Stackable cartons, as well as blanks and methods for forming them.

Abstract

The carton includes a bottom wall, a plurality of side walls connected to the bottom wall, and a top wall releasably coupled to one of the side walls. The carton also includes a handle formed by at least a portion of the top wall. The carton further includes a planar surface formed at least in part by the handle and the top wall.

Description

Technical Field

[0001] The present disclosure generally relates to product packaging, and more specifically to cartons for packaging products, blanks for forming cartons, and methods of forming cartons from blanks. More specifically, but not exclusively, the present disclosure relates to cartons that include an integrated handle and are configured to be stacked.

Background Art

[0002] In the field of packaging, and more specifically in the field of fresh food packaging, products are often provided with an external container. For example, products (such as fresh fruits and vegetables) can be packaged in a carton C (FIG. 1) or a bag B (FIG. 2). Such containers are desirable for product protection, for shipping and distribution, and for displaying product identification or promotional information.

[0003] Also, when the product is sold, it is desirable that the end consumer can use the container as a product carrier. For example, many product containers include a handle H (FIGS. 1 and 2), and the handle H provides the consumer with the ability to carry the product. Typically, the handle H is positioned at the top of the container and extends outwardly from the top of the container.

[0004] Also, it is desirable that the product containers be stackable for shipping (such as on a pallet), storage (such as in a warehouse), or display (such as on a store shelf). However, typical containers may make it difficult or impossible to stack the containers due to a lack of structural integrity of the container (such as bag B) or due to the configuration of the handle H of the container (such as carton C).

[0005] Considering shipping, product protection, and consumer transport, it is also desirable to ensure that such containers have adequate strength to hold and transport products. Considering cost and environmental factors, it is also desirable that such containers be made from as little material as possible and cause as little material waste as possible. Considering cost and process factors, it is also desirable that such containers be formed through the simplest possible set of actions to aid in the automation of the container formation and loading processes.

[0006] Therefore, those skilled in the art continue their research and development efforts in the field of product packaging. [Overview of the project] [Means for solving the problem]

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

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

[0009] In the example, the disclosed carton includes an internal volume of the carton, a handle, and a plurality of panels forming a planar surface. The plurality of panels include a first side panel, a second side panel foldably connected to the first side panel, a third side panel foldably connected to the second side panel, and a fourth side panel foldably connected to the third side panel. The plurality of panels also include a first handle panel, which is foldably connected to the first side panel and detachably connected to the second and fourth side panels. The plurality of panels further include a second handle panel, which is foldably connected to the third side panel and detachably connected to the second and fourth side panels. The first handle panel overlaps at least a portion of the second handle panel, so that the first and second handle panels form a handle and at least a portion of the planar surface.

[0010] In the example, the disclosed blank includes a first side panel, a second side panel foldably connected to the first side panel, a third side panel foldably connected to the second side panel, and a fourth side panel foldably connected to the third side panel. The blank also includes a first handle panel foldably connected to the first side panel and a second handle panel foldably connected to the third side panel. The blank further includes a first part of a locking mechanism on one of each of the first and second handle panels, and a second part of a locking mechanism on one of each of the second and fourth side panels. As the carton is formed from the blank, the first part of the locking mechanism and the second part of the locking mechanism cooperate to connect the first and second handle panels to the second and fourth side panels. As the carton is formed from the blank, the first handle panel and the second handle panel form the handle and planar surface of the carton.

[0011] In the example, the disclosed method includes (1) providing a blank comprising a plurality of panels; and (2) manipulating the blank so that the plurality of panels form a bottom wall, a top wall, a plurality of side walls, and a handle of the carton. The top wall is releasably connected to a plurality of opposing pairs of side walls. The handle is formed by at least a portion of the top wall. The handle and the top wall form a planar surface of the carton.

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

[0013] Other examples of the disclosed cartons, blanks, and methods will become apparent from the following detailed description, the accompanying drawings, and the accompanying claims. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic perspective view of an example of a conventional product packaging container in the form of a carton. [Figure 2] A schematic perspective view of another example of a conventional product packaging container in the form of a bag. [Figure 3] This is a schematic side perspective view of an example of a carton for packaging a product. [Figure 4] Figure 3 is a schematic perspective end view of an example of a carton. [Figure 5] This is a schematic side perspective view of an example of multiple cartons shown in a stacked arrangement. [Figure 6] This is a schematic perspective top view of an example of a carton. [Figure 7] Figure 6 is a schematic perspective view of an example of a carton. [Figure 8] Figure 6 is a schematic perspective view of an example of a carton, showing the carton with the end panels removed from a pair of top panels. [Figure 9] This is a schematic perspective top view of another example from Carton. [Figure 10] Figure 9 is a schematic perspective view of an example of a carton. [Figure 11] Figure 9 is a schematic perspective view of an example of a carton, showing the carton with the end panels removed from a pair of top panels. [Figure 12] This is a schematic side view of a portion of a carton example, illustrating an example of a carton locking mechanism. [Figure 13] This is a schematic side view of a portion of a carton example, showing another example of a carton locking mechanism. [Figure 14]A schematic side view of a portion of an example of a carton showing another example of a locking mechanism of the carton. [Figure 15] A schematic plan view of an example of a blank used to form a carton. [Figure 16] A schematic plan view of another example of a blank used to form a carton. [Figure 17] A schematic plan view of another example of a blank used to form a carton. [Figure 18] A schematic plan view of another example of a blank used to form a carton. **DETAILED DESCRIPTION OF THE INVENTION**

[0015] The following detailed description refers to the accompanying drawings, which illustrate specific examples of the disclosed cartons and blanks described by the present disclosure. It is to be understood that the disclosed examples are merely exemplary embodiments of ways in which particular aspects of the present invention may be implemented and do not represent an exhaustive list of all ways in which the present invention may be embodied. Other examples having different structures and operations are not outside the scope of the present disclosure. Like reference numbers may refer to the same feature, element, or component in different drawings. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Throughout the present disclosure, any one of a plurality of items may be referred to individually as an item, and a plurality of items may be referred to collectively as items. Moreover, as used herein, features, elements, components, or steps preceded by the word "a" or "an" should not be understood to exclude a plurality of such features, elements, components, or steps unless explicitly stated to the contrary.

[0016] Non-exhaustive examples of the subject matter according to the present disclosure, which may be claimed but are not necessarily so, are provided below. Referring to an "example" herein means that one or more features, structures, elements, components, characteristics, and / or operational steps described in relation to the example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Thus, throughout the present disclosure, the phrases "example", "another example", "one or more examples", and similar language may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may, but does not necessarily, be combined with the subject matter characterizing any other example.

[0017] Referring to FIGS. 3 - 14, by way of example, the present disclosure is directed to a carton 100 for packaging a product. The carton 100 facilitates the packaging, shipping, and display of the product. In other words, the carton 100 provides or serves as an external packaging container for the product. Also, the carton 100 provides or serves as a carrier for the product, for example, after purchase by a consumer. The carton 100 further provides or serves as a support structure for stacking one carton 100 on top of another carton 100.

[0018] The carton 100 can be made from any suitable packaging material. Examples of suitable packaging materials include cardboard, corrugated board, paperboard, plastic, combinations thereof, and any other suitable materials known to those skilled in the art and guided by the teachings provided herein.

[0019] The product can be any one of various types of primary products packaged in carton 100. In one or more examples, the product is perishable food (e.g., fresh fruit or fresh vegetables). Carton 100 can be appropriately sized and shaped to accommodate any reasonable number of products. Thus, throughout this disclosure, the term “product” refers to one or more products.

