Container with denesting features

Abstract

A container for holding one or more products may comprise a plurality of panels at least partially extending around an interior of the container. The plurality of panels may comprise a bottom panel, at least one end panel extending upwardly from the bottom panel, and at least one side panel extending upwardly from the bottom panel and at least partially defined between a first edge and a second edge. The container may include denesting features including an extending portion defined along the first edge.

Description

Attorney Docket No. 23202.1231 WO2Client Docket No. GPT9254CONTAINER WITH DENESTING FEATURESCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application No.63 / 742,543 filed on January 7, 2025.INCORPORATION BY REFERENCE

[0002] The disclosure of U.S. Provisional Patent Application No. 63 / 742,543, filed on January 7, 2025, is hereby incorporated by reference for all purposes as if presented herein in its entirety.TECHNICAL FIELD

[0003] The present disclosure generally relates to cartons, containers, trays, and / or other constructs for holding food products and / or other types of articles and / or products. More specifically, the disclosure relates to container / trays with denesting features.BACKGROUND

[0004] Conventional stackable containers may utilize nesting configurations to maximize storage efficiency during transport and warehousing operations. However, these nesting arrangements can create operational challenges when containers become too deeply nested, resulting in jamming or binding that complicates automated separation processes. Conventional container designs may struggle to balance the competing requirements of efficient space utilization during storage against reliable automated handling during high-speed packaging operations, where consistent denesting performance is required to prevent equipment damage and maintain production throughput.SUMMARY OF THE DISCLOSURE

[0005] According to one aspect, a container for holding one or more products may comprise a plurality of panels at least partially extending around an interior of the container. The plurality of panels may comprise a bottom panel, at least one end panel extending upwardly from the bottom panel, and at least one side panel extending upwardly from the bottom panel and between a firstAtorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 edge and a second edge. The container may include denesting features including an extending portion defined along the first edge.

[0006] In some embodiments, the extending portion may be a first extending portion and the at least one end panel may include a second extending portion. The at least one end panel may cooperate with the at least one side panel to form a sidewall such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container. A first interior surface of the first extending portion may be in at least partial face-to-face contact with a second interior surface of the second extending portion.

[0007] According to another aspect, the container may further comprise a comer flap in at least partial face-to-face contact with the at least one side panel. An interior surface of the comer flap may be in at least partial face-to-face contact with an exterior surface of the at least one side panel. The at least one side panel may comprise deboss features and the comer flap may comprise emboss features aligned with the deboss features. An exterior surface of the comer flap may be in at least partial face-to-face contact with an interior surface of the at least one side panel.

[0008] In some embodiments, the at least one side panel may be a first side panel, and the plurality of panels may further comprise a second side panel extending upwardly from the bottom panel. The second side panel may comprise a third extending portion. The at least one end panel may be a first end panel, and the plurality of panels may further comprise a second end panel extending upwardly from the bottom panel. The second end panel may comprise a fourth extending portion. The reinforced spacer lug may be a first reinforced spacer lug, and the third extending portion and the fourth extending portion may be in contact to form a second reinforced spacer lug at a second comer of the container for preventing deep nesting between the container and the lower nested container.

[0009] According to another aspect, the extending portion may be a first extending portion, and the container may further comprise a comer flap that includes a second extending portion. The comer flap may be in face-to-face contact with the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container.Atorney Docket No. 23202.1231 WO2Client Docket No. GPT9254

[0010] According to another aspect, a blank for forming the container may comprise a plurality of panels. The plurality of panels may comprise a bottom panel, at least one end panel arranged to extend upwardly from the bottom panel when the container is formed from the blank, and at least one side panel arranged to extend upwardly from the bottom panel and between a first edge and a second edge when the container is formed from the blank. The blank may include denesting features including an extending portion arranged to be defined along the first edge when the container is formed from the blank.

[0011] In some embodiments, the extending portion may be a first extending portion and the at least one end panel may include a second extending portion arranged such that the at least one end panel cooperates with the at least one side panel to form a sidewall such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container when the container is formed from the blank. A first interior surface of the first extending portion may be arranged to be in at least partial face-to-face contact with a second interior surface of the second extending portion when the container is formed from the blank.

