opening when the locking tabs are disengaged from each other, as will be described in more detail below. As shown in FIGS. 4 and 5B, the second locking edges 50, 51 can face away from the outer opening 52 and toward the upper panel 22 and can be spaced from the outer opening 52 and the upper panel 22. The outer structure 49 can be formed in other ways without departing from the present disclosure.

[0028] Figures 5A and 5B show structures 17, 49 in a separated or open configuration (e.g., such that the first opening 18 of the inner structure 17 is accessible for loading and / or removing articles 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 (Figs. 6 - 7B). In the embodiment, Figs. 5B, 6, and 7B show the interior or otherwise hidden sides of the structures 17, 49 in dashed lines. 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 move over the first locking edges 19, 20 of the inner structure such that the second locking edges 50, 51 are disposed below the first locking edges 19, 20 (Figs. 6 and 7B). As shown in Figs. 6 and 7B, when the carton 55 is in its closed configuration, the inner locking edges 19, 20 face away from and are spaced from the upper panel 22 of the outer structure 49, and the outer locking edges 50, 51 face away from and are spaced from the bottom panel 22 of the inner structure 17. In the embodiment, 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 both structures 17, 49 together.

[0029] In the illustrated embodiment, the carton 55 can be latched in its closed configuration (e.g., due to the position of the second latching edges 50, 51 below the first latching edges 19, 20). For example, the second latching edges 50, 51 can face the first latching edges 19, 20, i.e., by attempting to move the structures 17, 49 relative to each other, the first latching edges 19, 20 and the respective outer latching edges 50, 51 can be engaged (e.g., contacted, abutted, interacted, etc.). In an embodiment, the abutment of the first latching edges 19, 20 against the respective second latching edges 50, 51 can limit or prevent relative movement between the structures 17, 49 and limit or prevent unwanted extraction of the inner structure 17 from the opening 52 of the outer structure 49. Thus, in an embodiment, the inner latching tabs 9, 10 can engage the respective outer latching tabs 33, 34 (e.g., along the respective latching edges 19, 20 and 50, 51) such that the latching tabs 9, 10, 33, 34 cooperate to limit movement of the inner structure 17 relative to the outer structure 49. The carton 55 can be formed and / or assembled in other ways without departing from the present disclosure.

[0030] In an exemplary embodiment, the carton 55 can be operated to overcome the locking engagement of the inner locking tabs 9, 10 and the outer locking tabs 33, 34, such that the inner structure 17 moves from a first (e.g., closed) position (e.g., where the inner structure 17 is partially or fully received within the outer structure 49 and the first opening 18 is covered by the outer structure 49) to a second (e.g., open) position (e.g., where the inner structure 17 is removed from the outer structure 17 through the opening 52 and the first opening 18 is accessible). For example, the covers 41, 42 of the engagement devices 37, 38 are separated from their respective outer side panels 23, 25 along their respective weakened lines 39, 40 (e.g., by gripping the covers 41, 42 at the access openings 43, 44). In an embodiment, the removal of the covers 41, 42 may provide a first opening protection for the carton 55. In the illustrated embodiment, by removing the covers 41, 42, engagement holes (not shown) can be formed in their respective outer side panels 23, 25, such that the inner locking tabs 9, 10 of the inner structure 17 are accessible through the openings formed by their respective engagement devices 37, 38 of the outer structure 49. In the illustrated embodiment, the user can grip the engagement holes formed by the engagement devices 37, 38 (e.g., with the thumb and index finger of one hand) and push the inner locking tabs 9, 10 inward to move the first locking edges 19, 20 inward and away from the second locking edges 50, 51 (not aligned). When the inner locking tabs 9, 10 of the inner structure 17 are thus pushed inward, the second locking edges 50, 51 of the outer structure 49 are no longer blocked by the first locking edges of the inner structure 17.

[0031] While engaging the inner locking tabs 9, 10 through the openings formed by the engaging devices 37, 38, the user can grip the inner structure 17 through the engaging recesses 53, 54 of the outer structure 17 (e.g., with the thumb and index finger of the other hand). The user can pull apart the structures 17, 49 with both hands by pushing the inner locking tabs 9, 10 inward through the openings formed in the outer structure 49 by the engaging devices 37, 38 and pulling the inner structure 17 through the engaging recesses 53, 54 of the outer structure 49. In an embodiment, it is difficult or impossible for a child to perform the unlocking and opening operations (e.g., due to hand size and / or dexterity limitations).