[0020] Referring to Figures 3 and 4, in one or more examples, the carton 100 includes a bottom wall 104, a number of side walls 108, and a top wall 106. The bottom wall 104, the top wall 106, and the side walls 108 form the internal volume 110 of the carton 100. The bottom wall 104, the top wall 106, and the number of side walls 108 enclose the product for shipping and display.

[0021] In the examples illustrated in Figures 1 to 3, the carton 100 includes four sidewalls 108. For example, the carton 100 includes a first sidewall 116 (e.g., a front wall), a second sidewall 118 (e.g., a right-end wall) connected to the first sidewall 116, a third sidewall 120 (e.g., a rear wall) connected to the second sidewall 118 on the opposite side of the first sidewall 116, and a fourth sidewall 122 (e.g., a left-end wall) connected to both the third sidewall 120 and the first sidewall 116 on the opposite side of the second sidewall 118. In other examples, the carton 100 may include fewer than four or more sidewalls.

[0022] In one or more examples, multiple side walls 108 are connected to the bottom wall 104. In one or more examples, one of each of the first side wall 116, second side wall 118, third side wall 120, and fourth side wall 122 is connected to the bottom wall 104. The top wall 106 is on the opposite side of the bottom wall 104. In one or more examples, the top wall 106 is approximately parallel to the bottom wall 104.

[0023] The upper wall 106 is releasably connected (e.g., removable) to one of the side walls 108. In one or more examples, the upper wall 106 is releasably connected to two or more of the side walls 108. In one or more examples, the upper wall 106 is releasably connected to a first pair of opposing side walls 108 (e.g., a second side wall 118 and a fourth side wall 122). In one or more examples, the upper wall 106 is connected (e.g., non-removably connected) to a second pair of opposing side walls 108 (e.g., a first side wall 116 and a third side wall 120). With the upper wall 106 connected to the first pair of opposing side walls 108, the upper wall 106 is configured to hold the carton 100 in a constructed (e.g., upright) configuration and to keep the carton 100 closed around the product.

[0024] Furthermore, the carton 100 includes a handle 112. The handle 112 facilitates the transport of the carton 100. The handle 112 is integrated with the upper wall 106. For example, the handle 112 is formed by at least a portion of the upper wall 106. Alternatively, at least a portion of the upper wall 106 is formed by the handle 112.

[0025] The carton 100 further includes a planar surface 114. The planar surface 114 is at least partially formed by the handle 112 and the upper wall portion 106. For example, the handle 112 and the upper wall portion 106 are approximately parallel to the bottom wall portion 104. For example, when the handle 112 forms the upper wall portion 106, the handle 112 is parallel to the bottom wall portion 104. For another example, when the handle 112 is formed by a portion of the upper wall portion 106, the handle 112 and the upper wall portion 106 are coplanar and parallel to the bottom wall portion 104.

[0026] In one or more examples, a portion of at least one end 132 of a first pair of opposing sidewalls 108 (for example, a second sidewall 118 and / or a fourth sidewall 122) extends beyond the upper wall 106 and forms a portion of the planar surface 114 of the carton 100.

[0027] Referring to Figure 5, the carton 100 is self-supporting, facilitating stacking, for example, when shipping, storing, or displaying. The top wall 106 and handle 112 are supported by multiple side walls 108 in an approximately horizontal and planar orientation. Thus, the planar surface 114 formed by the handle 112 and top wall 106 allows the carton 100 to be stacked on top of another carton 100 in a vertical arrangement. For example, multiple cartons 100 are shown in Figure 5, where each carton 100 is stacked on top of another carton 100, and the bottom wall 104 of the upper carton 100 is in substantially coplanar contact (for example, substantially coplanar) with the handle 112 and top wall 106 of the lower carton 100. The interconnection of the upper wall portion 106 and the first opposing pair of side wall portions 108 provides structural integrity to the carton 100 when multiple cartons 100 are stacked.

[0028] Referring again to Figures 3 and 4, in one or more examples, the carton 100 includes a locking mechanism 124. The locking mechanism 124 connects the upper wall 106 and one of the side wall 108 together. For example, the locking mechanism 124 connects the upper wall 106 to one of each of the first opposing pair of side wall 108 (e.g., the second side wall 118 and the fourth side wall 122). As an example, the carton 100 includes an opposing pair of locking mechanisms 124. One of each of the pair of locking mechanisms 124 connects one end of the upper wall 106 to one of the opposing pair of side wall 108.

[0029] The locking mechanism 124 may include any suitable mechanical locking mechanism known to those skilled in the art and guided by the teachings provided herein. In one or more examples, the locking mechanism 124 includes a male part that forms a first part of a complementary locking mechanism and a female part that forms a second part of a complementary locking mechanism.

[0030] In one or more examples, the locking mechanism 124 includes a locking tab 126 (e.g., a male portion) and a corresponding locking slot 128 (e.g., a female portion). The locking tab 126 is received by and secured within the locking slot 128. In one or more examples, as illustrated in Figures 3 and 4, the locking tab 126 is associated with the upper wall portion 106 and the locking slot 128 is associated with one of the side wall portions 108 (e.g., a second side wall portion 118 or a fourth side wall portion 122). Alternatively, in one or more examples, the locking slot 128 is associated with the upper wall portion 106 and the locking tab 126 is associated with one of the side wall portions 108 (e.g., a second side wall portion 118 or a fourth side wall portion 122).

[0031] In the illustrated example, the carton 100 includes a pair of opposing locking mechanisms 124. For example, the top wall 106 includes a pair of opposing locking tabs 126, and one of the first pair of opposing side wall sections 108 (for example, the second side wall section 118 or the fourth side wall section 122) includes a locking slot 128. In another example, the top wall 106 includes a pair of opposing locking slots 128, and one of the first pair of opposing side wall sections 108 (for example, the second side wall section 118 or the fourth side wall section 122) includes a locking tab 126. As another example, the upper wall portion 106 includes a locking tab 126 and an opposing locking slot 128, one of the first opposing pair of side wall portions 108 (for example, the second side wall portion 118) includes a locking slot 128 corresponding to the locking tab 126 of the upper wall portion 106, and the other of the first opposing pair of side wall portions 108 (for example, the fourth side wall portion 122) includes a locking tab 126 corresponding to the locking slot 128 of the upper wall portion 106.

[0032] The upper wall 106, and consequently the handle 112, may have a double-wall or double-layer construction. In one or more examples, the upper wall 106 includes, or is formed by, a first handle panel 136 and a second handle panel 138 that overlap each other. The first handle panel 136 and the second handle panel 138 are releasably connected by a locking mechanism 124 to at least one of the side wall sections 108 (for example, to a first opposing pair of side wall sections 108). The upper wall 106 having a double-layer construction formed by the first and second handle panels 136 and 138 provides additional reinforcement and structural integrity to the carton 100.

[0033] In one or more examples, the carton 100 includes at least one opening 208 formed through at least one of the sidewalls 108. For example, the opening 208 can be formed through one or more of the first sidewall 116, the second sidewall 118, the third sidewall 120, and the fourth sidewall 122. The opening 208 can have any suitable shape and dimensions. The opening 208 provides visual access to the internal volume 110 of the carton 100, and consequently, to the products contained within the carton 100. The opening 208 also facilitates air circulation through the internal volume 110 of the carton 100, which may be beneficial for keeping the products fresh.

[0034] Referring here to Figures 6 to 11, which schematically illustrate examples of carton 100. In one or more examples, carton 100 includes a plurality of panels 134, which form the internal volume 110, handle 112, and planar surface 114 of carton 100. Generally, the plurality of panels 134 form the wall portion of carton 100 (Figures 3 to 5).