[0012] According to another aspect, the blank may further comprise a comer flap arranged to be in at least partial face-to-face contact with the at least one side panel when the container is formed from the blank. An interior surface of the comer flap may be arranged to be in at least partial face-to-face contact with an exterior surface of the at least one side panel when the container is formed from the blank. The at least one side panel may comprise deboss features and the comer flap may comprise emboss features arranged to be aligned with the deboss features when the container is formed from the blank. An exterior surface of the comer flap may be arranged to be in at least partial face-to-face contact with an interior surface of the at least one side panel when the container is formed from the blank.

[0013] In some embodiments, the at least one side panel may be a first side panel, and the plurality of panels may further comprise a second side panel arranged to extend upwardly from the bottom panel when the container is formed from the blank. The second side panel may comprise a third extending portion. The at least one end panel may be a first end panel, and the plurality of panels may further comprise a second end panel arranged to extend upwardly from the bottom panel when the container is formed from the blank. The second end panel may comprise a fourth extendingAttorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 portion. The reinforced spacer lug may be a first reinforced spacer lug, and the third extending portion and the fourth extending portion may be arranged to be in contact to form a second reinforced spacer lug at a second comer of the container for preventing deep nesting between the container and the lower nested container when the container is formed from the blank.

[0014] According to another aspect, the extending portion may be a first extending portion, and the blank may further comprise a comer flap that includes a second extending portion. The comer flap may be arranged to be in face-to-face contact with the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container when the container is formed from the blank.

[0015] According to another aspect, a method of forming the container may comprise obtaining a blank comprising a plurality of panels, the plurality of panels comprising a bottom panel, at least one end panel, and at least one side panel positioned between a first edge and a second edge. The method may further comprise positioning the plurality of panels at least partially around an interior of the container such that the at least one end panel extends upwardly from the bottom panel and the at least one side panel extends upwardly from the bottom panel and between the first edge and the second edge. The method may further comprise forming denesting features including an extending portion defined along the first edge.

[0016] In some embodiments, the extending portion may be a first extending portion and the at least one end panel may include a second extending portion, and the method may further comprise cooperating the at least one end panel with the at least one side panel to form a sidewall such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container. The method may further comprise positioning a first interior surface of the first extending portion in at least partial face-to-face contact with a second interior surface of the second extending portion.

[0017] According to another aspect, the blank may further comprise a comer flap, and the method may further comprise positioning the comer flap in at least partial face-to-face contact with the at least one side panel. The method may further comprise positioning an interior surface of the comer flap in at least partial face-to-face contact with an exterior surface of the at least one side panel. The at least one side panel may comprise deboss features and the comer flap may comprise embossAttorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 features, and the method may further comprise aligning the emboss features with the deboss features. The method may further comprise positioning an exterior surface of the comer flap in at least partial face-to-face contact with an interior surface of the at least one side panel.

[0018] In some embodiments, the at least one side panel may be a first side panel, the blank may further comprise a second side panel, the second side panel may comprise a third extending portion, and the method may further comprise positioning the second side panel to extend upwardly from the bottom panel. The at least one end panel may be a first end panel, the blank may further comprise a second end panel, the second end panel may comprise a fourth extending portion, and the method may further comprise positioning the second end panel to extend upwardly from the bottom panel. The reinforced spacer lug may be a first reinforced spacer lug, and the method may further comprise cooperating the third extending portion and the fourth extending portion to form a second reinforced spacer lug at a second comer of the container for preventing deep nesting between the container and the lower nested container.

[0019] According to another aspect, the extending portion may be a first extending portion, the blank may further comprise a comer flap that includes a second extending portion, and the method may further comprise positioning the comer flap in face-to-face contact with the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container.

[0020] Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] 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 the embodiments of the disclosure.Attorney Docket No. 23202.1231 WO2Client Docket No. GPT9254

[0022] Fig. 1 is an exterior plan view of a blank used to form a container or tray according to embodiments of the disclosure.

[0023] Figs.2 and 3 are perspective views of a container formed from the blank of Fig. 1 according to embodiments of the disclosure.

[0024] Fig. 4 is a perspective end view of the container of Figs. 2 and 3.

[0025] Figs. 5 is a perspective top view of the container from Figs. 2-4.

[0026] Fig. 6 is an enlarged perspective view of an end of the container of Figs. 2-5.

[0027] Fig. 7 is a perspective view of a stack of a plurality of the containers of Figs. 2-6 according to embodiments of the disclosure.

[0028] Fig. 8 is an exterior plan view of a blank used to form a container or tray according to a second embodiment of the disclosure.

[0029] Figs. 9 A and 9B are schematic perspective views of the container formed from the blank of Fig. 8 according to embodiments of the disclosure.

