Carton with Locking Features

Abstract

The carton has an inner structure including a plurality of inner panels extending at least partially around a first interior, an inner locking tab foldably connected to at least one inner panel, and at least one inner locking flap foldably connected to the at least one inner panel, and an outer structure including a plurality of outer panels extending at least partially around a second interior, and an outer locking tab foldably connected to the at least one outer panel. The inner locking tab and the inner locking flap cooperate with the outer locking tab to limit movement between the inner and outer structures in a locked position. The inner locking flap is movable relative to the at least one inner panel and generates an audible locking sound when the inner structure is positioned in the locked position.

Description

[Technical Field]

[0001] This application claims the benefit of German Utility Model Application No. 202022104856.8, filed August 29, 2022. Incorporation by Reference

[0002] The disclosure of German Utility Model Application No. 202022104856.8, filed August 29, 2022, is incorporated herein by reference for all purposes as if set forth herein in its entirety. [Background technology]

[0003] Background to the disclosure FIELD OF THE DISCLOSURE The present disclosure relates generally to cartons / boxes for holding one or more products. More specifically, the present disclosure relates to cartons having an inner structure at least partially received within an outer structure and locking features for selectively limiting and / or resisting relative movement between the structures of the carton.

[0004] Cartons / boxes with locking features can be used for a wide 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 may put them in their mouths, swallow them, or use them in other dangerous ways. By way of example, one may want to keep certain products out of the reach of babies, toddlers, kindergarteners, and preschool-aged children, i.e., children up to about age 6, for example. Summary of the Invention

[0005] Disclosure Overview Generally, one aspect of the present disclosure relates to a carton, the carton comprising an inner structure including a plurality of inner panels extending at least partially around a first interior of the inner structure. The inner structure includes an inner locking tab foldably connected to at least one of the inner panels and an inner locking flap foldably connected to at least one of the inner panels. The outer structure includes a plurality of outer panels extending at least partially around a second interior of the outer structure. The inner structure is at least partially received within the second interior of the outer structure and positionable in a locked position that restricts movement of the inner structure relative to the outer structure. The outer structure includes an outer locking tab foldably connected to at least one of the outer panels, the inner locking tab and the inner locking flap cooperating with the outer locking tab to restrict movement between the inner structure and the outer structure in the locked position. An engagement feature extends within at least one outer panel of the outer structure. The engagement feature includes an engagement hole in at least one outer panel. At least one of the inner locking tab and inner locking flap of the inner structure is adjacent to the engagement feature of the outer structure in the locked position, and the at least one of the inner locking tab and inner locking flap is positioned to disengage from the outer locking tab via the engagement hole to facilitate movement of the inner structure and the outer structure relative to each other from the locked position to an open position in which a first interior of the inner structure is accessible. The inner locking flap is movable relative to the at least one inner panel and produces an audible locking sound when the inner structure is positioned in the locked position.

[0006] In another aspect, the present disclosure generally relates to a first blank and a second blank for combining and cooperating to at least partially form a carton. The first blank includes a plurality of inner panels, an inner locking tab foldably connected to at least one of the plurality of inner panels, and an inner locking flap foldably connected to at least one of the plurality of inner panels. 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. 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 inner locking flap cooperate with the outer locking tab to limit movement between the inner structure formed from the first blank and the outer structure formed from the second blank in a locked position of the carton formed from the first blank and the second blank. The engagement feature extends into at least one outer panel of the second blank. The engagement feature comprises an engagement hole in the at least one outer panel. The engagement feature is for accessing at least one of the inner locking tab and the inner locking flap to disengage from the outer locking tab through the engagement hole to facilitate movement of the inner structure and the outer structure relative to one another of the carton formed from the first blank and the second blank from a locked position to an open position. The inner locking flap is movable relative to the at least one inner panel and produces an audible locking sound when the inner structure is positioned in the locked position within the carton formed from the first blank and the second blank.

[0007] In another aspect, the present disclosure generally relates to a method for forming a carton. The method may include obtaining a first blank including a plurality of inner panels, an inner locking tab foldably connected to at least one of the plurality of inner panels, and an inner locking flap foldably connected to at least one of the plurality of inner panels. The method includes forming an inner structure from the first blank by folding the plurality of inner panels at least partially around a first interior portion of the inner structure. The method also includes obtaining a second blank including a plurality of outer panels, an outer locking tab foldably connected to at least one of the plurality of outer panels, and an engagement feature extending within the at least one outer panel. The engagement feature includes an engagement hole in the at least one outer panel. The method includes forming an outer structure from the second blank by folding the plurality of outer panels at least partially around a second interior portion of the outer structure. The method includes moving at least one of the inner structure and the outer structure relative to the other to assemble the carton in a locked position with the inner structure at least partially received within a second interior of the outer structure, wherein the inner locking tab and the inner locking flap cooperate with the outer locking tab to limit movement between the inner and outer structures in the locked position. At least one of the inner locking tab and the inner locking flap is accessible through an engagement hole to disengage from the outer locking tab to facilitate movement of the inner and outer structures relative to each other from the locked position to an open position. Moving at least one of the inner structure and the outer structure relative to each other includes moving the inner locking flap relative to the at least one inner panel to generate an audible locking sound when the inner structure is moved to the locked position.

[0008] Those skilled in the art will appreciate these and other advantages and benefits of various additional embodiments upon reading the following detailed description of the embodiments with reference to the figures listed below. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the present disclosure. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a plan view of a first blank for forming an inner structure according to an exemplary embodiment of the present disclosure. [Figure 2] FIG. 2 is a perspective view of a first blank partially folded to form an inner structure. [Figure 3] FIG. 3 is a perspective view of a partially formed inner structure. [Figure 4] FIG. 4 is a perspective view of the inner structure. [Figure 5] FIG. 5 is a plan view of a second blank for forming an outer construct according to an exemplary embodiment of the present disclosure. [Figure 6] FIG. 6 is a perspective view of an inner structure and an outer structure positioned relative to one another for transferring the outer structure onto the inner structure and / or after removing the inner structure from the outer structure, according to an exemplary embodiment of the present disclosure. [Figure 7] FIG. 7 is a perspective view of an inner structure partially received and positioned within an outer structure, with hidden features of the inner and outer structures shown in dashed lines, according to an exemplary embodiment of the present disclosure. [Figure 8] FIG. 8 is a perspective view of a carton formed by assembling the inner and outer structures according to an exemplary embodiment of the present disclosure, showing the engaged locking tabs of the structures in dashed lines.