[0035] In one or more examples, the plurality of panels 134 include a first side panel 140. When constructed, the first side panel 140 can form a first side wall 116 (Figures 3 to 5). The plurality of panels 134 include a second side panel 142, which is foldably connected (e.g., hinged or movable) to the first side panel 140. When constructed, the second side panel 140 can form a second side wall 118 (Figures 3 to 5). The plurality of panels 134 include a third side panel 144, which is foldably connected to the second side panel 142. When constructed, the third side panel 144 can form a third side wall 120 (Figures 3 to 5). Multiple panels 134 include a fourth side panel 146, which is foldably connected to the third side panel 144. When constructed, the fourth side panel 146 can form a fourth side wall 122 (Figures 3-5). Multiple panels 134 include a first handle panel 136, which is foldably connected to the first side panel 140, and is detachably connected to the second side panel 142 and the fourth side panel 146. Multiple panels 134 include a second handle panel 138, which is foldably connected to the third side panel 144, and is detachably connected to the second side panel 142 and the fourth side panel 146. When constructed, the first handle panel 136 and the second handle panel 138 form the upper wall portion 106 (Figures 3-5) and the handle 112 of the carton 100, and thus form at least a portion of the planar surface 114 of the carton 100.

[0036] In one or more examples, the first handle panel 136 overlaps at least a portion of the second handle panel 138. In one or more examples, the first handle panel 136 overlaps the entire second handle panel 138. In one or more examples, the first handle panel 136 and the second handle panel 138 have substantially the same shape, and when overlapped, portions of the first and second handle panels 136 and 138 form the handle 112.

[0037] In one or more examples, the locking mechanism 124 connects the first handle panel 136 and the second handle panel 138 to the second side panel 142 and the fourth side panel 146. In one or more examples, the first handle panel 136 and the second handle panel 138 extend between the second side panel 142 and the fourth side panel 146, and the second handle panel 138 interlocks with the second side panel 142 and the fourth side panel 146, so that the first handle panel 136 and the second handle panel 138 provide or serve as retaining straps for holding the carton 100 in a constructed and closed configuration.

[0038] As illustrated in Figures 6-8 and 12, in one or more examples, the locking mechanism 124 includes a handle locking tab 148 and a wall locking slot 150. The handle locking tab 148 protrudes from each of the respective ends 130 of the first handle panel 136 and the second handle panel 138. The wall locking slot 150 is formed through one of the respective second side panels 142 and the fourth side panel 146. When the carton 100 is constructed, the handle locking tab 148 is received by the wall locking slot 150 and engages with the corresponding one of the second side panel 142 and the fourth side panel 146. The mating engagement of the handle locking tab 148 and the wall locking slot 150 locks the first handle panel 136 and the second handle panel 138 into the second side panel 142 and the fourth side panel 146.

[0039] As illustrated in Figure 12, in one or more examples, portions of the ends 132 of the second side panel 142 and the fourth side panel 146 extend beyond the handle 112 and are foldable to form a portion of the planar surface 114.

[0040] As illustrated in Figures 9–11, 13, and 14, in one or more examples, the locking mechanism 124 includes a wall locking tab 152 and a handle locking slot 154. The wall locking tab 152 protrudes from one end 132 of each of the second side panel 142 and the fourth side panel 146. The handle locking slot 154 is formed through one end 130 of each of the first handle panel 136 and the second handle panel 138. When the carton 100 is constructed, the wall locking tab 152 is received by the handle locking slot 154 and engages with the handle 112. The mating engagement of the wall locking tab 152 and the handle locking slot 154 locks the first handle panel 136 and the second handle panel 138 into the second side panel 142 and the fourth side panel 146.

[0041] As illustrated in Figures 13 and 14, in one or more examples, a portion of one end 132 of each of the second side panel 142 and the fourth side panel 146 forms a portion of the planar surface 114.

[0042] Referring again to Figures 6 to 11, in one or more examples, the carton 100 includes at least one opening 208 formed through at least one of the multiple panels 134. In one or more examples, as illustrated in Figures 9 to 11, Figure 13, and Figure 14, one of each of the second side panel 142 and the fourth side panel 146 includes an opening 210, the opening 210 is positioned close to one end 132 of each of the second side panel 142 and the fourth side panel 146. When the first and second handle panels 136 and 138 are connected to the second and fourth side panels 142 and 146 by a locking mechanism 124, the opening 210 allows the ends 130 of the first handle panel 136 and the second handle panel 138 to extend through the respective second side panel 142 and the fourth side panel 146.

[0043] Referring here to Figures 15–18, this disclosure also relates to blanks of sheet material (generally referred to herein as “blanks” 102). The blanks 102 are used to form cartons 100 (for example, by fabricating, erecting, or otherwise constructing). As an example, the cartons 100 illustrated in Figures 3–8 and 12 can be formed from the blanks 102 illustrated in Figures 15 and 18. As another example, the cartons 100 illustrated in Figures 9–11 and 13 can be formed from the blanks 102 illustrated in Figure 16. As yet another example, the carton 100 illustrated in Figure 14 can be formed from the blanks 102 illustrated in Figure 17.

[0044] Blank 102 can be made from a sheet of suitable stock material. Blank 102 can be cut (e.g., die-cut) from a sheet of stock material. Suitable stock material includes all forms of foldable sheet material. In one or more examples, the stock material is a cellulose material, e.g., cardboard (e.g., bleached sulfate cardboard), thick cardboard, or other heavy-duty paper-based material. In one or more examples, the stock material is a polymer material, e.g., plastic board (e.g., plastic cardboard) or sheet plastic. In one or more examples, the stock material is made from corrugated cardboard (e.g., cellulose or polymer), e.g., corrugated cardboard comprising two liner sheets and an inner foldable corrugated material sandwiched between and connected to the liner sheets.

[0045] The blank 102 comprises a series of panels, each connected to the next by a fold line. Any one of the fold lines and / or hinge lines described herein may include any suitable predefined or preformed weakening lines and / or separation lines (e.g., creases, scores, or perforations) known to those skilled in the art and guided by the teachings provided herein. Generally, the fold lines deform the blank 102 into a plurality of separate but integrated panels, flaps, and tabs, etc.

[0046] For clarification, it should be recognized that the first surface of the blank 102 is exposed (for example, protruding toward the viewer) and is shown in Figures 15–18. For example, the first surface of the blank 102 can be the internal surface 156 of the carton 100 (Figures 3 and 4). The blank 102 also includes a corresponding second surface (for example, the bottom surface) that is not visible until the carton 100 is formed from the blank 102. For example, the second surface of the blank 102 can be the external surface 158 of the carton 100 (Figures 3 and 4).

[0047] In one or more examples, the second surface of the blank 102 (forming the outer surface 158 of the carton 100) is coated (including, for example, an outer surface coating). The outer surface coating can be a waterproof coating, a protective coating, and an aesthetic coating, etc. In one or more examples, at least a portion of the second surface of the blank 102 (forming the outer surface 158 of the carton 100) is printed with various product information about the product. For example, the outer surface 158 of the carton 100 can include a brand name or other product identification that is easily visible to consumers when the carton 100 is on display.

[0048] In one or more examples, the first surface of the blank 102 (forming the internal surface 156 of the carton 100) is coated (including, for example, an internal surface coating). The internal surface coating can be a waterproof coating, a protective coating, or an aesthetic coating. For example, the internal surface 156 of the carton 100 may be coated to resist liquids or moisture from the product from weakening or damaging the carton 100.