[0030] Figs. 10-13 are perspective views of the container of Figs. 9 A and 9B according to embodiments of the disclosure.

[0031] Fig. 14 is a perspective view of a stack of a plurality of containers ofFigs.9A-13 according to embodiments of the disclosure.

[0032] Corresponding parts are designated by corresponding reference numbers throughout the drawings.DETAILED DESCRIPTION

[0033] In the following description, various embodiments will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art thatAtorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 the embodiments may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.

[0034] Techniques disclosed herein may relate generally to containers with denesting features. More specifically, techniques disclosed herein may relate to containers including extending portions defined along edges that can provide both effective denesting functionality and improved bonding between container surfaces. Various embodiments may be described herein, including containers, blanks, methods, processes, systems, devices, and the like.

[0035] In order to better appreciate the features and aspects of the present disclosure, further context for the disclosure is provided in the following section by discussing one particular implementation of a container that includes extending portions defined along edges that can provide both effective denesting functionality and improved bonding between container surfaces. These embodiments are for explanatory purposes only and other embodiments may be employed in other container applications. For example, embodiments of the disclosure may be used with any container that holds food products, consumer goods, industrial components, or shipping materials. In some instances, embodiments of the disclosure may be particularly well suited for use with stackable containers in high-volume manufacturing environments because of their ability to prevent deep nesting within the stacked containers.

[0036] In one example a container includes extending portions that act like spacers or bumpers at the comers where the container walls meet. When one container is placed inside another, these extending portions may contact each other and prevent the containers from nesting too deeply. This controlled spacing may allow the containers to be easily separated when needed, while still allowing efficient stacking for storage and transport.

[0037] The present disclosure relates generally to various aspects of containers, constructs, trays, materials, packages, elements, and articles, and methods of making such containers, constructs, trays, materials, packages, elements, and articles. Although severed different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations thereof, and modifications of the various aspects, implementations, and embodiments are contemplated hereby. In one illustrated embodiment, the present disclosure relates to forming a container or tray for holding food items or various other articles. However, inAtorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 other embodiments, the container or tray can be used to form other non-food containing articles or may be used for heating or cooking.

[0038] The container of the present disclosure can be useful in containing one or more products (e.g., a food product) or other articles such as any suitable type of product that can be stored, transported, cooled, frozen, heated, and / or cooked. Some suitable products could comprise cookies, crackers, chips, sandwiches, hot dogs, French fries, nachos, fruits, vegetables, popcorn, cuts of meat, or any other suitable food product or other suitable article. In some embodiments, the container of the present disclosure can be used for heating, cooking, browning, crisping, etc. the food product by use of a heating or cooking device such as a microwave oven. It is understood that food products (or non-food products) other than the food products listed herein may be contained in the package. Further, products contained in this package may be generally round, rectangular, triangular, square, irregular, or any other suitable shape. In this specification, the terms “inner,” “interior,” “outer,” “exterior,” "lower," "bottom," "upper," and "top" indicate orientations determined in relation to fully erected and upright packages. As described herein, constructs can be formed from blanks by being glued with multiple panels, portions, tabs, flaps, fold lines and / or other suitable lines of weakening, and / or other aspects, which may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or nonsequential reference, without departing from the disclosure.

[0039] Fig. 1 is a plan view of a blank 103, used to form a tray or container 105 (see Figs. 2-7) according to embodiments of the disclosure. As shown in Fig. 1 , the blank 103 is oriented with the exterior surface 102 up. The container 105 can be used to hold and / or support a food product (not shown), such as cookies, crackers, French bread pizzas, sandwiches, hot dogs, turnovers, burritos, meats, French fries, and / or any other food product, such as during storing, selling, serving, chilling, freezing, cooking, etc. of the food product. In an alternative embodiment, the container 105 can hold and / or support a non-food item or article.