[0032] In the illustrated embodiment, when the structures 17, 49 are separated (e.g., as shown in FIGS. 5A and 5B), the opening 18 of the inner structure 17 is accessible for removing or adding an article. The carton 55 can be re-closed and / or re-opened according to the assembly and unlocking / separation operations as described above. In an embodiment, the re-closed 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 respective outer locking tabs 33, 34 when the inner structure 17 is fully inserted within the outer structure 49.

[0033] In an exemplary embodiment, the shortest distance from each other of the engagement features 37, 38 and / or the engagement recesses 53, 54 along the outside of the carton 55 in the closed configuration is such that a child (e.g., up to 3 years old, up to 4 years old, up to 5 years old, up to 6 years old, etc.) has difficulty or is unable to unlock the carton 55, and it is difficult or impossible to pull apart the outer structure 49 and the inner structure 17 when in the locked configuration. In an embodiment, this sizing is based on the average body measurements of children in each age group, regardless of gender, in the EU, or in North America, depending on the area where the inverted box is intended. In an example, the distance between the outsides of the second side walls can be about 50 to about 120 mm, about 70 to about 100 mm, about 60 to about 90 mm, about 80 to about 90 mm, or about 70 to about 80 mm. This helps ensure that a child's hand cannot engage all the engagement holes simultaneously to unlock the folding carton, while an adult (e.g., having larger hands) can reach the locking mechanism to unlock and open the carton 55.

[0034] In carton 55 according to the present disclosure, the inner locking tabs 9, 10 and the outer locking tabs 33, 34 form an interlock when the inner structure 17 is moved into the outer structure 49. This is because the inner locking edges 19, 20 can abut against the outer locking edges 50, 51 to 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 requires, for example, the release of the interlock between the outer and inner portions. To do this, the user can use the thumb and index finger of one hand to engage the engagement openings 45, 46 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 grip a portion of the inner structure 17 (e.g., along or adjacent to the bottom panel 2) through the second engagement openings / recesses 53, 54 and pull the inner structure 17 and the outer structure 49 apart. At that time, the inner locking tabs 9, 10 slide past the thumb and index finger of the user engaging the first engagement openings 45, 46 and slightly compress the first locking tabs 9, 10. Unlocking by a child is prevented or made difficult by determining the size of the carton such that the child cannot engage the engagement openings 45, 46 as described above due to the relatively small size of the child's hand. Unlocking may require, for example, some understanding of the function of the latch, which is usually not yet present in children, for example, up to the age of 6 years. As a result, the child is prevented from unlocking the carton 55 according to the present invention and is protected from the associated risks. In addition, the carton 55 is protected from unintentional opening that can occur in a carton being turned inside out without a locking mechanism, for example, when the outer structure is lifted without supporting the inner structure and the inner structure slides out of the outer structure in the absence of a locking mechanism.

[0035] In an embodiment of the carton 55 according to the present disclosure, cover panels 41, 42 can be provided that prevent or inhibit partial compression of the inner locking tabs 9, 10 so that the inner locking tabs 9, 10 are not disengaged from the outer locking tabs 33, 34, providing initial opening protection. For example, it is possible to first open the carton 55 by compressing the inner locking tabs 9, 10 simply by tearing along the weakened lines 39, 40 to at least partially remove the cover panels 41, 42 to form the engagement openings 45, 46. In an exemplary embodiment, the cover panels 41, 42 within the outer side panels 23, 25 of the outer structure 49 can adhere to the inner structure 17 (e.g., the respective inner locking tabs 9, 10), which can further help resist or prevent the opening of the carton 55 until the cover panels 41, 42 are separated from the outer side panels 23, 25. Further, the package is prevented from being opened before a consumer of interest purchases it. For example, tearing of the weakened lines 39, 40 and / or other tearing of the carton 55 by an attempt to pry open the carton may provide an indication to a potential purchaser that the package has been accessed or tampered with (e.g., the product may have been removed from the carton 55 and / or other objects may have been inserted into the carton 55).