[0049] In one or more examples, the blank 102 includes a first side panel 140, a second side panel 142, a third side panel 144, a fourth side panel 146, a first handle panel 136, and a second handle panel 138. In one or more examples, the first side panel 140 forms the first side wall portion 116 of the carton 100 when the carton 100 is formed from the blank 102. In one or more examples, the second side panel 142 forms the second side wall portion 118 of the carton 100 when the carton 100 is formed from the blank 102. In one or more examples, the third side panel 144 forms the third side wall portion 120 of the carton 100 when the carton 100 is formed from the blank 102. In one or more examples, the fourth side panel 146 forms the fourth side wall portion 122 of the carton 100 when the carton 100 is formed from the blank 102. In one or more examples, the first handle panel 136 and the second handle panel 138 collectively form the top wall portion 106 and the handle 112 of the carton 100 when the carton 100 is formed from the blank 102.

[0050] Each of the side panels 140, 142, 144, and 146 can have any suitable two-dimensional shape and / or any desired dimensions. In the illustrated example, each of the side panels 140, 142, 144, and 146 has an approximately rectangular shape. Thus, when the carton 100 is formed from the blank 102, the side walls 116, 118, 120, and 122 of the carton 100 can have any suitable or desired shape (for example, an approximately rectangular shape).

[0051] In one or more examples, the first side panel 140, the second side panel 142, the third side panel 144, and the fourth side panel 146 are connected linearly in series along the longitudinal axis of the blank 102. The second side panel 142 extends from the first side panel 140 and is foldably connected to the first side panel 140 along a folding line 160 (e.g., the first side panel folding line). The folding line 160 extends laterally and separates the second side panel 142 from the first side panel 140. The third side panel 144 extends from the second side panel 142 on the opposite side of the first side panel 140 and is foldably connected to the second side panel 142 along a folding line 162 (e.g., the second side panel folding line). Folding line 162 extends laterally, approximately parallel to folding line 160, separating the third side panel 144 from the second side panel 142. The fourth side panel 146 extends from the third side panel 144 on the opposite side of the second side panel 142 and is foldably connected to the third side panel 144 along folding line 164 (for example, the folding line of the third side panel). Folding line 164 extends laterally, approximately parallel to folding line 162, separating the fourth side panel 146 from the third side panel 144.

[0052] The second side panel 142 is hinged to the first side panel 140 around a folding line 160 (for example, it is foldable) so that it can move from an orientation shown in a flat configuration (for example, as shown in Figures 15 to 18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3 to 11). The third side panel 144 is hinged to the second side panel 142 around a folding line 162 so that it can move from an orientation shown in a flat configuration (for example, as shown in Figures 15 to 18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3 to 11). The fourth side panel 146 is hinged to the third side panel 144 around a folding line 164, allowing it to move from an orientation shown in a flat configuration (for example, as shown in Figures 15-18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3-11).

[0053] In one or more examples, the blank 102 includes at least one opening 208 formed through at least one of a plurality of panels 134. The opening 208 can be formed (e.g., cut out) during the formation of the blank 102. In one or more examples, the opening 208 can interrupt the fold line, thereby allowing the blank 102 to be folded more easily during the erection of the carton 100.

[0054] In one or more examples, one or more of the side panels 140, 142, 144, and 146 may include a lower portion 192 and an upper portion 194. For example, one lower portion 192 of each of the side panels 140, 142, 144, and 146 is collapsibly connected to one adjacent lower portion 192 of the side panels 140, 142, 144, and 146 along their respective fold lines 160, 162, and 164. The upper portion 194 extends from the lower portion 192 and is collapsibly connected to the lower portion 192 along a fold line 196. The fold line 196 extends longitudinally, approximately perpendicular to the respective fold lines 160, 162, and 164, separating the upper portion 194 from the lower portion 192.

[0055] The upper portion 194 is hinged to the lower portion 192 around a fold line 196 (for example, it is foldable), so that it can move from an orientation shown in a flat configuration (for example, as shown in Figures 15 to 18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3 to 11).

[0056] Each of the lower portion 192 and upper portion 194 of each side panel 140, 142, 144, and 146 can have any suitable two-dimensional shape and / or any desired dimensions. In the illustrated example, the lower portion 192 has an approximately rectangular shape, and the upper portion 194 has an approximately trapezoidal shape. Thus, when the carton 100 is formed from the blank 102, one or more of the side wall portions 116, 118, 120, and 122 of the carton 100 can have a lower portion having any suitable or desired shape (e.g., approximately rectangular) and an upper portion having any suitable or desired shape (e.g., approximately trapezoidal).

[0057] As illustrated in Figures 3 to 11, in one or more examples, when the carton 100 is formed from the blank 102, the lower portions 192 of each side panel 140, 142, 144, and 146 are folded so that the lower portions of each side wall 116, 118, 120, and 122 are oriented approximately vertically (for example, approximately perpendicular to the bottom wall 104). The upper portions 194 of each side panel 140, 142, 144, and 146 are folded at an oblique angle to the lower portions 192 so that the upper portions of each side wall 116, 118, 120, and 122 are oblique to the lower portions of each side wall 116, 118, 120, and 122.

[0058] Referring to Figures 15 to 17, in one or more examples, one upper portion of each side panel 140, 142, 144, and 146 is free from (for example, not foldably connected to) an adjacent upper portion 194 of the side panel 140, 142, 144, and 146. For example, a "V" shaped cutout is formed in the blank 102 between adjacent pairs of upper portions 194 of the side panels 140, 142, 144, and 146, making it possible to separate each upper portion 194 from the adjacent upper portion 194.

[0059] Referring to Figure 18, in one or more examples, one upper portion of each of the side panels 140, 142, 144, and 146 is foldably connected to an adjacent upper portion 194 of the side panels 140, 142, 144, and 146. For example, the blank 102 may include a gusset panel 198, which is foldably connected to the upper portion 194 of each of the side panels 140, 142, 144, and 146. The gusset panel 198 provides increased structural integrity to the carton 100 when the carton 100 is formed from the blank 102.

[0060] In one or more examples, the gusset panel 198 includes a pair of tuck-in panels. For example, a first tuck-in panel extends from an upper portion 194 of one of the side panels 140, 142, 144, and 146 and is foldably connected to an upper portion 194 of one of the side panels 140, 142, 144, and 146 along a fold line, and a second tuck-in panel extends from an upper portion 194 of one of the side panels 140, 142, 144, and 146 which is directly adjacent and is foldably connected to an upper portion 194 of one of the side panels 140, 142, 144, and 146 along a fold line. The first and second tuck-in panels are foldably connected along a fold line. As the carton 100 is formed from the blank 102, the gusset panel 198 folds inward (for example, into the internal volume 110 of the carton 100), thereby holding one upper portion 194 of each of the side panels 140, 142, 144, and 146, and consequently one upper portion of each of the side wall portions 116, 118, 120, and 122, in a constructed configuration (for example, as shown in Figures 3 to 11).

[0061] In one or more examples, the first and second tuck-in panels of the gusset panels 198 connecting the upper portion 194 of the first side panel 140 and the upper portion 194 of the fourth side panel 146 are initially separated (for example, when the blank 102 is in a flat configuration) and joined together (for example, glued together) when the carton 100 is formed from the blank 102. For example, a flap 200 can extend from the first tuck-in panel and can be foldably connected to the first tuck-in panel. The flap 200 can be connected to the second tuck-in panel when the carton 100 is formed from the blank 102.

[0062] Referring again to Figures 15-18, the first handle panel 136 extends from the first side panel 140 and is foldably connected to the first side panel 140 along a folding line 166 (for example, the first handle panel folding line). The folding line 166 extends longitudinally and separates the first handle panel 136 from the first side panel 140. The second handle panel 138 extends from the third side panel 144 and is foldably connected to the third side panel 144 along a folding line 168 (for example, the second handle panel folding line). The folding line 168 extends longitudinally and separates the second handle panel 138 from the third side panel 144.