[0040] The blank 103 has a longitudinal axis LI and a lateral axis L2. The blank 103 includes a bottom panel 110, a first side panel 112 foldably connected to the bottom panel 110 along a longitudinal fold line 114, and a second side panel 116 foldably connected to the bottom panel 110 along a longitudinal fold line 118. In the illustrated embodiments, a first end panel 120 can beAttorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 foldably connected to the bottom panel 110 along a first lateral fold line 122 at one end of the bottom panel 110, and a second end panel 124 can be foldably connected to the bottom panel 110 along a second lateral fold line 126 at an opposing end of the bottom panel 110. As shown in Fig.1, the blank 103 can include comer flaps 130, 132 foldably connected at respective ends of the first end panel 120 along respective fold lines 134, 136 and can include comer flaps 138, 140 foldably connected at respective ends of the second end panel 124 along respective fold lines 142, 144. In the illustrated embodiments, the fold lines 134, 136, 142, 144 can be oblique. Any of the bottom panel 110, the side panels 112, 116, the end panels 120, 124, the comer flaps 130, 132, 138, 140, and / or the fold lines 114, 118, 122, 126, 134, 136, 142, 144 could be omitted or could be otherwise shaped, arranged, positioned, and / or configured without departing from the disclosure. For example, the comer flaps 130, 138, 132, 140 could be foldably connected to the respective side panels 112, 116 and / or the fold lines 134, 136, 142, 144 could be orthogonal.

[0041] As shown in FIG. 1 , each side panel 112, 116 may extend between a first edge and a second edge. The first edge may be defined along a boundary where the side panel meets an adjacent panel or where extending portions are positioned. For example, side panel 112 may extend between a first edge 113 and a second edge 115, where the first edge 113 may be positioned adjacent to end panel 120 and the second edge 115 may be positioned adjacent to end panel 124. Similarly, side panel 116 may extend between a third edge 117 and a fourth edge 119, where the third edge 117 may be positioned adjacent to end panel 124 and the fourth edge 119 may be positioned adjacent to end panel 120.

[0042] The extending portions 190 may be positioned along the respective edges of the side panels 112 and 116. For example, extending portions 190 of side panel 112 may be defined along edges 113, 115 and extending portions 190 of side panel 116 may be defined along edges 117, 119. This positioning of the extending portions along the edges may facilitate proper alignment and contact with corresponding extending portions 192 of the end panels 120, 124 when the container 100 is formed from the blank 103. The second edges 115, 119 of the side panels 112, 116 may be positioned opposite to the first edges and may provide structural boundaries for the side panels during container formation.Atorney Docket No. 23202.1231 WO2Client Docket No. GPI9254

[0043] Similarly, each end panel 120, 124 may extend between a first edge and a second edge. For example, end panel 120 may extend between a first edge 107 and a second edge 111, where the first edge 107 may be positioned adjacent to side panel 112 and the second edge 111 may be positioned adjacent to side panel 116. End panel 124 may extend between a third edge 121 and a fourth edge 123, where the third edge 121 may be positioned adjacent to side panel 116 and the fourth edge 123 may be positioned adjacent to side panel 112. The extending portions 192 may be positioned along the edges of the end panels 120, 124, with extending portions 192 of end panel 120 being defined along edges 107, 111 and extending portions 192 of end panel 124 being defined along edges 121, 123.

[0044] As shown in Fig. 1, the blank 103 can include denesting features including a side shoulder, side spacer lug or extending portion 190 and an end shoulder, end spacer lug, or extending portion 192 in each comer of the blank 103 (e.g., the extending portions 190, 192 at each comer extending along the respective comer flaps 130, 132, 138, 140). In some embodiments, the extending portions 190 can extend outwardly from each end of each of the side panels 112, 116, and the extending portions 192 can extend outwardly from each end of each of the end panels 120, 124. In the illustrated embodiments, the extending portions 190 can be separable from the respective comer flaps 130, 138, 132, 140 along respective cut lines 194 (e.g., wherein the cut lines 194 can be oblique, extending largely in the longitudinal direction LI), and the extending portions 192 can be separable from the respective comer flaps 130, 132, 138, 140 along respective cut lines 196 (e.g., including a lateral segment 196a and a longitudinal segment 196b). In some embodiments, the cut lines 194 and the lateral segments 196a at each comer of the blank 103 can cooperate to at least partially form a respective engagement edge of the respective denesting features at the respective comers of the container 105 formed from the blank 103, as described in more detail below. Any of the extending portions (e.g., extending portion 190 or extending portion 192) could be omitted or could be otherwise shaped, arranged, positioned, and / or configured without departing from the disclosure. For example, the cut lines 194 and the segments 196a, 196b of the cut line 196 can extend along any suitable angle.