[0036] In an exemplary embodiment, the carton 55 may have tolerances in its formation, for example, when the structures 17, 49 are formed from flat glued blanks 1, 21 by a packager. These tolerances can result in small variations in the relative sizes of the structures 17, 49. However, the two layers of the thickness of the inner locking tabs 9, 10 and the outer locking tabs 33, 34 (e.g., when their respective proximal and distal portions are in an overlapping relationship) serve to compensate for such tolerances and variations that can occur during the manufacture of the blank and during the assembly and joining of the inner and / or outer structures. This is advantageous for securely locking the carton despite the tolerances.

[0037] Blanks according to any of the embodiments of the present disclosure can be formed from, for example, coated paperboard and similar materials. For example, the inner and / or outer sides of the blank can be coated with a clay coating. Then, products, advertisements, price codes, and other information or images can be printed on top of the clay coating. Next, the blank can be coated with varnish to protect any information printed on the blank. The blank may also be coated on one or both sides with, for example, a moisture barrier layer. According to the above-described embodiments, the blank may be composed of paperboard having a thickness such that it is heavier and more rigid than ordinary paper. The blank can also be composed of other materials such as thick paper, cardboard, or any other material having properties suitable to enable at least generally functioning as described herein. The blank can also be laminated or coated with one or more sheet-like materials in selected panels or panel portions.

[0038] According to an exemplary embodiment of the present disclosure, the fold line can be any substantially linear form of weakening that is not necessarily a straight line but facilitates folding along it. More specifically, without intending to limit the scope of the present disclosure, the fold line can be a cut line such as a line formed by a dull cutting knife that creates a portion of the material that has been crushed or indented along the desired weakening line, a slit that extends partially into the material along the desired weakening line, and / or a series of slits that extend partially and / or completely through the material along the desired weakening line, as well as various combinations of these features. In situations where cutting is used to form the fold line, typically the cutting is not overly extensive such that a reasonable user might mistakenly consider the fold line to be a tear line.

[0039] As an example, the tear line can include a slit that extends partially into the material along a desired weakening line and / or a series of spaced slits that extend partially and / or completely through the material along the desired weakening line, 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 slits that extend completely through the material, with adjacent slits being slightly spaced such that nicks (e.g., small somewhat bridge-like pieces of the material) are defined between adjacent slits to typically temporarily connect the material across the tear line. The score lines are broken during tearing along the tear line. The score lines are typically a relatively small percentage of the tear line and, alternatively, the score lines can be omitted from or cut into the tear line such that the tear line is a continuous cut. That is, replacing each of the tear lines with continuous slits or the like is within the scope of the present disclosure. For example, the cut can be a continuous slit or wider than a slit without departing from the present disclosure.

[0040] The above embodiments can be described as having one or more panels that are adhered to each other by an adhesive during assembly of the carton embodiment. The term "adhesive" is intended to encompass any type of adhesive commonly used to secure the carton panels in place.

[0041] The foregoing description of the present disclosure illustrates and describes various embodiments. Since various changes can be made to the above configuration without departing from the scope of the present disclosure, all matters included in the above description or shown in the accompanying drawings should be construed as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure encompasses various modifications, combinations, changes, etc. of the above-described embodiments. In addition, although the present disclosure shows and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the present disclosure as presented herein, are consistent with the above teachings, and / or are within the skill or knowledge of the relevant technical field. Moreover, some features and characteristics of each embodiment can be selectively exchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure.

Claims

Claim 1 A carton comprising an inner structure, an outer structure, and an engagement feature extending to at least one outer panel of the outer structure, wherein the inner structure comprises a plurality of inner panels that at least partially extend around a first interior of the inner structure, and the inner structure comprises an inner locking tab foldably connected to at least one of the plurality of inner panels, the outer structure comprises a plurality of outer panels that at least partially extend around a second interior of the outer structure, and the inner structure is at least partially received within the second interior of the outer structure, 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, the engagement feature includes a cover panel that is at least partially separable from the at least one outer panel to form an engagement hole in the at least one outer panel, the inner locking tab of the inner structure extends along the engagement feature of the outer structure, and when the cover panel is at least partially removed, the inner locking tab is engaged through the engagement hole to move the inner locking tab relative to the outer locking tab, facilitating movement of the inner structure and the outer structure from a closed configuration to an open configuration relative to each other. A carton characterized by this. Claim 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 weakened line. Claim 3 The carton according to claim 1, further comprising an engagement recess extending within the outer structure, and at least a portion of the inner structure extends along at least a portion of the engagement recess within the outer structure so as to be able to grip the inner structure through at least the engagement recess within the outer structure. Claim 4 The carton according to claim 3, wherein the engagement recess extends along at least a portion of the outer locking tab and at least a portion of the at least one outer panel. Claim 5 The plurality of outer panels of the outer structure include an upper panel that is foldably connected to at least one of the outer panels. The outer structure has an opening on the opposite side of the upper panel. The inner structure is selectively movable through the opening. The engaging feature is closer to the upper panel than the opening, and the engaging recess extends along the opening. The carton according to claim 3.