[0010] Corresponding parts are designated by corresponding reference numerals throughout the drawings. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present disclosure generally relates to structures, boxes, cartons, carriers, trays, and the like, and packages for holding one or more products or articles, such as products or articles to be kept out of reach of children (e.g., for safety reasons). The products may be dishwashing agents, household cleaners, cleaning products such as soap, pharmaceuticals, cosmetics, candles, tobacco, items that may pose a choking hazard, any other suitable products or materials, or combinations thereof.

[0012] Structures according to the present disclosure can accommodate products or articles of any shape. As used herein, the terms "inside," "internal," "outside," "exterior," "lower," "bottom," "upper," and "top" refer to orientations determined with respect to fully erect and upright structures and cartons. As described herein, structures can be formed from blanks by adhering together multiple panels, sections, tabs, and / or flaps, which may be designated herein by terms such as "first," "second," "third," etc., in contiguous or non-contiguous reference to one another, without departing from the present disclosure.

[0013] According to FIG. 1 , a first blank 1 is used to form an inner side article or inner structure 61 ( FIGS. 3-8 ) having a first opening 65 according to an exemplary embodiment of the present disclosure. The inner structure 61 can be a container used to hold one or more products (not shown). FIG. 5 illustrates a second blank 25 used to form an outer side article or outer structure 60 (e.g., cover 60) ( FIGS. 6-8 ) having a second opening 62 according to an exemplary embodiment of the present disclosure. In an embodiment, the inner (inner) structure 61 and the outer (outer) structure 60 cooperate to form a carton 68 ( FIG. 8 ), with the outer structure 60 extending at least partially around the inner structure 61, the inner structure being selectively movable within the outer structure between a closed / locked configuration or first position ( FIG. 8 ) and an open configuration or second position ( FIG. 6 ), as described in more detail below. In the illustrated embodiment, the inner structure 61 and the outer structure 60 may include locking features that cooperate to resist and / or limit movement of the inner structure 61 relative to the outer structure 60, as described in more detail below. Additionally, the inner structure 61 and / or the outer structure 60 may include an audible feature that indicates when the inner structure is in a closed / locked position for the carton 68, as described in more detail below. In an exemplary embodiment, the blanks 1, 25 may be made of paperboard, cardboard, corrugated board, or other suitable material.

[0014] As shown in FIG. 1 , a 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 foldably connected at its edges to four first side walls or inner panels 3, 4, 5, and 6 along respective fold lines 2.1, 2.2, 2.3, and 2.4. For example, the bottom panel 2 can be foldably connected to respective first inner side panels 3 and second inner side panels 5 along respective transverse fold lines 2.1 and 2.3, and the bottom panel 2 can be foldably connected to respective first inner end panels 4 and second inner end panels 6 along respective longitudinal fold lines 2.2 and 2.4. As shown in FIG. 1 , at least the bottom panel 2 and inner end panels 4 and 6 can be rectangular. Any of the bottom panel 2 and / or inner panels 3, 4, 5, and 6 can be omitted or can have other shapes, arrangements, and / or configurations without departing from this disclosure.

[0015] In the illustrated embodiment, the inner side panel 3 can be foldably connected to first or inner locking tabs 9.1, 9.2 at respective transverse fold lines 7.1, 7.2. Similarly, the inner side panel 5 can be foldably connected to first or inner locking tabs 10.1, 10.2 at respective transverse fold lines 8.1, 8.2. As shown in FIG. 1 , each of the inner locking tabs 9.1, 9.2 can include a respective first / triangular portion 11.1, 11.2 and a respective second / rectangular portion 11.3, 11.4, and each of the inner locking tabs 10.1, 10.2 can include a respective first / triangular portion 12.1, 12.2 and a respective second / rectangular portion 12.3, 12.4. In the illustrated embodiment, second portions 11.3, 11.4 of locking tabs 9.1, 9.2 have locking edges 13.1, 13.2 spaced apart from fold lines 7.1, 7.2. In the illustrated embodiment, second portions 12.3, 12.4 of inner locking tabs 10.1, 10.2 have locking edges 14.1, 14.2 spaced apart from fold lines 8.1, 8.2. Portions 11.1, 11.2, 11.3, 11.4, 12.1, 12.2, 12.3, 12.4 of inner locking tabs 9.1, 9.2, 10.1, 10.2 may have alternative sizes and shapes to those shown and / or described herein without departing from the scope of this disclosure.

[0016] As shown in FIG. 1 , the first inner side panel 3 is foldably connected to the inner locking flap 19 at a horizontal fold line 21, and the inner side panel 5 is foldably connected to the inner locking flap 20 at a horizontal fold line 22. In one embodiment, the inner locking flap 19 is spaced apart from the adjacent inner locking tabs 9.1, 9.2, and the inner locking flap 20 is spaced apart from the adjacent inner locking tabs 10.1, 10.2. In the illustrated embodiment, the inner locking flap 19 has a distal edge 19.1 that is spaced apart from the fold line 21 a distance less than the locking edges 13.1, 13.2 are spaced apart from their respective fold lines 7.1, 7.2. Thus, the locking flap 19 extends from the inner side panel 3 a smaller distance than the inner locking tabs 9.1, 9.2. Similarly, inner locking flap 20 has a distal edge 20.1 that is spaced a shorter distance from fold line 22 than locking edges 14.1, 14.2 are spaced from their respective fold lines 8.1, 8.2, and inner locking flap 20 extends a shorter distance from inner side panel 5 than inner locking tabs 10.1, 10.2. Inner locking flaps 19, 20 may be otherwise shaped, arranged, and / or positioned without departing from this disclosure.

[0017] As shown in FIG. 1 , the first inner side panel 3 is foldably connected to a respective inner dust flap or inner side end flap 15, 16 along a respective longitudinal fold line 3.1, 3.3. Similarly, the second inner side panel 5 is foldably connected to a respective inner dust flap or inner side end flap 17, 18 along a respective longitudinal fold line 5.1, 5.3. In embodiments, the longitudinal fold lines 3.1, 3.3 and 5.1, 5.3 may extend along a rectangular portion of the respective inner side panel 3, 5. Any of the inner locking tabs 9.1, 9.2, 10.1, 10.2, inner locking flaps 19, 20, inner side end flaps 15, 16, 17, 18, and / or inner side panels 3, 5 may be omitted or otherwise shaped, positioned, and / or configured without departing from this disclosure.

[0018] The blank 1 may have other shapes, configurations, and / or configurations without departing from this disclosure.

[0019] In a first processing step of forming the inner structure 61 from the first blank 1, the inner locking tabs 9.1, 9.2, 10.1, 10.2 may be folded and secured (e.g., glued) to the outside of the respective inner side panels 3, 5 (FIG. 2). In an exemplary embodiment, the inner locking tabs 9.1, 9.2, 10.1, 10.2 may be folded and glued (e.g., by a packaging manufacturer) to the respective inner side panels 3, 5, and then stored and / or shipped (e.g., to a packaging supplier) in a flat, glued blank configuration (not shown), e.g., a stack with other similar or identical blanks.