[0045] As shown in Fig. 1, the blank 103 can include deboss features 152 in the side panels 112, 116 (e.g., debossed as viewed from the exterior side of the blank 103) and emboss features 154 in the comer flaps 130, 132, 138, 140 (e.g., embossed as viewed from the exterior side of the blankAtorney Docket No. 23202.1231 WO2Client Docket No. GPI9254 103). In some embodiments, the deboss features 152 near the opposing ends of the side panels 112, 116 can be aligned with and / or proximate to the respective emboss features in the respectively adjacent comer flaps 130, 138, 132, 14O.,The combination of the emboss features 154 and deboss features 152 may raise portions of surfaces of these panels, bringing them closer together when nested to improve the ability for adhesive to bond to each surface by closing gaps between glued surfaces. Any of the deboss features 152 and / or the emboss features 154 could be omitted or could be otherwise shaped, arranged, positioned, and / or configured without departing from the disclosure. The blank 103 could be otherwise shaped, arranged, positioned, and / or configured without departing from the disclosure.

[0046] As shown in Figs. 2 and 3, the container 105 can be formed from the blank 103 by folding the end panels 120, 124 and the side panels 112, 116 upwardly with respect to the bottom panel 110 along the respective fold lines 122, 126, 114, 118 with the fold lines 134, 142 of the respective end panels 120, 124 being adjacent or abutting the respective end edges of the first side panel 112 and the fold lines 136, 144 of the respective end panels 120, 124 being adjacent or abutting the end respective edges of the second side panel 116. Further, the comer flaps 130, 138, 132, 140 can be folded along the respective fold lines 134, 142, 136, 144 to be in an overlapping relationship with the respective side panels 112, 116 (e.g., with the interior surfaces of the comer flaps in face-to-face contact with the exterior surfaces of the respective side panels, as shown in Figs. 2 and 7). Alternatively, the exterior surfaces of the comer flaps 130, 138, 132, 140 could be positioned in face-to-face contact with the interior surfaces of the respective side panels 112, 116 (e.g., as shown in Figs. 3-6). In some embodiments, the comer flaps 130, 138, 132, 140 can be attached / secured (e.g., glued) to the respective side panels 112, 116. In various embodiments, the side panels 112, 116 and the end panels 120, 124 can cooperate to at least partially form a sidewall 160 extending around an interior 162 of the container 105 (e.g., extending around the entire interior 109 of the container 105 and / or around the perimeter of the bottom panel 110).

[0047] In some embodiments, the side panels 112, 116 and the comer flaps 130, 138, 132, 140 can separate along respective cut or tear lines as the side panels 112, 116 and the end panels 120, 124 are folded relative to the bottom panel 110. In addition, the extending portions 190 extending from the ends of the side panels 112, 116 can separate from the respective comer flaps 130, 138, 132, 140 along the cut lines 194 so that a free edge of the respective extending portions 190 extendsAtorney Docket No. 23202.1231 WO2Client Docket No. GPI9254 outwardly from the at least partially vertical edges of the respective side panels 112, 116. Further, as the comer flaps 130, 132, 138, 140 are folded with respect to the end panels 120, 124, the comer flaps 130, 132, 138, 140 can separate from the respective extending portions 192 along the respective cut lines 196 so that the extending portions 192 extend outwardly from the respective end panels 120, 124 above the respective fold lines 134, 136, 142, 144. As shown in Fig. 2, 3, 5, and 6, as the sidewall 160 of the container 105 is formed, each of the extending portions 190 and the extending portions 192 can come into contact (e.g., at least partial face-to-face contact) at the respective comers of the container 105 to at least partially form a reinforced spacer lug 198 at each comer of the container 105. In the illustrated embodiments, contact between the interior surfaces of the extending portion 190 and the extending portion 192 at each comer of the container 105 can at least partially result in the reinforced spacer lugs 198 extending outwardly from the sidewall 160 in an oblique direction with respect to the side panels 112, 116 and the end panels 120, 124 (Figs. 2-7).

[0048] As shown in Figs. 2-7, each of the reinforced spacer lugs 198 can have an engagement edge 199, which can include at least a portion of at least one of the respective extending portions 190 and the respective extending portion 192. For example, the engagement edge 199 can include the edge of the respective extending portion 190 formed when the extending portion 190 separates from the respective comer flap 130, 132, 138, 140 along the cut line 194 and / or the edge of the respective extending portion 192 formed when the extending portion 192 separates from the respective comer flap 130, 132, 138, 140 along the segment 196a of the cut line 196.

[0049] In some embodiments, the container 105 can be formed from the folded blank 104 manually or by one or more forming tools. As shown in Figs. 2-7, the bottom panel 110 and the sidewall 160 can extend along the interior 162 of the container 105. After loading products or articles into the interior 162, the container 105 can be enclosed and / or sealed (e.g., by a film, a bag, an outer carton, etc.).

