US20250083860A1

US20250083860A1 - Carton

Info

Publication number: US20250083860A1
Application number: US18/828,067
Authority: US
Inventors: Steven A. Mayer
Original assignee: Inno Pak LLC
Current assignee: Inno Pak LLC
Priority date: 2023-09-13
Filing date: 2024-09-09
Publication date: 2025-03-13

Abstract

A carton. The carton may include a floor panel; a plurality of side panels extending about a periphery of the floor panel, the plurality of side panels may include a front side panel, an opposing rear side panel, a first side end panel, and an opposing second side end panel. The carton may further include a corner gussets extending between adjacent side panels; a closure portion, wherein the closure portion may be configured to secure a top opening of the container portion; and an arrangement of vent openings, and wherein the floor panel, side panels, and corner gussets may be configurable to form a compartment region.

Description

RELATED APPLICATIONS

This application is related and claims priority to U.S. Provisional Patent Application No.: 63/538,171, filed on Sep. 13, 2023 the application of which is incorporate herein by reference in its entirety.

TECHNICAL FIELD

The subject matter relates generally to cartons and more particularly to carry-out food containers including ventilation and methods of using same.

BACKGROUND

Various products are known to be purchased by consumers that require a container for ease of transport. For example, in the food and grocery industry it is common to place food items in individual “carry-out” or “to-go” food containers. Carry-out food containers may provide one or more compartments for holding food. However, there may be certain drawbacks to commonly used carry-out food containers. For example, one drawback of carry-out food containers is that they lack ventilation. Consequently, when holding hot food, excessive moisture may build up inside the container, which may cause the food inside to get soggy.

SUMMARY

In one embodiment, a carton is provided. The carton may include a floor panel; a plurality of side panels extending about a periphery of the floor panel, the plurality of side panels may include a front side panel, an opposing rear side panel, a first side end panel, and an opposing second side end panel. The carton may further include a corner gussets extending between adjacent side panels; a closure portion, wherein the closure portion may be configured to secure a top opening of the container portion; and an arrangement of vent openings, and wherein the floor panel, side panels, and corner gussets may be configurable to form a compartment region. The closure portion may include, closure flaps extending from an uppermost edge of the side panels forming a moveable joint where the closure flaps and corresponding side panels intersect. A first closure flap and a second closure flap may be adapted to engage with one another when in a folded closed position. The first closure flap and the second closure flap may be configured to interlock with one another via a tab formed on one of the first closure flap or the second closure flap and a corresponding slot formed in the other of the first closure flap or the second closure flap. One or more of the vent openings may be formed substantially in the closure portion of the carton. The vent openings may be of a generally semi-circular shape. The bottom edge of one or more of the vent openings may be formed along one or more of the fold lines. The bottom edge portion of one or more of the vent openings may extend slightly below one or more of the fold lines, and the remaining portion may extend into its respective closure flap. One or more of the vent openings may be formed in one or more of the closure flaps. One or more of the vent openings may be configured as any one or more of a through-hole, a punchout, or a vent flap. The one or more vent openings, when configured in the through-hole configuration, may be defined by an opening. The one or more vent openings, when configured in the punchout configuration, may be defined by a perforated line or a score line formed about a part of, or all of, a periphery of the vent openings, and wherein the vent openings may be partially or fully removable about the perforated line or the score line. The one or more vent openings, when configured in the vent flap configuration, may be defined by a perforated line or a score line formed about a part of a periphery of the vent openings, and wherein the vent openings may be partially removable about the perforated line or the score line. The carton may include a single piece of material including a plurality of fold lines, and wherein the plurality of fold lines may be configured to allow the carton to be transformed from a flat pre-folded first configuration to an assembled folded second configuration. One or more of the moveable joints may be weakened, and wherein one or more of the closure flaps may be configured to be removable from its respective side panel by tearing along a respective one of the weakened moveable joints. The corner gussets may be configured to be foldable and securable to an inner surface or outer surface of one of their adjacent side panels, wherein securing the corner gussets to their corresponding adjacent side panels secures the compartment region in its formed state.
In another embodiment, a method of using a carton is provided. The method may include providing an assembled, wherein the carton may include a floor panel; a plurality of side panels extending about a periphery of the floor panel, the plurality of side panels may include a front side panel, an opposing rear side panel, a first side end panel, and an opposing second side end panel. The carton may further include a corner gussets extending between adjacent side panels; a closure portion, wherein the closure portion may be configured to secure a top opening of the container portion; and an arrangement of vent openings, and wherein the floor panel, side panels, and corner gussets may be configurable to form a compartment region. The method may further include placing contents into the compartment region of the carton; closing the top opening of the compartment region using the closure portion; and venting the carton via the vent openings. Venting the carton may include partially or fully removing material covering one or more of the vent openings.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the subject matter in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 through FIG. 5 illustrate various views of an example of a carton, in accordance with an embodiment of the invention;