[0020] 3 and 4, the assembled inner structure 61 can be formed (e.g., by a fold-and-glue system, packaging machine, etc.) from the flat, bonded blank 1 by folding the inner side panels 3, 5 along the transverse fold lines 2.1, 2.3 to extend upwardly from the bottom panel 2, folding the inner end flaps 15, 18 and 16, 17 along respective longitudinal fold lines 3.1, 5.3 and 3.3, 5.1 across each end of the inner structure 61, and folding the inner end panels 6, 4 along respective longitudinal fold lines 2.4, 2.2 across each end of the inner structure 61. In the illustrated embodiment, the inner side end flaps 15, 16, 17, 18 can be folded perpendicular to the inner side panels 3, 5 so as to extend between them. In embodiments, the first inner end panel 4 can be overlapped and secured (e.g., glued) to the inner side end flaps 16, 17 to form a first inner end wall, and the second inner end panel 6 can be overlapped and secured (e.g., glued) to the inner side end flaps 15, 18 to form a second inner end wall. In the illustrated embodiment, the bottom panel 2, inner panels 3, 4, 5, 6, and inner end flaps 15, 16, 17, 18 can extend at least partially around a first interior of the inner structure 61 to receive articles within the inner structure 61. In the illustrated embodiment, the assembled inner structure 61 can have a first or inner opening 65 defined between the inner panels 3, 4, 5, 6 relative to the bottom panel 2 (e.g., for inserting and removing products from the inner structure 17). As shown in Figure 4, the folded inner locking tabs 9.1, 9.2, 10.1, 10.2 have locking edges 13.1, 13.2, 14.1, 14.2 spaced downwardly from the respective top edges of the respective inner side panels 3, 5. In the illustrated embodiment, the locking edges 13.1, 13.2, 14.1, 14.2 can face away from the inner opening 65 toward the bottom panel 2 and can be spaced apart from the inner opening 65 and the bottom panel 2. As shown in Figure 3, the inner locking flaps 19, 20 can be folded downwardly at respective fold lines 21, 22 to abut the respective inner side panels 3, 5.In one embodiment, the inner locking flaps 19, 20 are not attached to the outer surfaces of the inner side panels so that the inner locking flaps can move freely relative to the inner side panels. The inner locking flap 19 is adjacent to and spaced apart from each of the inner locking tabs 9.1, 9.2, and the inner locking flap 20 is adjacent to and spaced apart from each of the inner locking tabs 10.1, 10.2. As shown in FIG. 4 , the distal edges 19.1, 20.1 of the locking flaps 19, 20 are closer to the top edges of the respective inner side panels 3, 5 than the locking edges 13.1, 13.2, 14.1, 14.2 of the folded and attached inner locking tabs 9.1, 9.2, 10.1, 10.2.

[0021] The inner structure 61 may be formed in other ways without departing from this disclosure.

[0022] As shown in FIG. 5 , the second blank 25 for the outer portion / structure 60 can have a longitudinal direction L1 and a transverse direction L2. In the illustrated embodiment, the second blank 25 can include a top wall or top panel 26 foldably connected at its edges to four second side walls or outer panels 27, 28, 29, 30 along respective fold lines 26.1, 26.2, 26.3, 26.4. For example, the top panel 26 can be foldably connected to respective first and second outer side panels 27, 29 along respective transverse fold lines 26.1, 26.3, and the top panel 26 can be foldably connected to respective first and second outer end panels 28, 30 along respective longitudinal fold lines 26.2, 26.4. In an embodiment, each of the top wall 26 and outer panels 27, 28, 29, 30 can be rectangular. Any of the top panel 26 and / or outer panels 27, 28, 29, 30 may be omitted or may be otherwise shaped, arranged, and / or configured without departing from this disclosure.

[0023] In the illustrated embodiment, the first outer side panel 27 may be foldably connected to a respective outer dust flap or outer side end flap 46, 47 along a respective longitudinal fold line 27.1, 27.2. Similarly, the second outer side panel 29 may be foldably connected to a respective outer dust flap or outer side end flap 48, 49 along a respective longitudinal fold line 29.1, 29.2. Any of the outer side end flaps 46, 47, 48, 49 and / or the outer side panels 27, 29 may be omitted or may be of other shapes, arrangements and / or configurations without departing from this disclosure.

[0024] As shown in FIG. 5 , the outer side panels 27, 29 can be foldably connected to respective second or outer locking tabs 35, 36 along respective transverse fold lines 31, 32 at opposing edges of the outer side panels 27, 29. In the illustrated embodiment, each of the outer locking tabs 35, 36 can include a respective proximal portion 35.1, 36.1 (e.g., an outer or second proximal portion) and a respective distal portion 43, 44 (e.g., an outer or second distal portion). In the embodiment, the proximal portions 35.1, 36.1 are foldably connected (e.g., directly foldably connected) to the respective outer side panels 27, 29 along the respective transverse fold lines 31, 32 and foldably connected to the respective distal portions 43, 44 along respective transverse fold lines 41, 42 opposite the respective transverse fold lines 31, 32. In an exemplary embodiment, each of the proximal portions 35.1, 36.1 can have two portions, with the respective first portions 33, 34 adjacent the respective transverse fold lines 31, 32 being rectangular (e.g., defined by free edges extending in the longitudinal direction LI). In an embodiment, the second portions 39, 40 adjacent the respective transverse fold lines 41, 42 being trapezoidal (e.g., defined by oblique free edges), with each second portion 39, 40 widening toward the respective first portion 33, 34. In an exemplary embodiment, the distal portions 43, 44 can be rectangular and foldably connected to the short edges of the proximal portions 35.1, 36.1 along the transverse fold lines 41, 42. Alternatively, the portions 35.1, 43, 36.1, 44 can have any suitable shape.