[0063] In one or more examples, the first handle panel 136 extends from the upper portion 194 of the first side panel 140 and is foldably connected to the upper portion 194 of the first side panel 140 along a folding line 166. The folding line 166 extends longitudinally, approximately parallel to the folding line 196, and separates the first handle panel 136 from the upper portion 194 of the first side panel 140. The second handle panel 138 extends from the upper portion 194 of the third side panel 144 and is foldably connected to the upper portion 194 of the third side panel 144 along a folding line 168. The folding line 168 extends longitudinally, approximately parallel to the folding line 196, and separates the second handle panel 138 from the upper portion 194 of the third side panel 144.

[0064] The first handle panel 136 is hinged to the first side panel 140 around a folding line 166 (for example, it is foldable) so that it can move from an orientation shown in a flat configuration (for example, as shown in Figures 15 to 18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3 to 11). The second handle panel 138 is hinged to the first side panel 140 around a folding line 168 (for example, it is foldable) so that it can move from an orientation shown in a flat configuration (for example, as shown in Figures 15 to 18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3 to 11).

[0065] In one or more examples, the blank 102 includes a cutout or opening formed between a first side panel 140 and a first handle panel 136, and a cutout or opening formed between a third side panel 144 and a second handle panel 138. For example, the cutouts can be positioned along or interrupted by the respective fold lines 166 and 168. The cutouts provide a contoured edge on one side of each of the first handle panel 136 and the second handle panel 138, thereby forming the handle 112 and, consequently, the handle portion of the upper wall 106.

[0066] In one or more examples, the blank 102 includes at least one bottom panel, the at least one bottom panel extending from at least one of the side panels 140, 142, 144, and 146, and being foldably connected to at least one of the side panels 140, 142, 144, and 146. The at least one bottom panel forms the bottom wall portion 104 of the carton 100 when the carton 100 is formed from the blank 102.

[0067] In the illustrated example, the blank 102 includes a first bottom panel 170, a second bottom panel 172, a third bottom panel 174, and a fourth bottom panel 176. The first bottom panel 170 extends from the first side panel 140 and is foldably connected to the first side panel 140 along a fold line 178 (e.g., the first bottom panel fold line). The fold line 178 extends longitudinally, approximately parallel to the fold line 166 and approximately perpendicular to the fold line 160, separating the first bottom panel 170 from the first side panel 140. The second bottom panel 172 extends from the second side panel 142 and is foldably connected to the second side panel 142 along a fold line 180 (e.g., the second bottom panel fold line). The eighth fold line 180 extends longitudinally, approximately collinear with fold line 166 and approximately perpendicular with fold lines 160 and 162, separating the second bottom panel 172 from the second side panel 142. The third bottom panel 174 extends from the third side panel 144 and is foldably connected to the third side panel 144 along fold line 182 (e.g., the third bottom panel fold line). The fold line 182 extends longitudinally, approximately collinear with fold line 180, approximately parallel with fold line 168, and approximately perpendicular with fold lines 162 and 164, separating the third bottom panel 174 from the third side panel 144. The fourth bottom panel 176 extends from the fourth side panel 146 and is foldably connected to the fourth side panel 146 along a folding line 184 (for example, the folding line of the fourth bottom panel). The folding line 184 extends longitudinally, approximately collinear with respect to the folding line 180 and approximately perpendicular with respect to the folding line 164, separating the fourth bottom panel 176 from the fourth side panel 146.

[0068] Each of the bottom panels 170, 172, 174, and 176 is hinged and movable (for example, foldable) around its respective folding line 178, 180, 182, and 184 relative to its respective side panel 140, 142, 144, and 146, so that it can move from an orientation shown in a flat configuration (for example, as shown in Figures 15-18) to an orientation shown in a constructed configuration (for example, as shown in Figures 3-11).

[0069] In other examples, the blank 102 may contain a different number (e.g., fewer than four) of bottom panels, and / or different configurations of bottom panels. Therefore, the illustrated example of bottom panels forming the bottom wall portion 104 of the carton 100 should not be seen as a limiting factor.

[0070] Each of the bottom panels 170, 172, 174, and 176 can have any suitable two-dimensional shape and / or any desired dimensions. In the illustrated example, one or more of the bottom panels 170, 172, 174, and 176 have a rectangular or trapezoidal shape. Thus, when the carton 100 is formed from the blank 102, the bottom wall portion 104 of the carton 100 can have any suitable or desired shape (for example, roughly rectangular).

[0071] One or more of the bottom panels 170, 172, 174, and 176 can be connected to one or more other bottom panels 170, 172, 174, and 176 by any suitable technique known to those skilled in the art and guided by the teachings provided herein. For example, one or more of the bottom panels 170, 172, 174, and 176 can be interlocked with each other, bonded together, taped together, and a combination thereof.

[0072] In one or more examples, for example, when an adhesive is used to join the bottom panels 170, 172, 174, and 176 together, at least one portion of the bottom panels 170, 172, 174, and 176 may include an uncoated area 186 to facilitate the adhesive bond.

[0073] In one or more examples, one or more of the bottom panels 170, 172, 174, and 176 may include a flap 188, which extends from one of each of the bottom panels 170, 172, 174, and 176. The flap 188 can facilitate the connection of corresponding pairs of bottom panels 170, 172, 174, and 176. For example, a flap 188 of one of the bottom panels 170, 172, 174, and 176 may engage with and bond to an uncoated area 186 of the corresponding bottom panel 170, 172, 174, and 176 when the carton 100 is formed from the blank 102.

[0074] In one or more examples, the flap 188 can be foldably connected to one of each of the bottom panels 170, 172, 174, and 176 along a fold line 190 (e.g., a flap fold line). The flap 188 is hinged (e.g., foldable) around the fold line 190 to one of each of the bottom panels 170, 172, 174, and 176 so that it can be moved during the construction of the carton 100 from the blank 102. In one or more examples, the fold line 190 can include intermittent cuts or perforations that allow the flap 188 to be folded more easily during construction.

[0075] The blank 102 includes at least one locking mechanism 124 for interlocking the first handle panel 136 and the second handle panel 138 with the second side panel 142 and the fourth side panel 146 when the carton 100 is formed from the blank 102.

[0076] In one or more examples, the blank 102 includes a first portion of the locking mechanism 124 (for example, a male portion as shown in Figures 15 and 18, or a female portion as shown in Figures 16 and 17) on one of the first handle panels 136 and one of the second handle panels 138. The blank 102 also includes a second portion of the locking mechanism 124 (for example, a female portion as shown in Figures 15 and 18, or a male portion as shown in Figures 16 and 17) on one of the second side panels 142 and one of the fourth side panels 146. When the carton 100 is formed from the blank 102, the first portion of the locking mechanism 124 and the second portion of the locking mechanism 124 cooperate to connect the first handle panel 136 and the second handle panel 138 to the second side panel 142 and the fourth side panel 146. As the carton 100 is formed from the blank 102, the first handle panel 136 and the second handle panel 138 form the handle 112, the upper wall portion 106, and the planar surface 114 of the carton 100.