[0050] As shown in Fig. 7, multiple containers 105a-105c can be arranged in a stack 202, wherein one or more containers (e.g., 105a) are at least partially received in the interior space 163 of at least one lower container (e.g., 105b) in the stack 202. In the illustrated embodiments, the containers 105a-105c can have tapered sides and ends, for example, due to shapes of the sideAtorney Docket No. 23202.1231 WO2Client Docket No. GPI9254 panels 112, 116 and the end panels 120, 124 (e.g., the top of each container 105a, 105b, 105c can be wider between the side panels and between the end walls than the bottom of each container 105a, 105b, 105c) for facilitating the stacking of the containers 105a- 105c. Further, the reinforced spacer lugs 198 and their engagement edges 199 can extend outwardly from the sidewall 160 of each container 105a, 105b, 105c (e.g., from each of the comers of each container) to at least partially limit the movement of a container (e.g., container 105a) into a lower container (e.g., container 105b) in the stack 202. For example, the engagement edges 199 can engage / contact an upper edge of the lower container 105b (e.g., the upper edge of the sidewall 160 and / or the extending portions 190, 192 of the lower container 105b) to help prevent further movement of the container 105a into the lower container 105b in the stack 202. In exemplary embodiments, this can facilitate separation of the containers 105a, 105b, 105c when removing the containers 105a, 105b, 105c from the stack 202.

[0051] The reinforced spacer lugs 198 and / or other aspects of the container 105 could be otherwise shaped, arranged, positioned, and / or configured without departing from the disclosure. For example, the container 105 could have any suitable number of spacer lugs. Further, the container 105 could be otherwise formed without departing from the disclosure. For example, the forming steps of forming the container 105 can be carried out in any suitable order.

[0052] In some embodiments, the opposing extending portions 190, 192 at each comer of the container 105 can form the reinforced spacer lugs 198 (e.g., multi-layer tabs). In embodiments the increased thickness of the multi-layer reinforced spacer lugs 198 can form stronger spacer lugs and can help prevent the spacer lugs from bending.

[0053] Fig. 8 shows a blank 303 for forming a tray or container 305 (see Figs. 9-14) according to a second embodiment of the disclosure. The second embodiment is generally similar to the prior embodiments, except for variations noted and variations that will be apparent to one of ordinary skill in the art. Accordingly, similar or identical features of the embodiments have been given like or similar reference numbers. In the second embodiment, the blank 303 is similar to the blank 103 of the first embodiment, except that the extending portions 190 which extend from the respective ends of the side panels 112, 116 are separable from the respective comer flaps 330, 338, 332, 340 along respective cuts 394, each cut 394 having a longitudinal segment 394a and a lateral segmentAtorney Docket No. 23202.1231 WO2Client Docket No. GPI9254 394b. as shown in Fig. 8, each of the comer flaps 330, 332, 338, 340 can include an extending portion 392 that is separable from the respective end panels 320, 324 along respective cut lines 396. The blank 303 could be otherwise shaped, arranged, positioned, and / or configured without departing from the disclosure.

[0054] In some embodiments, the container 305 can be formed in a similar manner as the container 105 of the prior embodiments. When the sidewall 360 is formed from the side panels 112, 116 and the end panels 120, 124, the comer flaps 330, 338, 332, 340 can be placed in an overlapping relationship with the respective side panels 112, 116 (e.g., with an exterior surface of each of the comer panels 330, 338, 332, 340 in face-to-face contact with an interior surface of the respective side panels 112, 116, as shown in Figs. 9A-14). In some embodiments, the comer flaps 330, 338, 332, 340 can be positioned so that the extending portions 392 are folded away from the respective end panels 320, 324 and so that the extending portions 392 and the extending portions 190 are in an overlapping relationship (e.g., with an exterior surface of the extending portions 392 in face-to-face contact with the interior surface of the respective extending portions 190) to at least partially form reinforced spacer lugs 398, each having a respective engagement edge 399 (Figs. 9A-14).

[0055] A plurality of the containers 305a, 305b, 305c can be arranged in a stack 402, as shown in Fig. 14. The container 305 could be otherwise shaped, arranged, positioned, and / or configured and / or could be otherwise formed without departing from the disclosure.