[0025] In the illustrated embodiment, the second blank 25 can include engagement features or features 50, 51 extending into the respective outer side panels 27, 29. As shown in FIG. 5 , the engagement features 50, 51 can be located closer to the top panel 26 than the respective outer locking tabs 35, 36 and can have an oval shape. In an embodiment, the engagement features 50, 51 can include respective lines of weakness 52, 53 (e.g., cut or tear lines) that at least partially define the respective engaging covers or cover panels 54, 55. In an exemplary embodiment, the lines of weakness 52, 53 can be formed by offset scribe lines, tear lines, cut lines, or any suitable lines of weakness on the outer and inner surfaces of the outer side panels 27, 29. As shown in FIG. 5 , the engagement features 50, 51 can include respective access openings 56, 57 (e.g., having a lens shape) extending along the edges of the respective lines of weakness 52, 53 (e.g., proximate the top panel 26). Alternatively, the access openings 56, 57 may be positioned along any portion of the respective cover panels 54, 55 or may be omitted. In embodiments, the covers 54, 55 may be removed by tearing along the lines of weakness 52, 53 to form respective engagement holes 51.1, 51.2 in the respective outer side panels 27, 29. In some embodiments, the engagement features 50, 51 may include fold lines (not shown) with the respective lines of weakness 52, 53 extending from the ends of the respective fold lines such that the covers 54, 55 are partially removed from the respective outer panels 27, 29 along the respective lines of weakness 52, 53 and folded outward along the respective fold lines (not shown). Alternatively, the cover panels 54, 55 may be removed from the blank 25 to expose the engagement openings 50.1, 51.1 prior to forming the outer structure 60 from the second blank, or the cover panels 54, 55 may be eliminated and not included in the blank 25.

[0026] As shown in FIG. 5 , the second blank 25 can further include engagement openings 58, 59 (e.g., oval-shaped). In embodiments, the opening 58 can extend through the first outer side panel 27 and the proximal portion 35.1 of the first outer locking tab 35 (e.g., half of the outer side panel 27 and half of the proximal portion 35.1 are symmetrically disposed about the transverse fold line 31). Additionally, the engagement opening 59 extends through the second outer side panel 29 and the proximal portion 36.1 of the second outer locking tab 36 (e.g., half of the outer side panel 29 and half of the proximal portion 36.1 are symmetrically disposed about the transverse fold line 32). Any of the engagement features 50, 51, 58, 59 can be omitted or otherwise shaped, arranged, and / or configured without departing from the present disclosure. For example, the engagement features can have any suitable shape. In another example, covers 54, 55 can be omitted such that engagement features 50, 51 are openings 50.1, 51.1 in outer side panels 27, 29. Additionally, at least partially removable panels (not shown) (e.g., similar to cover panels 54, 55) can be included in blank 25 and can be removed by tearing along lines of weakness (not shown) to form engagement openings 58, 59 (e.g., similar to lines of weakness 52, 53).

[0027] The blank 25 may have other shapes, configurations, and / or configurations without departing from this disclosure.

[0028] In a first processing step of forming the outer structure 60 ( FIG. 6 ) from the second blank 25, the distal portions 43, 44 of the outer locking tabs 35, 36 can be folded and secured (e.g., adhesively bonded) to the inside of the respective proximal portions 35.1, 36.1 of the outer locking tabs 35, 36. Furthermore, the outer proximal portions 35.1, 36.1 can be folded against the inside of the respective outer side panels 27, 29, and the distal portions 43, 44 can be secured (e.g., adhesively bonded) to the inside of the respective outer side panels 27, 29. Thus, the distal portions 43, 44 can be secured between the respective proximal portions 35.1, 36.1 and the respective outer side panels 27, 29. Alternatively, the proximal portions 33.1, 34.1 can be disposed between the respective outer side panels 27, 29 and the respective distal portions 43, 44 and secured to the outer side panels 27, 29. In the illustrated embodiment, the folded outer locking tabs 35, 36 can form second or outer locking edges 45.1, 45.2 along the respective transverse fold lines 41, 42 and are positioned between the engagement features 50, 51 and the respective transverse fold lines 31, 32 (FIGS. 6-8). As shown in FIGS. 6-8, engagement openings 58, 59 are formed in respective engagement recesses or notches in the outer structure 60 when the outer locking tabs 35, 36 are folded against the inside of the outer side panels 27, 29. In an embodiment, the engagement recesses 58, 59 can have a semi-elliptical shape and can extend along the lower edges of the outer side panels 27, 29. In an exemplary embodiment, the outer locking tabs 35, 36 can be folded and glued (e.g., by a packaging manufacturer) to the respective outer side panels 27, 29 and then stored and / or shipped (e.g., to a packaging manufacturer) in a flat, glued (not shown) blank configuration, e.g., a stack with other similar or identical blanks and / or the first blank 1.

[0029] 6, the assembled outer structure 60 may be formed (e.g., by a fold-and-glue system, packaging machine, etc.) from the flat, bonded blank 25 by folding the outer side panels 27, 29 along the transverse fold lines 26.1, 26.3 to extend downwardly from the top panel 26, folding the outer end flaps 46, 49 and 47, 48 along their respective longitudinal fold lines 27.1, 29.1 and 27.2, 29.1 to cover their respective ends of the outer structure 60, and folding the outer end panels 30, 28 along their respective longitudinal fold lines 26.4, 26.2 to cover their respective ends of the outer structure 60. In the illustrated embodiment, the outer side end flaps 46, 47, 48, 49 may be folded between and extend perpendicular to the outer side panels 27, 29. In embodiments, the first outer end panel 28 can overlap and be secured (e.g., glued) to the outer side end flaps 47, 48 to form a first outer end wall, and the second outer end panel 30 can overlap and be secured (e.g., glued) to the outer end flaps 46, 49 to form a second outer end wall. As shown in FIGS. 6-8 , the top panel 26, the outer panels 27, 28, 29, 30, and the outer end flaps 46, 47, 48, 49 can extend at least partially around a second interior of the outer structure 60, where the inner structure 60 is at least partially received in the second interior of the outer structure 60 when the carton 68 is in its closed configuration. In the illustrated embodiment, the assembled outer structure 60 can have a second or outer opening 62, and the inner structure 60 can be movable in and out of the second interior of the outer structure 61 through the second opening when the locking tabs disengage from one another, as described in more detail below. 6-8, the second locking edges 45.1, 45.2 can face away from the outer opening 62 toward the top panel 26 and can be spaced apart from the outer opening 62 and the top panel 26. The outer structure 60 can be formed in other manners without departing from this disclosure.