[0077] Referring to Figures 15 and 18, in one or more examples, the first part of the locking mechanism 124 includes a handle locking tab 148. The handle locking tab 148 is an example of a locking tab 126 (for example, shown in Figures 3 to 5). The handle locking tab 148 protrudes from each of the respective ends 130 of the first handle panel 136 and the second handle panel 138. The second part of the locking mechanism 124 includes a wall locking slot 150. The wall locking slot 150 is an example of a locking slot 128 (for example, shown in Figures 3 to 5). The wall locking slot 150 is formed through one of the second side panel 142 and the fourth side panel 146. The handle locking tab 148 is configured to be received by the wall locking slot 150 when the carton 100 is formed from the blank 102, and is also configured to engage with the corresponding one of the second side panel 142 and the fourth side panel 146, thereby connecting the first handle panel 136 and the second handle panel 138, as well as the second side panel 142 and the fourth side panel 146 together.

[0078] Generally, the wall locking slots 150 are positioned close to (for example, in or near) one end 132 of each of the second side panel 142 and the fourth side panel 146. In one or more examples, the wall locking slots 150 are spaced away from one end edge of each of the second side panel 142 and the fourth side panel 146, so that when the carton 100 is formed from the blank 102 (for example, as shown in Figures 6-8 and 12), portions of one end 132 of each of the second side panel 142 and the fourth side panel 146 extend beyond the overlapping first handle panel 136 and the second handle panel 138. Thus, portions of the ends 132 of each of the second side wall 118 and the fourth side wall 122 extend beyond the top wall 106 (for example, as shown in Figures 3-5).

[0079] In one or more examples, one of the second side panel 142 and one of the fourth side panel 146 includes a hinge panel 202 positioned at one end 132 of the second side panel 142 and one of the fourth side panel 146. The hinge panel 202 extends from one of the second side panel 142 and one of the fourth side panel 146 and is foldably connected to one of the second side panel 142 and one of the fourth side panel 146 along a folding line 204 (e.g., a hinge panel folding line). For example, the hinge panel 202 extends from one of the upper portion 194 of the second side panel 142 and one of the fourth side panel 146 and is foldably connected to one of the upper portion 194 of the second side panel 142 and one of the fourth side panel 146 along a folding line 204. The folding lines 204 extend longitudinally, roughly parallel to each folding line 196, separating the hinge panel 202 from one of the second side panels 142 and one of the fourth side panels 146.

[0080] The hinge panel 202 is hinged to one of the second side panels 142 and the fourth side panel 146 around a folding line 204 (for example, it is foldable), so that it can move so as to be approximately coplanar with the first handle panel 136 and the second handle panel 138, thereby forming a portion of the planar surface 114 when the second carton 100 is stacked on top of the carton 100.

[0081] In one or more examples, the folding line 204 may include intermittent cuts or perforations that allow the hinge panel 202 to fold more easily between stacks. In one or more examples, the wall locking slot 150 interrupts the folding line 204 or is positioned along the folding line 204, thereby allowing the hinge panel 202 to fold more easily between stacks and positioning the hinge panel 202 directly above the stacked first handle panel 136 and second handle panel 138.

[0082] Referring to Figures 16 and 17, in one or more examples, the first part of the locking mechanism 124 includes a handle locking slot 154. The handle locking slot 154 is an example of a locking slot 128 (for example, shown in Figures 3 to 5). The handle locking slot 154 is formed through one of each end 130 of the first handle panel 136 and the second handle panel 138. The second part of the locking mechanism 124 includes a wall locking tab 152. The wall locking tab 152 is an example of a locking tab 126 (for example, shown in Figures 3 to 5). The wall locking tab 152 protrudes from one of each end 132 (for example, an end edge) of the second side panel 142 and the fourth side panel 146. The wall locking tabs 152 are configured to be received by the handle locking slots 154 when the carton 100 is formed from the blank 102, and are also configured to engage with the handle 112 and to connect the first handle panel 136 and the second handle panel 138, as well as the second side panel 142 and the fourth side panel 146 together.

[0083] Generally, the handle locking slot 154 is positioned close to (for example, in or near) one of each opposing end 130 of the first handle panel 136 and the second handle panel 138. In one or more examples, the handle locking slot 154 is positioned away from each of the opposing end edges of the first handle panel 136 and the second handle panel 138.

[0084] In one or more examples, the wall locking tab 152 extends from one hinge panel 202 of each of the second side panel 142 and the fourth side panel 146, and is foldably connected to one hinge panel 202 of each of the second side panel 142 and the fourth side panel 146 along a folding line 206 (e.g., a locking tab folding line). The folding line 206 extends longitudinally, approximately parallel to each folding line 204. The wall locking tab 152 is hinged (e.g., foldable) around the folding line 206 relative to the hinge panel 202, so that it can move during insertion into the corresponding handle locking slot 154 when the carton 100 is formed from the blank 102. In one or more examples, the folding line 206 may include intermittent cuts or perforations that allow the hinge panel 202 to fold more easily between stacks.

[0085] In one or more examples, the hinge panel 202 is hinged to move (for example, foldable) around a folding line 204 with respect to one of the second side panels 142 and the fourth side panel 146, so that it can move to be approximately coplanar with the first handle panel 136 and the second handle panel 138, thereby forming a portion of the planar surface 114 when the wall locking tab 152 is received by the handle locking slot 154 (for example, as shown in Figure 13).

[0086] In one or more examples, the opening 210 interrupts or is positioned along the folding line 204, thereby allowing the hinge panel 202 to fold while the wall locking tab 152 is inserted into the handle locking slot 154. The opening 210 also allows one end 130 of each of the first and second handle panels 136 and 138 to extend through one of each of the second and fourth side panels 142 and 146 while the wall locking tab 152 is inserted into the handle locking slot 154 (for example, as shown in Figures 13 and 14).

[0087] Referring to Figure 17, in one or more examples, the first part of the locking mechanism 124 includes a pair of handle locking slots 154. The pair of handle locking slots 154 is an example of a locking slot 128 (shown, for example, in Figures 3 to 5). The pair of handle locking slots 154 are formed through one of each end 130 of the first handle panel 136 and the second handle panel 138, respectively.

[0088] In one or more examples, a pair of handle locking slots 154 are spaced apart from each other and parallel to each other. When the carton 100 is formed from the blank 102, the wall locking tab 152 is inserted from a first direction through the first of the pair of handle locking slots 154, and then from a second direction opposite to the first direction through the second of the pair of handle locking slots 154, so that the wall locking tab 152 loops or wraps around the pair of handle locking slots 154 (as shown, for example, in Figure 14), thereby providing a double lock. This double locking arrangement between the wall locking tab 152 and the pair of handle locking slots 154 provides a more secure interlock between the first and second handle panels 136 and 138 and the second and fourth side panels 142 and 146.

[0089] Generally, the locking tab 126 (e.g., handle locking tab 148 or wall locking tab 152) and the locking slot 128 (e.g., handle locking slot 154 or wall locking slot 150) have complementary shapes and mating shapes that allow the locking tab 126 to pass through the locking slot 128 in one direction, but prevent the locking tab 126 from passing through the locking slot 128 in the opposite direction. For example, the locking tab 126 may have an arrowhead shape with a cut-off top.

[0090] As illustrated in Figures 15 and 18, in one or more examples, the handle locking tab 148 may include a main portion and a pair of opposing anchor fixing portions, the main portion being connected to and extending from the ends 130 of the respective first handle panels 136 and second handle panels 138, and the pair of opposing anchor fixing portions being connected to and extending outward from the main portion. A notch or recess may be formed between one of each anchor fixing portion and the end edge of the respective first handle panel 136 and second handle panel 138. When the handle locking tab 148 is received by the wall locking slot 150, a portion of each of the second side panel 142 and fourth side panel 146 may be positioned within the notch, thereby holding the handle locking tab 148 in the wall locking slot 150 by interference fit.