[0056] In embodiments, the aligned, overlapping extending portions 190, 392 at each comer of the container 305 can form the reinforced spacer lugs 398 (e.g., multi-layer tabs). In embodiments the increased thickness of the multi-layer reinforced spacer lugs 398 can form stronger spacer lugs and can help prevent the spacer lugs from bending.

[0057] Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure.

[0058] In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carrier toAtorney Docket No. 23202.1231 WO2Client Docket No. GPI9254 function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

[0059] A cut or tear line as disclosed herein can include: a slit that extends partially into the material along the desired line of weakness, and / or a series of spaced apart slits that extend partially into and / or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or tom in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.

[0060] In accordance with the example embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a 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 cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.Atorney Docket No. 23202.1231 WO2Client Docket No. GPI9254

[0061] The above embodiments may be described as having one or more panels adhered together by glue during erection of the carrier embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carrier panels in place.

[0062] The foregoing description of the disclosure illustrates and describes various embodiments. Various additions, modifications, changes, etc., could be made to the embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept 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 non-illustrated embodiments of the disclosure.

Claims

Attorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 WHAT IS CLAIMED IS:

1. A container for holding one or more products, the container comprising:a plurality of panels at least partially extending around an interior of the container, the plurality of panels comprising a bottom panel, at least one end panel extending upwardly from the bottom panel, and at least one side panel extending upwardly from the bottom panel and at least partially defined between a first edge and a second edge; anddenesting features including an extending portion defined along the first edge.

2. The container of claim 1, wherein the extending portion is a first extending portion, the at least one end panel at least partially defined between a third edge and a fourth edge, the denesting features further comprising a second extending portion defined along the third edge, wherein the at least one side panel cooperates with the at least one end panel to form a sidewall such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container.

3. The container of claim 2, wherein a first interior surface of the first extending portion is in at least partial face-to-face contact with a second interior surface of the second extending portion.

4. The container of claim 2, the container further comprising a comer flap in at least partial face-to-face contact with the at least one side panel.

5. The container of claim 4, wherein an interior surface of the comer flap is in at least partial face-to-face contact with an exterior surface of the at least one side panel.

6. The container of claim 5, wherein the at least one side panel comprises deboss features and wherein the comer flap comprises emboss features aligned with the deboss features.

7. The container of claim 4, wherein an exterior surface of the comer flap is in at least partial face-to-face contact with an interior surface of the at least one side panel.Atorney Docket No. 23202.1231 WO2Client Docket No. GPT92548. The container of claim 3, wherein the at least one side panel is a first side panel, the plurality of panels further comprising a second side panel extending upwardly from the bottom panel and at least partially defined between a fifth and a sixth edge, the denesting features further including a third extending portion defined along the fifth edge.

9. The container of claim 8, wherein the at least one end panel is a first end panel, the plurality of panels further comprising a second end panel extending upwardly from the bottom panel and at least partially defined between a seventh edge and an eighth edge, the denesting features further including a fourth extending portion defined along the seventh edge.

10. The container of claim 9, wherein the reinforced spacer lug is a first reinforced spacer lug, and wherein the third extending portion and the fourth extending portion are in contact to form a second reinforced spacer lug at a second comer of the container for preventing deep nesting between the container and a lower nested container.

11. The container of claim 1, wherein the extending portion is a first extending portion, the container further comprising a comer flap that includes a second extending portion, the comer flap in face-to-face contact with the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container.

12. A blank for forming a container for holding one or more products, the blank comprising:a plurality of panels extending at least partially around an interior of the container formed from the blank, the plurality of panels comprising a bottom panel, at least one end panel arranged to extend upwardly from the bottom panel when the container is formed from the blank, and at least one side panel arranged to extend upwardly from the bottom panel and at least partially defined between a first edge and a second edge when the container is formed from the blank; and denesting features including an extending portion defined along the first edge when the container is formed from the blank.Attorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 13. The blank of claim 12, wherein the extending portion is a first extending portion, the at least one end panel arranged to extend upwardly between a third edge and a fourth edge when the container is formed from the blank, the denesting features further including a second extending portion arranged to be defined along the third edge when the container is formed from the blank and wherein the at least one end panel cooperates with the at least one side panel to form a sidewall such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container when the container is formed from the blank.

14. The blank of claim 13, wherein a first interior surface of the first extending portion is arranged to be in at least partied face-to-face contact with a second interior surface of the second extending portion when the container is formed from the blank.

15. The blank of claim 13, the blank further comprising a comer flap arranged to be in at least partial face-to-face contact with the at least one side panel when the container is formed from the blank.