[0030] FIG. 6 shows the structures 60, 61 in a separated or open configuration (e.g., first opening 65 in inner structure 61 is accessible for loading and / or removing items from inner structure 61). In the illustrated embodiment, second opening 62 in outer structure 49 is aligned with first opening 65 in inner structure 61 in preparation for assembling carton 68 into its closed configuration (FIGS. 7-8). In embodiments, FIGS. 6-8 show interior or other hidden aspects of structures 60, 61 in dashed lines. When the outer structure 60 moves over the inner structure 61 to assemble the carton 68 in its closed configuration, the second locking edges 45.1, 45.2 of the outer structure 60 move past the first locking edges 13.1, 13.2, 14.1, 14.2 of the inner structure, such that the second locking edges 45.1, 45.2 are positioned below the first locking edges 13.1, 13.2, 14.1, 14.2 ( FIG. 8 ). As shown in FIG. 8 , when the carton 68 is in its closed / locked configuration, the inner locking edges 13.1, 13.2, 14.1, 14.2 face away from and are spaced apart from the top panel 26 of the outer structure 60, and the outer locking edges 45.1, 45.2 face away from and are spaced apart from the bottom panel 27 of the inner structure 61. In embodiments, the carton 68 can be assembled by moving the outer structure 60 onto the inner structure 61, moving the inner structure 61 into the outer structure 60, or moving both structures 60, 61 together. In this disclosure, Figures 6-8 illustrate the engagement and disengagement of locking features on one side of the carton 68 (e.g., the side corresponding to the inner side panel 5 and the outer side panel 29), including the outer locking tab 36, outer locking edge 45.1, engagement hole 51.1, inner locking tabs 10.1, 10.2, inner locking flap 20, inner locking edges 14.1, 14.2, and distal edge 20.1, some of which may be shown in dashed lines in one or more of the figures. The locking features on the opposite side of the carton 68 (e.g., the side corresponding to the inner side panel 3 and the outer side panel 27) are not shown in detail in Figures 6-8, but the locking features on the opposite side can include the outer locking tab 35, the outer locking edge 45.2, the engagement hole 50.1, the inner locking tabs 9.1, 9.2, the inner locking flap 19, the inner locking edges 13.1, 13.2 and the distal edge 19.1.The opposing locking features, not shown, may be identical to the locking features shown in Figures 6-8 and may operate in the same manner as described herein. Alternatively, the opposing locking features may be configured in other manners without departing from this disclosure. Additionally, the locking features on both sides of the carton 68 may engage and / or disengage in a similar manner as described herein, and an audible locking sound may be generated by the inner locking flaps 19, 20 on both sides of the carton 68 without departing from this disclosure.

[0031] In the illustrated embodiment, the inner locking flaps 19, 20 are movable relative to the inner side panels 3, 5, respectively, and generate an audible sound when the inner structure 61 is positioned in a locked position on the carton 68 and the inner structure is received by the outer structure 60. The locking flaps 19, 20 are spaced apart from respective adjacent locking tabs 9.1, 9.2, 10.1, 10.2 attached to the respective inner panels 3, 5. As shown in Figures 7 and 8, when the inner structure 61 is received by the outer structure 60, the inner locking flaps 19, 20 are pushed inward by the respective outer locking tabs 35, 36 as the inner structure is received by the outer structure. As the inner structure 61 is inserted further into the outer structure 60, the distal edges 19.1, 20.1 of the inner locking flaps 19, 20 pass the second outer locking edges 45.1, 45.2, causing the inner locking flaps 19, 20 to press into contact with the outer side panels 27, 29 of the outer structure 60 when the inner structure is fully inserted into the outer structure. The foldable connections of the inner locking flaps 19, 20 at the fold lines 21, 22 bias the inner locking flaps 19, 20 outwardly against the inner side panels 3, 5. The biasing of the inner locking flaps 19, 20 causes contact with the outer side panels 27, 29, and a resulting audible "click" sound indicates that the carton 68 is positioned in the locked position, with the locking edges 13.1, 13.2, 14.1, 14.2 of the locking tabs 9.1, 9.2, 10.1, 10.2 and the distal edges 19.1, 19.2 of the inner locking flaps 19, 20 positioned above the outer locking edges 45.1, 45.2 of the outer locking tabs 35, 36. The inner locking flaps 19, 20 snap outward when the inner structure 61 contacts the outer side walls 27, 29 and is fully inserted into the outer structure 60, creating an audible sound indicating that the carton 68 is locked.

[0032] Additionally, when the outer structure 60 and the inner structure 61 are pressed together, the inner locking flaps 19, 20 produce a clearly perceptible sound that clearly indicates to the user that the carton 68 is locked. The sound may be referred to herein as a locking sound and may be a clicking or tapping sound. The locking sound is caused by the movement of the inner locking flaps 19, 20 against the inner surface of the outer side panels when the inner structure 61 is received by the outer structure 60. When the inner locking flaps 19, 20 no longer contact the outer locking tabs 35, 36, a gap exists between the inner locking flaps 19, 20 and the respective outer sidewalls 27, 29. The biasing force of each inner locking flap 19, 20 causes the inner locking flap to move away from the inner side panels 3, 5, into the gap between the inner locking flaps 19, 20 and the outer sidewalls 27, 29, and contact the outer sidewalls, thereby producing the audible locking sound.

[0033] In the illustrated embodiment, the carton 68 can be locked in its closed configuration (e.g., due to the positioning of the second locking edges 45.1, 45.2 below the first locking edges 13.1, 13.2, 14.1, 14.2). For example, the second locking edges 45.1, 45.2 can face the first locking edges 13.1, 13.2, 14.1, 14.2 such that attempting to move the formations 60, 61 relative to one another will cause the first locking edges 13.1, 13.2, 14.1, 14.2 and the respective outer locking edges 45.1, 45.2 to engage (e.g., contact, abut, interact). In embodiments, abutment of first locking edges 13.1, 13.2, 14.1, 14.2 against respective second locking edges 45.1, 45.2 can limit or prevent relative movement between structures 60, 61 to limit or prevent undesired withdrawal of inner structure 61 from opening 62 in outer structure 60. Thus, in embodiments, inner locking tabs 9.1, 9.2, 10.1, 10.2 can engage respective outer locking tabs 35, 36 (e.g., along respective locking edges 13.1, 13.2, 14.1, 14.2 and 45.1, 45.2) such that locking tabs 9.1, 9.2, 10.1, 10.2 cooperate to limit movement of inner structure 61 relative to outer structure 60. Additionally, the distal edges 19.1, 20.1 of the inner locking flaps 19, 20 also interfere / contact with the second locking edge 45.1 to prevent movement of the inner structure 61 relative to the outer structure 60 in the locked position of the carton 68. The carton 55 may be formed and / or assembled in other manners without departing from this disclosure.