6. 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 engaging feature is a first engaging feature. The inner structure further includes a second locking tab that is foldably connected to a second inner panel among the plurality of inner panels. The outer structure further includes a second outer locking tab that is foldably connected to a second outer panel among the plurality of outer panels, and a second engaging feature that extends within the second outer panel. The second inner locking tab and the second outer locking tab cooperate to limit movement between the inner structure and the outer structure. The carton according to claim 1.

7. The cover panel is a first cover panel, the engaging hole is a first engaging hole, and the second engaging feature includes a second cover panel that is at least partially separable from the second outer panel to form a second engaging hole in the second outer panel. The second inner locking tab of the inner structure extends along the second engaging feature of the outer structure such that the second inner locking tab can engage through the second engaging hole when the second cover panel is at least partially removed to move the second inner locking tab relative to the second outer locking tab. The carton according to claim 6.

8. 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 that faces the respective first locking edge to limit movement between the inner structure and the outer structure. The carton according to claim 6.

9. The inner locking tab includes an inner proximal portion bendably connected to the at least one inner panel, and an inner distal portion bendably connected to the inner proximal portion along a first fold line, The inner distal portion is bent along the first fold line to be in face-to-face contact with the inner proximal portion, and at least one of the inner proximal portion and the inner distal portion is attached to the at least one inner panel, The outer locking tab includes an outer proximal portion bendably connected to at least one outer panel, and an outer distal portion bendably connected to the outer proximal portion along a second fold line, The outer distal portion is bent along the second fold line to be in face-to-face contact with the outer proximal portion, and at least one of the outer proximal portion and the outer distal portion is attached to 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, the carton according to claim 1.

10. The inner structure includes a first opening, and the inner proximal portion is bendably connected to the at least one inner panel along the first opening, The outer structure includes a second opening on the opposite side of the first opening of the inner structure, and the outer proximal portion is bendably connected to the at least one outer panel along the second opening, the carton according to claim 9.

11. The plurality of outer panels of the outer structure includes an upper panel bendably connected to the at least one outer panel, the outer structure includes an opening on the opposite side of the upper panel, the inner structure is movable through the opening, and the engaging feature is closer to the upper panel than the opening, the carton according to claim 1.

12. The inner structure includes an opening for inserting and / or removing an article from the first interior, and the opening of the inner structure is at least partially surrounded by the outer structure, the carton according to claim 1.

13. A combination of a first blank and a second blank for cooperatively forming the carton at least partially, The first blank includes a plurality of inner panels and an inner locking tab foldably connected to at least one of the plurality of inner panels, and the first blank is for forming an inner structure. The second blank includes a plurality of outer panels and an outer locking tab foldably connected to at least one of the plurality of outer panels, and the second blank is for forming an outer structure for at least partially receiving the inner structure formed from the first blank when the carton is formed from the first blank and the second blank. The inner locking tab and the outer locking tab are configured to selectively cooperate to limit movement between the inner structure formed from the first blank and the outer structure formed from the second blank when the carton is formed from the first blank and the second blank. The engaging feature extends into the at least one outer panel of the second blank, and the engaging feature includes a cover panel at least partially separable from the at least one outer panel to form an engaging hole in the at least one outer panel, and the engaging feature facilitates engagement of the inner locking tab with respect 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 weakened line.

15. The combination according to claim 13, further comprising an engaging opening extending into the second blank for forming an engaging recess when the outer structure is formed from the second blank to facilitate gripping of the inner structure formed from the first blank when the carton is formed from 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 engaging opening extends along the fold line to at least a part of the outer locking tab and the at least one outer panel.

17. The plurality of outer panels of the second blank include an upper panel that is foldably connected to the at least one outer panel on the opposite side of the outer locking tab, the engaging feature is closer to the upper panel than the outer locking tab, and the engaging opening extends into the at least one outer panel and the outer locking tab. The combination according to claim 15.