[0091] In one or more examples, the anchoring portion of the handle locking tab 148 can be bent or curved relative to the main portion while being inserted into the wall locking slot 150. Once the handle locking tab 148 clears the edge of the wall locking slot 150, the anchoring portion can spring back to a more planar condition relative to the main portion (for example, flattening due to the natural elasticity of the stock material of the blank 102), so that the edge of the anchoring portion abuts against one inner surface each of the second side panel 142 and the fourth side panel 146 when tension is applied in the direction opposite to the locking direction.

[0092] In one or more examples, the wall locking slot 150 may have a first portion and a second portion, as illustrated in Figures 15 and 18. The first portion is appropriately sized to allow insertion of the handle locking tab 148 through the first portion (for example, larger than the handle locking tab 148). The second portion is appropriately sized to prevent removal of the handle locking tab 148 through the second portion (for example, smaller than the handle locking tab 148).

[0093] As illustrated in Figures 16 and 17, in one or more examples, the wall locking tab 152 may include a main portion and a pair of opposing anchor fixing portions, the main portion being connected to and extending from the ends 132 of the respective second side panels 142 and fourth side panels 146, and the pair of opposing anchor fixing portions being connected to and extending outward from the main portion. A notch or recess may be formed between one of each anchor fixing portion and the end edge of the respective second side panels 142 and fourth side panels 146. When the wall locking tab 152 is received by the handle locking slot 154, portions of the first handle panel 136 and second handle panel 138 may be positioned within the notch, thereby holding the wall locking tab 152 in the handle locking slot 154 by interference fit.

[0094] In one or more examples, the anchoring portion of the wall locking tab 152 may be bent or curved relative to the main portion while being inserted into the handle locking slot 154. Once the wall locking tab 152 clears the edge of the handle locking slot 154, the anchoring portion may spring back to a more planar condition relative to the main portion (for example, becoming flat due to the natural elasticity of the stock material of the blank 102), so that the edge of the anchoring portion abuts against one of the underlying inner surfaces of the overlapping first and second handle panels 136 and 138 when tension is applied in the direction opposite to the locking direction.

[0095] In one or more examples, the handle locking slot 154 can be approximately linear (for example, as shown in Figure 17). In one or more examples, the handle locking slot 154 can be nonlinear (for example, as shown in Figure 16), thereby allowing insertion of the wall locking tab 152 when the anchor fixing portion is bent, but without requiring much rebound so that the edge of the anchor fixing portion contacts one of the underlying internal surfaces of the overlapping first and second handle panels 136 and 138.

[0096] This disclosure is further directed toward a method for forming a carton 100 from a blank 102. The method may include a series of sequential folding operations. The folding process is not limited to any particular folding process and may be modified according to specific manufacturing requirements.

[0097] In one or more examples, the method includes the step of providing a blank 102 including a plurality of panels 134. The method includes the step of manipulating the blank 102 so that the plurality of panels 134 form a bottom wall 104, a top wall 106, a plurality of side walls 108, a handle 112, and a planar surface 114 of the carton 100. The top wall 106 is releasably connected to a pair of opposing side walls 108. The handle 112 is formed by at least a portion of the top wall 106. The handle 112 and the top wall 106 form the planar surface 114 of the carton 100.

[0098] In one or more examples, carton 100 can be formed by erecting around the product. In one or more examples, carton 100 can be partially erected and filled with the product. The erection and filling processes can be carried out manually, using machines in an automated process, or a combination thereof.

[0099] This disclosure is further directed to a method for packaging a product in a carton 100. The carton 100 includes a bottom wall 104, a plurality of side walls 108, a top wall 106, a handle 112 formed by at least a portion of the top wall 106, and a planar surface 114 formed at least partially by the handle 112 and the top wall 106. In one or more examples, the method includes the step of erecting the carton 100 so that one of the side walls 108 is detached from the top wall 106. The method includes the step of loading the product into the internal volume 110 of the carton 100. The method includes the step of further erecting the carton 100 so that one of the side walls 108 is connected to the top wall 106. In one or more examples, the carton 100 is the first of a plurality of cartons 100. This method includes the step of stacking a second carton 100 on the planar surface 114 of a first carton 100 (as shown in Figure 5, for example).

[0100] The disclosed carton 100 provides a minimal material solution with performance (e.g., integrity and marketability) equivalent to conventional product containers. Various examples of the disclosed carton 100 formed from a blank 102 include a handle 112, thereby enabling the carton 100 to function as a product carrier. The handle 112 essentially forms the top wall portion 106 of the carton 100 and has a portion (either male or female) of a locking mechanism 124 at its lateral end portion, which engages with a corresponding portion of the locking mechanism 124 positioned above the upper portion of each side wall portion 108, thereby forming the end of the carton 100, respectively. Thus, the handle 112 extends between and engages with the side wall portions 108 (e.g., side panels) of the carton 100, rather than engaging with the top panel of the carton (e.g., as in conventional product packaging), thereby providing the carton 100 with increased structural integrity. Additionally, the handle 112, and consequently the upper wall 106, has a double-layer construction formed by two substantially identical handle panels 136 and 138, which provides additional reinforcement and structural integrity to the carton 100. Furthermore, the configuration of the side wall 108 (e.g., side panel), the upper wall 106, and the handle 112 (e.g., handle panels 136, 138) provides a planar surface 114 on which a second carton can be stacked, thereby enabling stacking while providing the carton 100 with handles.

[0101] For the purposes of this disclosure, the terms “interior,” “exterior,” “bottom,” “top,” “bottom,” “upper,” “front,” “rear,” “side,” “edge,” and similar terms, or other forms of such terms, are relative and refer to examples of spatial relationships between structures, elements, items, components, or features, or to orientations determined in relation to a fully upright and upright carton (as shown, for example, in Figures 3 to 11). Therefore, the examples of cartons 100 and blanks 102 described herein and illustrated in the figures are not intended to be limited by any particular relative terms used to describe any structure, element, item, component, or feature of carton 100 or blank 102.

[0102] Examples of the disclosed carton 100 and the blank 102 for producing it are described in detail above. The blank 102 and carton 100 are not limited to the specific examples described herein; rather, the components, elements, and / or features of the blank and / or container can be used independently and separately from other components, elements, and / or features described herein. For example, the blank can also be used in combination with other types of products and is not limited to the practice of articles as described and illustrated herein. Rather, the exemplary embodiments can be implemented and used in connection with many other applications.

[0103] Unless otherwise indicated, terms such as “first,” “second,” and “third” are used herein solely as labels and are not intended to impose any sequential, positional, or hierarchical requirements on the items they refer to. Furthermore, a reference to, for example, the “second” item does not require or exclude the existence of, for example, the “first” or lower-numbered item, and / or, for example, the “third” or higher-numbered item.

[0104] As used herein, the phrase “at least one of” means, when used with a list of items, that one or more different combinations of the enumerated items may be used, and only one of each item in the list may be required. For example, “at least one of item A, item B, and item C” could, but not be limited, include item A, or item A and item B. This example could also include item A, item B, and item C, or item B and item C. In other examples, “at least one of” could, for example, two of item A, one of item B, and ten of item C; four of item B and seven of item C; and other suitable combinations.

[0105] For the purposes of this disclosure, the terms “connected,” “linked,” and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, communicated, or otherwise related to one another. In various examples, elements may be related directly or indirectly. For example, element A may be directly related to element B. In another example, element A may be indirectly related to element B, for example, through another element C. It will be understood that not all associations between various disclosed elements are necessarily represented. Therefore, other connections may exist that are not depicted in the diagrams.