[0034] In an exemplary embodiment, the carton 68 can be manipulated to overcome the locking engagement of the inner locking tabs 9.1, 9.2, 10.1, 10.2 and inner locking flaps 19, 20 with the outer locking tabs 35, 36 so that the inner structure 61 can be moved from a first (e.g., closed or locked) position (e.g., the inner structure 61 is partially or completely contained within the outer structure 60 and the first opening 65 is covered by the outer structure 60) to a second (e.g., open) position (e.g., the inner structure 61 is removed from the outer structure 60 through the opening 62 so that the first opening 65 is accessible). For example, the covers 54, 55 of the engagement mechanisms 50, 51 are separated from the respective outer side panels 27, 29 along the respective weakened lines 52, 53 (e.g., by grasping the covers 54, 55 at the access openings 56, 57). In an embodiment, removal of covers 54, 55 can provide protection for a first opening for carton 68. In the illustrated embodiment, removal of covers 54, 55 can form engagement holes 51.1, 51.2 ( FIG. 6 ) in the respective outer side panels 27, 29 such that inner locking tabs 9.1, 9.2, 10.1, 10.3 and inner locking flaps 19, 20 of inner structure 61 are accessible through openings formed by respective engagement features 50, 51 in outer structure 60. In the illustrated embodiment, a user can grasp the engagement holes 50.1, 51.1 formed by the engagement features 50, 51 (e.g., with the thumb and index finger of one hand) and push the inner side panels 3, 5, inner locking tabs 9.1, 9.2, 10.1, 10.2, and / or inner locking flaps 19, 20 inward to move the first locking edges 13.1, 13.2, 14.1, 14.2 and / or distal edges 19.1, 20.1 inward and away from (out of alignment with) the second locking edges 45.1, 45.2. When the inner locking tabs 9.1, 9.2, 10.1, 10.2 and inner locking flaps 19, 20 of the inner structure 61 are pressed inward in this manner, the second locking edges 45.1, 45.2 of the outer structure 60 are no longer locked by the first locking edges 13.1, 13.2, 14.1, 14.2 and / or distal edges 19.1, 19.2 of the inner structure 17.In one embodiment, the central portions of the inner side panels 3, 5 can be pushed inward through the engagement holes 50.1, 51.1 enough to move the first locking edges 13.1, 13.2, 14.1, 14.2 and distal edges 19.1, 19.2 away from the second locking edges 45.1, 45.2 and allow the inner structure 61 to move freely relative to the outer structure 60.

[0035] A user can grasp the inner structure 61 (e.g., with the thumb and index finger of the other hand) via the engagement recesses 58, 59 in the outer structure 60 while pressing the inner side panels 3, 5 inward, engaging the inner locking tabs 9.1, 9.2, 10.1, 10.2 with the inner locking flaps 19, 20 through the openings formed by the engagement features 50, 51. With the engagement features 50, 51 disengaging the inner locking flaps 19, 20 and inner locking tabs 9.1, 9.2, 10.1, 10.2 from the locking edges 45.1, 45.2, and by pulling the inner structure 61 via the engagement recesses 58, 59 in the outer structure 60, a user can pull the structures 60, 61 apart with both hands while pressing the side panels 3, 5 inward through the openings formed in the outer structure 60. In embodiments, the unlocking and opening operations may be difficult or impossible for children to perform (eg, due to limited hand size and / or dexterity).

[0036] In the illustrated embodiment, once the structures 60, 61 are separated (e.g., similar to that shown in FIG. 6 ), the opening 65 in the inner structure 61 is accessible for removing or adding items. The carton 68 can be reclosed and / or reopened following the assembly and unlocking / separation operations as described above. In an embodiment, the reclosed carton 68 is again protected from unwanted opening (e.g., by a child) by the locking engagement of the inner locking tabs 9.1, 9.2, 10.1, 10.2 with the respective outer locking tabs 35, 36 once the inner structure 61 is fully inserted into the outer structure 60. Reclosing the carton 68 generates an audible locking sound by the inner locking flaps 19, 20 in the same manner as described above for the initial closure and locking of the carton 68.

[0037] In exemplary embodiments, the shortest distance between the engagement features 50, 51 and / or engagement recesses 58, 59 along the exterior of the carton 68 in the closed configuration is dimensioned so that it is difficult or impossible for 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.) to unlock the carton 68 and to pull the outer structure 60 and inner structure 61 apart when in the locked configuration. In embodiments, this dimension is determined based on average body measurements of children in the respective age group, EU, or North America, regardless of gender, depending on the region for which the inside-out box is intended. In examples, the distance between the exterior surfaces 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 can help ensure that an adult (e.g., who may have larger hands) can reach the locking features to unlock and open the carton 68, but that a child's hands cannot simultaneously engage all of the engagement holes to unlock the folding carton.

[0038] In the carton 68 according to the present disclosure, the inner locking tabs 9.1, 9.2, 10.1, 10.2, the inner locking flaps 19, 20, and the outer locking tabs 35, 36 form an interlock when the inner structure 61 is moved into the outer structure 60. This is because the inner locking edges 13.1, 13.2, 14.1, 14.2 and the distal edges 19.1, 19.2 can press against the outer locking edges 45.1, 45.2, thereby preventing the inner structure 61 from being pulled out of the outer structure 60. To pull the inner structure 61 out of the outer structure 60, for example, it is necessary to release the interlock between the outer and inner portions. To do this, a user can use the thumb and index finger of one hand to engage the engagement openings of the access features 50, 51, compress the inner side panels 3, 5 inward, and engage the inner locking tabs 9.1, 9.2, 10.1, 10.2 and inner locking flaps 19, 20 through the openings formed by the engagement features 50, 51, so that the outer locking edges 45.1, 45.2 no longer block the path of the inner locking edges 13.1, 13.2, 14.1, 14.2 and distal edges 19.1, 20.1. With the thumb and index finger of the other hand, the user can grasp a portion of the inner structure 61 (e.g., along or adjacent to the bottom panel 2) by the second engagement openings / recesses 58, 59 and pull the inner and outer structures 61, 60 apart. In doing so, the inner locking flaps 19, 20 and inner locking tabs 9.1, 9.2, 10.1, 10.2 engage the engagement openings of the access features 50, 51 and slide past the user's thumb and index finger, slightly compressing the inner locking flaps 19, 20 and inner locking tabs 9.1, 9.2, 10.1, 10.2. Unlocking by a child can be prevented or made difficult by sizing the carton 68 so that a child cannot engage the engagement openings of the access features 50, 51 in the described manner due to the relatively small size of a child's hands. Unlocking may require, for example, a particular understanding of the function of the latch that is not typically present in children up to, for example, the age of six. As a result, children are prevented from unlocking a carton 68 according to the present disclosure and are protected from the associated hazards.Additionally, the carton 68 is protected from unintentional opening, which can occur with an inside-out carton that does not include locking features, for example, when it is lifted on the outer structure without supporting the inner structure, resulting in the inner structure sliding out of the outer structure in the absence of the locking features.

[0039] In the exemplary embodiment, carton 68 may have tolerances in its formation, for example, when structures 60, 61 are formed from flat, bonded blanks 1, 25 by a packaging machine. These tolerances may result in small variations in the relative sizes of structures 60, 61. However, the two thickness layers of inner locking tabs 9.1, 9.2, 10.1, 10.2 and outer locking tabs 45.1, 45.2 (e.g., when their respective proximal and distal portions are in an overlapping relationship) may help compensate for such tolerances and variations that may occur during blank manufacturing and assembly and bonding of the inner and / or outer structures. This may be advantageous for secure locking of the carton despite the tolerances.