16. The blank of claim 15, wherein an interior surface of the comer flap is arranged to be in at least partial face-to-face contact with an exterior surface of the at least one side panel when the container is formed from the blank.

17. The blank of claim 16, wherein the at least one side panel comprises deboss features and wherein the comer flap comprises emboss features arranged to be aligned with the deboss features when the container is formed from the blank.

18. The blank of claim 15, wherein an exterior surface of the comer flap is arranged to be in at least partial face-to-face contact with an interior surface of the at least one side panel when the container is formed from the blank.

19. The blank of claim 14, wherein the at least one side panel is a first side panel, the plurality of panels further comprising a second side panel arranged to extend upwardly from the bottomAtorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 panel and at least partially defined between a fifth edge and a sixth edge when the container is formed from the blank, the denesting features further including a third extending portion defined along the fifth edge.

20. The blank of claim 19, wherein the at least one end panel is a first end panel, the plurality of panels further comprising a second end panel arranged to extend upwardly from the bottom panel and between a seventh edge and an eighth edge when the container is formed from the blank, the denesting features further comprising a fourth extending portion defined along the seventh edge.

21. The blank of claim 20, wherein the reinforced spacer lug is a first reinforced spacer lug, and wherein the third extending portion and the fourth extending portion are arranged to be in contact to form a second reinforced spacer lug at a second comer of the container for preventing deep nesting between the container and a lower nested container when the container is formed from the blank.

22. The blank of claim 12, wherein the extending portion is a first extending portion, the blank further comprising a comer flap that includes a second extending portion, the comer flap arranged to be in face-to-face contact with the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container when the container is formed from the blank.

23. A method of forming a container for holding one or more products, the method comprising:obtaining a blank comprising a plurality of panels, the plurality of panels comprising a bottom panel, at least one end panel, and at least one side panel;forming the plurality of panels such that the at least one end panel extends upwardly from the bottom panel and the at least one side panel extends upwardly from the bottom panel, the at least one side panel at least partially defined between a first edge and a second edge; and forming denesting features including an extending portion defined along the first edge.Atorney Docket No. 23202.1231 WO2Client Docket No. GPT925424. The method of claim 23, wherein the extending portion is a first extending portion, the at least one end panel at least partially defined between a third edge and a fourth edge, the denesting features further include a second extending portion defined along the third edge, the method further comprising forming a sidewall at least in part from the at least one end panel and the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container.

25. The method of claim 24, further comprising positioning a first interior surface of the first extending portion in at least partial face-to-face contact with a second interior surface of the second extending portion.

26. The method of claim 24, the blank further comprising a comer flap, the method further comprising positioning the comer flap in at least partial face-to-face contact with the at least one side panel.

27. The method of claim 26, further comprising positioning an interior surface of the comer flap in at least partial face-to-face contact with an exterior surface of the at least one side panel.

28. The method of claim 27, wherein the at least one side panel comprises deboss features and wherein the comer flap comprises emboss features, the method further comprising aligning the emboss features with the deboss features.

29. The method of claim 26, further comprising positioning an exterior surface of the comer flap in at least partial face-to-face contact with an interior surface of the at least one side panel.

30. The method of claim 25, wherein the at least one side panel is a first side panel, the blank further comprising a second side panel, the method further comprising positioning the second side panel to extend upwardly from the bottom panel, the second side panel at least partially definedAtorney Docket No. 23202.1231 WO2Client Docket No. GPT9254 between a fifth edge and a sixth edge, the denesting features further comprising a third extending portion defined along the fifth edge.

31. The method of claim 30, wherein the at least one end panel is a first end panel, the blank further comprising a second end panel, the method further comprising positioning the second end panel to extend upwardly from the bottom panel, wherein the second end panel is at least partially defined between a seventh edge and an eighth edge, the denesting features further comprising a fourth extending portion defined along the seventh edge.

32. The method of claim 31, wherein the reinforced spacer lug is a first reinforced spacer lug, the method further comprising cooperating the third extending portion and the fourth extending portion to form a second reinforced spacer lug at a second comer of the container for preventing deep nesting between the container and a lower nested container.

33. The method of claim 23, wherein the extending portion is a first extending portion, the blank further comprising a comer flap that includes a second extending portion, the method further comprising positioning the comer flap in face-to-face contact with the at least one side panel such that the first extending portion contacts the second extending portion to form a reinforced spacer lug at a comer of the container.

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