[0106] As used herein, the term “substantially” refers to a condition that is essentially the same as the stated condition, which performs the desired function or achieves the desired result. As used herein, the term “approximately” refers to a condition that is similar to the stated condition but is not exactly the same as the stated condition, and which still performs the desired function or achieves the desired result. However, the use of the terms “substantially” and “approximately” does not exclude conditions that are exactly the same as the stated condition.

[0107] Those skilled in the art will recognize that not all elements described and illustrated in Figures 1 to 18 are necessarily included in all examples, and not all elements described herein are necessarily shown in each exemplary example. Unless otherwise explicitly stated, the schematic illustrations of the examples shown in Figures 1 to 18 do not imply any structural limitations with respect to the exemplary examples. Rather, it should be understood that one exemplary structure is shown, but the structure may be modified where appropriate. In addition, modifications, additions, and / or omissions may be made to the illustrated structures.

[0108] Furthermore, throughout this specification, no references to features, advantages, or similar language used herein imply that all features and advantages that may be realized by the examples disclosed herein must be found in any single example. Rather, the language referring to features and advantages is understood to mean that any particular feature, advantage, or characteristic described in relation to an example is contained in at least one example. Thus, discussions of features, advantages, and similar language used throughout this disclosure may, but may not, refer to the same example.

[0109] The described features, advantages, and characteristics of one example can be combined in any suitable manner in one or more other examples. A person skilled in the art will recognize that the examples described herein can be practiced without one or more of the particular features or advantages of a particular example. In other cases, additional features and advantages that may not be present in all examples may be recognized in a particular example. Furthermore, although various examples of carton 100 and blank 102 for forming carton 100 and method have been shown and described, modifications may be conceived by a person skilled in the art upon reading this specification. This application includes such modifications and is limited only by the claims. [Explanation of Symbols]

[0110] 100 cartons 102 Blank 104 Bottom wall 106 Upper wall section 108 Side wall section 110 Internal volume 112 Handle 114 Planar surface 116 First side wall section 118 Second side wall section 120 Third side wall section 122 Fourth side wall section 124 Locking Mechanism 126 Locking Tabs 128 locking slots 130 End 132 End 134 Multiple Panels 136 First handle panel 138 Second handle panel 140 First side panel 142 Second side panel 144 Third side panel 146 Fourth side panel 148 Handle Locking Tabs 150 wall-mounted locking slots 152 Wall-mounted locking tabs 154 handle locking slots 156 Internal surface 158 External surface 160 folding lines 162 Folding lines 164 Folding lines 166 Folding lines 168 Folding lines 170 First bottom panel 172 Second bottom panel 174 Third bottom panel 176. Fourth bottom panel 178 Folding lines 180 folding lines 182 Folding lines 184 Folding lines 186 Uncoated areas 188 Flap 190 folding lines 192 Lower part 194 Upper part 196 Folding lines 198 gusset panel 200 flaps 202 Hinge Panel 204 Folding line 206 Folding lines 208 Opening 210 Opening B Bag C Carton H Handle

Claims

1. Bottom wall and; Multiple side walls connected to the bottom wall; An upper wall portion that is detachably connected to one of the aforementioned side wall portions; A handle formed by at least a portion of the upper wall; The plane formed at least partially by the handle and the upper wall portion A carton for packaged products comprising, A carton, wherein the handle is positioned to at least partially form the plane, and functions to carry the carton.

2. The carton according to claim 1, further comprising a locking mechanism for connecting the upper wall portion and one of the side wall portions together.

3. The locking mechanism is, (i) a locking tab associated with one of the upper wall portion or (ii) one of the side wall portions; (i) a locking slot associated with the upper wall portion or (ii) the other of one of the side walls portion Includes, The carton according to claim 2, wherein the locking tab is configured to be received by and fixed within the locking slot.

4. The carton according to claim 1, wherein a portion of the end of one of the side wall portions forms a portion of the plane.

5. The upper wall portion includes a first handle panel and a second handle panel that overlap each other at least partially; The carton according to claim 1, wherein the first handle panel and the second handle panel are releasably connected to one of the side walls by a locking mechanism.

6. The carton according to claim 1, further comprising at least one opening formed through at least one of the plurality of side wall portions.

7. A blank for forming the carton described in claim 1.

8. A carton for packaging products, The carton includes an internal volume and a plurality of panels that form a handle and a flat surface. The aforementioned multiple panels are First side panel and; A second side panel is foldably connected to the first side panel; A third side panel is foldably connected to the second side panel; A fourth side panel is foldably connected to the third side panel; A first handle panel, which is foldably connected to the first side panel and detachably connected to the second and fourth side panels; A second handle panel is foldably connected to the third side panel and detachably connected to the second and fourth side panels. Includes, A carton in which the first handle panel overlaps at least a portion of the second handle panel, and the first handle panel and the second handle panel form at least a portion of the handle and the plane.

9. The carton according to claim 8, further comprising a locking mechanism for connecting the first handle panel and the second handle panel to the second side panel and the fourth side panel.

10. The locking mechanism is, Handle locking tabs protruding from each end of the first handle panel and the second handle panel; A wall locking slot formed through one of the second side panel and one of the fourth side panel Includes, The carton according to claim 9, wherein the handle locking tab is received by the wall locking slot and engages with a corresponding one of the second side panel and the fourth side panel.

11. The carton according to claim 10, wherein portions of the ends of the second and fourth side panels protrude above the handle and are foldable to form a portion of the plane.

12. The locking mechanism is, The wall locking tabs protruding from one end of each of the second and fourth side panels; A handle locking slot formed through each of the ends of the first handle panel and the second handle panel, Includes, The carton according to claim 9, wherein the wall locking tab is received by the handle locking slot and engages with the handle.

13. The carton according to claim 12, wherein a portion of one end of each of the second side panel and the fourth side panel forms a portion of the plane.

14. A blank for forming the carton described in claim 8.

15. The carton according to claim 8, wherein the first handle panel and the second handle panel are positioned to form at least a portion of the plane and function to carry the carton.

16. A blank for forming a carton, wherein the blank is First side panel and; A second side panel is foldably connected to the first side panel; A third side panel is foldably connected to the second side panel; A fourth side panel is foldably connected to the third side panel; A first handle panel is foldably connected to the first side panel; A second handle panel is foldably connected to the third side panel; A first portion of a locking mechanism on one of the first handle panel and the second handle panel; The second portion of the locking mechanism on one of the second side panel and the fourth side panel, respectively. Includes, When the carton is formed from the blank, The first part and the second part of the locking mechanism cooperate to connect the first handle panel and the second handle panel to the second side panel and the fourth side panel, The first handle panel and the second handle panel form the handle and at least a portion of the planar surface of the carton, blank.

17. The first portion of the locking mechanism includes handle locking tabs protruding from each of the ends of the first and second handle panels; The second portion of the locking mechanism includes a wall locking slot formed through one of the second side panel and one of the fourth side panel; The blank according to claim 16, wherein the handle locking tab is configured to be received by the wall locking slot and to engage with a corresponding one of the second side panel and the fourth side panel.

18. The first portion of the locking mechanism includes a handle locking slot formed through each of the end portions of the first handle panel and the second handle panel; The second portion of the locking mechanism includes wall locking tabs protruding from one end of each of the second and fourth side panels; The blank according to claim 16, wherein the wall locking tab is configured to be received by the handle locking slot and to engage with the handle.

19. The blank according to claim 16, further comprising at least one opening formed through at least one of the first side panel, the second side panel, the third side panel, and the fourth side panel.

20. The blank according to claim 16, wherein the first handle panel and the second handle panel are positioned to form at least a portion of the plane and function to carry the carton.

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