[0040] Blanks according to any of the embodiments of the present disclosure can be formed, for example, from coated paperboard and similar materials. For example, the inside and / or outside of the blank can be coated with a clay coating. The clay coating can then be printed with product, advertising, price coding, and other information or images. The blank can then be coated with a varnish to protect any information printed on the blank. The blank can also be coated on one or both sides of the blank with, for example, a moisture barrier layer. In accordance with the above-described embodiments, the blank can be constructed of caliper paperboard so that it is heavier and more rigid than regular paper. The blank can also be constructed from other materials, such as cardboard, stiff paper, or any other material having suitable properties to enable the carton to function, at least generally, as described herein. The blank can also be laminated or coated with one or more sheet-like materials at selected panels or panel portions.

[0041] According to exemplary embodiments of the present disclosure, a fold line is not necessarily straight, but can be any substantially straight form of weakening that facilitates folding therealong. More specifically, without intending to narrow the scope of the present disclosure, fold lines include score lines, such as lines formed with a blunt scoring knife or the like, that create a crushed or depressed portion in the material along the desired line of weakness, cuts that extend partially into the material along the desired line of weakness, and / or a series of cuts that extend partially into and / or completely through the material along the desired line of weakness, and various combinations of these features. In situations where cuts are used to create fold lines, the cuts typically do not extend excessively in a manner that would cause a reasonable user to mistakenly consider the fold line to be a tear line.

[0042] By way of example, the tear line can include a slit extending partially into the material along the desired line of weakness, and / or a series of spaced slits extending partially into the material along the desired line of weakness and / or 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 slits extending completely through the material, with adjacent slits spaced slightly apart, typically resulting in a nick (e.g., a somewhat bridge-like piece of material) defined between adjacent slits to temporarily connect the material across the tear line. The nick is broken during tearing along the tear line. Nicks are typically a relatively small percentage of the tear line; alternatively, nicks can be omitted from or positioned within the tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure to replace each tear line with a continuous slit, etc. For example, the cut line may be a continuous slit or may be wider than the slit without departing from the present disclosure.

[0043] The above embodiments may be described as having one or more panels adhesively bonded together during assembly of the carton embodiment. The term "adhesive" is intended to encompass any style of adhesive typically used to secure carton panels in place.

[0044] The foregoing description of the present disclosure illustrates and describes various embodiments. Because various changes can be made in the above configurations without departing from the scope of the present disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Moreover, the scope of the present disclosure encompasses various modifications, combinations, variations, etc. of the above-described embodiments. In addition, while the present disclosure illustrates and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the present disclosure as expressed herein, commensurate with the above teachings, and / or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure.

Claims

1. an inner structure having a plurality of inner panels extending at least partially around a first interior of the inner structure, the inner structure including an inner locking tab foldably connected to at least one inner panel of the plurality of inner panels, and an inner locking flap foldably connected to the at least one inner panel of the plurality of inner panels; an outer structure having 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 received within the second interior portion of the outer structure and positionable in a locked position in which movement of the inner structure relative to the outer structure is restricted, the outer structure including an outer locking tab foldably connected to at least one outer panel of the plurality of outer panels, the inner locking tab and the inner locking flap cooperating with the outer locking tab to restrict movement between the inner structure and the outer structure in the locked position; an engagement feature extending into the at least one outer panel of the exterior structure and comprising an engagement hole in the at least one outer panel; and at least one of the inner locking tab and the inner locking flap of the inner structure is adjacent to the engagement feature of the outer structure in the locked position so as to be positioned to disengage from the outer locking tab through the engagement hole to facilitate movement of the inner structure and the outer structure relative to one another from the locked position to an open position in which the first interior of the inner structure is accessible; The carton, wherein the inner locking flap is movable relative to the at least one inner panel and produces an audible locking sound when the inner structure is positioned in the locked position.

2. 2. The carton of claim 1, wherein the inner locking tab is attached to the at least one inner panel.

3. 3. The carton of claim 2, wherein the inner locking tab is a first inner locking tab and the carton includes a second inner locking tab attached to the at least one inner panel.

4. 4. The carton of claim 3, wherein the inner locking flap is adjacent to and spaced from each of the first inner locking tab and the second inner locking tab.

5. 5. The carton of claim 4, wherein the inner locking flap is folded against the at least one inner panel and is not attached to the at least one inner panel.

6. 2. The carton of claim 1, wherein the at least one inner panel is accessible through the engagement hole and is pressed inward to facilitate disengagement of the inner locking tab and the inner locking flap from the outer locking tab.

7. further comprising an engagement recess extending into the outer structure; 2. The carton of claim 1, wherein at least a portion of the inner structure extends along at least a portion of the engagement recess of the outer structure, and the inner structure is gripped via at least the engagement recess of the outer structure.

8. 8. The carton of claim 7, wherein the engagement recess extends along at least a portion of the outer locking tab and the at least one outer panel.

9. 8. The carton of claim 7, wherein the outer panels of the outer structure include a top panel foldably connected to at least one of the outer panels, the outer structure including an opening opposite the top panel, the inner structure being selectively movable through the opening, the engagement feature being closer to the top panel than the opening, and the engagement recess extending along the opening.

10. the inner locking tab is a first inner locking tab, the inner locking flap is a first inner locking flap, the at least one inner panel comprises a first inner panel, the outer locking tab is a first outer locking tab, the at least one outer panel comprises a first outer panel, the engagement feature is a first engagement feature, the inner structure further comprises a second inner locking tab foldably connected to a second inner panel of the plurality of inner panels and a second inner locking flap foldably connected to the second inner panel of the plurality of inner panels, the outer structure further comprises a second outer locking tab foldably connected to a second outer panel of the plurality of outer panels and a second engagement feature extending into the second outer panel, the second inner locking tab and the second inner locking flap cooperate with the second outer locking tab to limit movement between the inner structure and the outer structure in the locked position, the second inner locking flap is movable relative to the second inner panel and cooperates with the first inner locking flap to produce an audible locking sound when the inner structure is positioned in the locked position.

2. The carton of claim 1.

11. 11. The carton of claim 10, wherein the engagement hole is a first engagement hole, the second engagement feature comprises a second engagement hole, and at least one of the second inner locking tab and the second inner locking flap is positioned to disengage from the second outer locking tab through the second engagement hole to facilitate movement of the inner structure and the outer structure relative to one another from the locked position to the open position.