18. 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 engaging feature is a first engaging feature. The first blank further includes a second locking tab foldably connected to a second inner panel among the plurality of inner panels, and 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 engaging feature extending into the second outer panel. The second inner locking tab and the second outer locking tab are configured to selectively cooperate to restrict movement between the inner structure formed from the first blank and the outer structure formed from the second blank when the carton is formed from the first blank and the second blank. The combination according to claim 13.

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

20. The inner locking tab includes an inner proximal portion foldably connected to the at least one inner panel and an inner distal portion foldably connected to the inner proximal portion along a first fold line. When the inner structure is formed from the first blank, the inner distal portion is folded along the first fold line to be in face-to-face contact with the inner proximal portion. The outer locking tab includes an outer proximal portion foldably connected to at least one outer panel and an outer distal portion foldably connected to the outer proximal portion along a second fold line. When the outer structure is formed from the second blank, the outer distal portion is bent along a second fold line to be in face-to-face contact with the outer proximal portion, and the first fold line of the inner locking tab and the second fold line of the outer locking tab are configured to engage with each other to resist movement between the inner structure formed from the first blank and the outer structure formed from the second blank when the carton is formed from the first blank and the second blank. The combination according to claim 13.

21. The plurality of outer panels of the outer structure include an upper panel foldably connected to the at least one outer panel on the opposite side of the outer locking tab, and the engaging feature is closer to the upper panel than the outer locking tab. The combination according to claim 13.

22. Obtaining a first blank comprising 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 at least partially folding the plurality of inner panels around a first interior of the inner structure; Obtaining a second blank comprising a plurality of outer panels, an outer locking tab foldably connected to at least one of the plurality of outer panels, and an engaging feature extending within the at least one outer panel, the engaging feature comprising a cover panel at least partially separable from the at least one outer panel to form an engaging hole within the at least one outer panel; Forming an outer structure from the second blank by at least partially folding the plurality of outer panels around a second interior of the outer structure; Moving at least one of the inner structure and the outer structure relative to the other to assemble the carton with the inner structure at least partially received within the second interior of the outer structure, the inner locking tab and the outer locking tab cooperating to limit movement between the inner structure and the outer structure. The inner locking tab of the inner structure extends along the engaging feature of the outer structure, and when the cover panel is at least partially removed, the inner locking tab is engaged through the engaging hole to move the inner locking tab relative to the outer locking tab, facilitating the movement of the inner structure and the outer structure from a closed configuration to an open configuration relative to each other. A method of forming a carton, characterized in that.

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 score line.

24. The second blank further includes an engaging opening extending along at least a part of the outer locking tab and the at least one outer panel. Forming the outer structure includes bending the outer locking tab to overlap the at least one outer panel, and forming the engaging opening in the engaging recess of the outer structure to facilitate gripping of the inner structure. The method according to claim 22.

25. The plurality of outer panels of the second blank include an upper panel foldably connected to the at least one outer panel on the opposite side of the outer locking tab, and the engaging feature is closer to the upper panel than the outer locking tab of the second blank. The method according to claim 24.

26. The inner locking tab includes an inner proximal portion foldably connected to the at least one inner panel and an inner distal portion foldably connected to the inner proximal portion along a first fold line. Forming the inner structure includes bending the inner distal portion along the first fold line to be in face-to-face contact with the inner proximal portion, bending the inner locking tab to overlap the at least one inner panel, and attaching at least one of the inner proximal portion and the inner distal portion to the at least one inner panel. The outer locking tab includes an outer proximal portion foldably connected to at least one outer panel and an outer distal portion foldably connected to the outer proximal portion along a second fold line. Forming the outer structure includes bending the outer distal portion along the second fold line to bring it into face-to-face contact with the outer proximal portion, bending the outer locking tab into an overlapping relationship with the at least one outer panel, and attaching at least one of the outer proximal portion and the outer distal portion to the at least one outer panel. The method according to claim 22, wherein 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 inner structure includes a first opening, and the inner proximal portion is foldably connected to the at least one inner panel along the first opening. The method according to claim 26, wherein the outer structure includes a second opening on the opposite side of the first opening of the inner structure, and the outer proximal portion is foldably connected to the at least one outer panel along the second opening.

28. The inner structure includes an opening for inserting an article into and / or removing an article from the first interior, and the opening of the inner structure is at least partially surrounded by the outer structure. The method according to claim 22.

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