12. 12. The carton of claim 11, wherein the first inner locking tab and the second inner locking tab each have a first locking edge, and the first outer locking tab and the second outer locking tab each have a second locking edge facing the respective first locking edge to limit movement between the inner structure and the outer structure in the locked position.

13. 13. The carton of claim 12, wherein the first and second inner locking flaps each have a distal edge positioned to engage the second locking edge of a respective first and second outer locking tab and cooperate with the first and second inner locking tabs to limit movement between the inner structure and the outer structure in the locked position.

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

15. A combination of a first blank and a second blank that cooperate to at least partially form a carton, comprising: the first blank comprises a plurality of inner panels, an inner locking tab foldably connected to at least one of the inner panels, and an inner locking flap foldably connected to the at least one of the inner panels, the first blank being for forming an inner structure; the second blank comprises a plurality of outer panels and an outer locking tab foldably connected to at least one of the outer panels, the second blank being 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 inner locking flap cooperating with the outer locking tab to limit movement between the inner structure formed from the first blank and the outer structure formed from the second blank in a locked position of the carton formed from the first blank and the second blank; an engagement feature extending into the at least one outer panel of the second blank, the engagement feature comprising an engagement hole in the at least one outer panel, the engagement feature for accessing at least one of the inner locking tab and the inner locking flap for disengagement from the outer locking tab through the engagement hole to facilitate movement of the inner structure and the outer structure relative to one another of the carton formed from the first blank and the second blank from the locked position to an open position; the inner locking flap is movable relative to the at least one inner panel and produces an audible locking sound upon positioning the inner structure in a locked position within the carton formed from the first blank and the second blank. A combination characterized by:

16. 16. The combination of claim 15, wherein the inner locking tab is a first inner locking tab for attachment to the at least one inner panel, the first blank includes a second inner locking tab for attachment to the at least one inner panel, and the inner locking flap is spaced adjacent to each of the first and second inner locking tabs.

17. 16. The combination of claim 15, further comprising an engagement opening extending into said second blank to form an engagement recess when said outer structure is formed from said second blank to facilitate gripping of said inner structure formed from said first blank when said carton is formed from said first blank and said second blank.

18. 18. The combination of claim 17, wherein the outer locking tab is foldably connected to the at least one outer panel along a fold line, and the engagement opening extends through the outer locking tab and at least a portion of the at least one outer panel along the fold line.

19. 18. The combination of claim 17, wherein the plurality of outer panels of the second blank include a top panel foldably connected to the at least one outer panel opposite the outer locking tab, the engagement feature being closer to the top panel than the outer locking tab, and the engagement opening extending into the at least one outer panel and the outer locking tab.

20. The inner locking tab is a first inner locking tab, the inner locking flap is a first inner locking flap, the at least one inner panel comprises a first inner panel, the outer locking tab is a first outer locking tab, the at least one outer panel comprises a first outer panel, the engagement feature is a first engagement feature, and the first blank further comprises a second locking tab foldably connected to a second inner panel of the plurality of inner panels, and a second inner locking tab foldably connected to the second inner panel of the plurality of inner panels. and a second inner locking flap, the second blank further comprising a second outer locking tab foldably connected to a second outer panel of the plurality of outer panels and a second engagement feature extending into the second outer panel, the second inner locking tab and the second inner locking flap cooperating with the second outer locking tab to limit movement between the inner structure formed from the first blank and the outer structure formed from the second blank in the locked position when the carton is formed from the first blank and the second blank; the second inner locking flap is movable relative to the second inner panel to cooperate with the first inner locking flap and produces an audible locking sound when the inner structure is positioned in the locked position within the carton formed from the first blank and the second blank.

17. The combination of claim 16.

21. 21. The combination of claim 20, wherein the engagement hole is a first engagement hole and the second engagement feature comprises a second engagement hole in the second outer panel.

22. 1. A method of forming a carton, comprising: obtaining a first blank comprising a plurality of inner panels, an inner locking tab foldably connected to at least one of the plurality of inner panels, and an inner locking flap foldably connected to the 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 portion 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 engagement feature extending within the at least one outer panel, the engagement feature comprising an engagement hole within the at least one outer panel; forming an outer structure from the second blank by folding the plurality of outer panels at least partially around a second interior portion of the outer structure; assembling the carton in a locked position with the inner structure at least partially received within the second interior of the outer structure, wherein the inner locking tab and the inner locking flap cooperate with the outer locking tab to limit movement between the inner and outer structures in the locked position, and moving at least one of the inner and outer structures relative to the other; at least one of the inner locking tab and the inner locking flap is accessible through the engagement hole for disengagement from the outer locking tab to facilitate movement of the inner structure and the outer structure relative to one another from the locked position to an open position; 10. The method of claim 9, wherein moving the at least one of the inner structure and the outer structure relative to one another includes moving the inner locking flap relative to the at least one inner panel to produce an audible locking sound when the inner structure is moved to the locked position.

23. 23. The method of claim 22, wherein the inner locking tab is a first inner locking tab, the first blank includes a second inner locking tab, the inner locking flap is spaced adjacent to each of the first and second inner locking tabs, and the step of forming the inner structure includes the steps of folding the first and second inner locking tabs and attaching each of the first and second inner locking tabs to the at least one inner panel.

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

25. 25. The method of claim 24, further comprising the steps of: disengaging the at least one of the inner locking tab and the inner locking flap from the outer locking tab via the engagement hole; gripping the inner structure via the engagement recess; and moving the inner structure to the open position relative to the outer structure to allow access to the first interior of the inner structure.

26. The inner locking tab is a first inner locking tab, the inner locking flap is a first inner locking flap, the at least one inner panel comprises a first inner panel, the outer locking tab is a first outer locking tab, the at least one outer panel comprises a first outer panel, the engagement feature is a first engagement feature, and the first blank further comprises a second locking tab foldably connected to a second inner panel of the plurality of inner panels, and a second inner locking tab foldably connected to the second inner panel of the plurality of inner panels. and a second inner locking flap, the second blank further comprising a second outer locking tab foldably connected to a second outer panel of the plurality of outer panels and a second engagement feature extending into the second outer panel, the second inner locking tab and the second inner locking flap cooperating with the second outer locking tab to limit movement between the inner structure formed from the first blank and the outer structure formed from the second blank in the locked position when the carton is formed from the first blank and the second blank; 24. The method of claim 23, wherein the step of moving the at least one of the inner structure and the outer structure relative to one another includes: moving the first inner locking flap relative to the first inner panel and moving the second inner locking flap relative to the second inner panel to produce an audible locking sound when the inner structure moves to the locked position.

27. 23. The method of claim 22, wherein the inner structure includes an opening for inserting and removing items from the first interior, the opening in the inner structure being at least partially surrounded by the outer structure in the locked position and accessible in the open position.

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