FIG. 6 illustrates a plan view of the carton shown in FIG. 1 through FIG. 5 in a flat pre-folded configuration, in accordance with an embodiment of the invention;

FIG. 7 through FIG. 9 illustrate various views of another example of a carton, in accordance with an embodiment of the invention;

FIG. 10 illustrates a plan view of the carton shown in FIG. 7 through FIG. 9 in a flat pre-folded configuration, in accordance with an embodiment of the invention;

FIG. 11 through FIG. 13 illustrate various views of another example of a carton, in accordance with an embodiment of the invention;

FIG. 14 illustrates a plan view of the carton shown in FIG. 11 through FIG. 13 in a flat pre-folded configuration, in accordance with an embodiment of the invention; and

FIG. 15 illustrates a flow diagram of an example of a method of using any of the cartons shown in FIG. 1 through FIG. 14 , in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

The subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the subject matter are shown. Like numbers refer to like elements throughout. The subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the subject matter set forth herein will come to mind to one skilled in the art to which the subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.
In some embodiments, the subject matter of the invention provides cartons and method of using same.
In some embodiments, the cartons and method provide a container body for holding any desired contents (e.g., food items), two foldable lid end flaps, and two foldable lid end flaps.
In some embodiments, the cartons and method provide a container body, two foldable lid end flaps, and two foldable lid end flaps and further including any number, arrangements, and/or combinations of vent openings, vent punchouts, and/or vent flaps for preventing the buildup of excessive moisture inside the carton and thereby helping to keep the contents, e.g., food, crisp and not soggy.
Further, a method of using the cartons is provided.
Referring now to FIG. 1 through FIG. 5 illustrate various views of an example of a carton 100, in accordance with an embodiment of the invention. For example, FIG. 1 and FIG. 2 show perspective views of carton 100 in a closed state. FIG. 3 , FIG. 4 , and FIG. 5 are perspective views showing carton 100 in different configurations, for example, during closing. Carton 100 may be for holding and/or transporting items, such as food items.
Referring still to FIG. 1 through FIG. 5 , carton 100 may include container body 110, a pair of foldable lid end flaps 120, and a pair of foldable lid side flaps 126 (126 a and 126 b). Container body 110 may include, for example, a floor panel 112, two opposing side panels 114, and two opposing end panels 116. The ends of the side panels 114 and the end panels 116 may be coupled, for example, via webbed corners 118. The webbed corners 118 may be, for example, a webbed corner inside glue design. Alternatively, webbed corners 118 may be, for example, a webbed corner outside glue design. The webbed corners 118 may be secured to either of side panels 114 and/or end panels 116, for example, via an adhesive, thermal bonding, or any other suitable technique or mechanism.
The foldable lid side flaps 126 may be coupled to the top of the side panels 114 along fold lines 140. Similarly, the foldable lid end flaps 120 may be coupled to the top of the end panels 116 along fold lines 142. Fold lines 140 and/or fold lines 142 may be perforated, scored, or otherwise weakened, such that foldable lid end flaps 120 and/or foldable lid side flaps 126 may be removed, for example by tearing along an associated fold lines 140 and or 142.
In one example, each of the foldable lid end flaps 126 may be generally tapered away from container body 110. The tip of one of the foldable lid side flaps 126 (e.g., 126 a) may include a locking tab 128. The other foldable lid side flap 126 (e.g., 126 b) may include a foldable tip 130 with a slot 132 that is designed to receive the locking tab 128 of the other foldable lid side flap 126 (e.g., 126 a).
Further, carton 100 may include an arrangement of any number of vent openings 150. In one example, there may be one or more vent openings 150 on one or more sides of carton 100 with a bottom edge of the vent openings 150 slightly below, slightly above, or along fold lines 140. Alternatively, or in addition, there may be one or more vent openings 150 on one or more ends of carton 100 with a bottom edge of the vent openings 150 slightly below, slightly above, or along fold lines 140. Further, and alternatively, or in addition, in another example, there may be one or more vent openings 150 disposed in one or both of the foldable lid side flaps 126 and/or in one or both of the foldable lid end flaps 120. Vent openings 150 may be formed as a through-hole in the material, as a punchout, and/or as a vent flap. Vent openings 150 may be of a generally circular, half-circular, ovular, and/or any other suitable shape.
With respect to carton 100 being, for example, a disposable food container, carton 100 may be formed of any lightweight, rigid or semi-rigid material that is suitable for holding and/or transporting, for example, a quantity of cold and/or hot food and that is also suitable for disposing of after use. For example, carton 100 can be formed of corrugated cardboard, micro-fluted corrugated material, paper, solid unbleached sulphate (SUS) paperboard, solid bleached sulphate (SBS) paperboard, post-consumer paperboard (i.e., recycled materials), biodegradable materials (e.g., sugarcane and paper), polystyrene foam (e.g., Styrofoam), plastic, molded fiber, and/or the like.
Referring now to FIG. 6 is an outside plan view of carton 100 shown in FIG. 1 through FIG. 5 in a flat pre-folded configuration, in accordance with an embodiment of the invention. With respect to forming, for example, paperboard products, this flat pre-folded configuration is also called a “blank.”
Referring to FIG. 6 , carton 100 in the flat pre-folded configuration may, in one non-limiting example, have the following example dimensions:

- D1 about 12½ inches
- D2 about 12½ inches
- D3 about 6 inches
- D4 about 2½ inches
- D5 about 4¾ inches

The dimensions listed herein are exemplary only, and could be dimensions greater than or less than those listed as may be need for a particular carton size.
Referring now to FIG. 7 through FIG. 9 illustrates an example of a carton 102, in accordance with an embodiment of the invention. Carton 102 may be another example of a carton including ventilation. Carton 102 shown in FIG. 7 through FIG. 9 may be substantially the same as carton 100 shown in FIG. 1 through FIG. 6 except that the bottom edge of the vent openings 150 may be disposed along fold lines 140 and/or 142. In this example, each of the vent openings 150 may be configured as a punchout defined by a perforated line or a score line formed about a part of, or all of, the periphery of vent opening 150. As a punchout, vent openings 150 may provide capability for the user to create vent openings in carton 102 at will. Either by partially or fully punching out the punchouts of vent openings 150. That is, in one example, a punchout of vent openings 150 may be partially punched out to form a vent flap. In another example, a punchout of vent openings 150 may be fully punched out to form a vent through-hole.
Referring now to FIG. 10 is a plan view of carton 102 shown in FIG. 7 through FIG. 9 in a flat pre-folded configuration, in accordance with an embodiment of the invention. With respect to forming, for example, paperboard products, this flat pre-folded configuration is also called a “blank.” Carton 102 may have similar dimensions as that of carton 100.
Referring now to FIG. 11 through FIG. 13 illustrates an example of a carton 104, in accordance with an embodiment of the invention. Carton 104 may be yet another example of a food carton. In this example, carton 104 may be substantially the same as carton 100 shown in FIG. 1 through FIG. 6 except that the vent openings 150 are disposed in one or both of the foldable lid side flaps 126 and/or in one or both of the foldable lid end flaps 120. In this example, vent openings 150 may be configured as vent flaps. For example, as shown in FIG. 8 vent openings 150 are configured as a flap having an edge portion attached to its respective foldable lid side flap 126 and/or foldable lid end flap 120, and its remaining portion separated (or separatable) from its respective foldable lid side flap 126 and/or foldable lid end flap 120.
Referring now to FIG. 14 is a plan view of carton 104 shown in FIG. 11 through FIG. 13 in a flat pre-folded configuration, in accordance with an embodiment of the invention. With respect to forming, for example, paperboard products, this flat pre-folded configuration is also called a “blank.” Carton 104 may have similar dimensions as that of carton 100.
Referring now to FIG. 1 through FIG. 13 , any of the cartons 100, 102, 104 disclosed herein may include any number, arrangements, and/or combinations of vent openings 150, and may be configured as any one of, or combination of, through-holes (as shown for example in FIG. 1 ), punchouts (see for example FIG. 7 ), and/or vent flaps (see for example FIG. 11 ),
Referring now to FIG. 15 is a flow diagram of an example of a method 200 of using any of the cartons 100, 102, 104 shown in FIG. 1 through FIG. 14 that include ventilation, in accordance with an embodiment of the invention. Method 200 may include, but is not limited to, the following steps.
At a step 210, a carton is provided that includes ventilation. For example and referring to FIG. 1 through FIG. 14 , a carton 100, 102 or 104 may be provided that includes container body 110 for holding any desired contents (e.g., food items), two foldable lid end flaps 120, and two foldable lid end flaps 126. In this example, carton 100, 102 or 104 may include any number and locations of vent openings 150.
At a step 215, any contents may be placed into the container body of the carton. For example, any cold or hot food items may be placed into container body 110 of carton 100, 102 or 104. In a specific example, heated fried chicken may be placed in container body 110 of carton 100, 102 or 104.
At a step 220, the carton is closed using the foldable lid flaps of the carton to secure the contents thereof. For example, carton 100, 102 or 104 may be closed using the two foldable lid end flaps 120 and the two foldable lid end flaps 126 to secure the contents thereof. That is, by first folding together the two foldable lid end flaps 120. Then, folding together the two foldable lid end flaps 126 a, 126 b and fitting locking tab 128 of foldable lid side flap 126 a into slot 132 of foldable lid side flap 126 b. An example of a process of closing carton 100 is shown in FIG. 3 through FIG. 5 .
At a step 225, the ventilation of the contents of the carton is allowed. For example, in carton 100, 102 or 104, the presence of vent openings 150 allows ventilation of the food contents of container body 110. Using the example of heated fried chicken within container body 110 of carton 100, 102 or 104, ventilation is allowed of the heated fried chicken via vent openings 150. In this way, it may help the heated fried chicken to remain crispy and not soggy within carton 100, 102 or 104 for some period of time.
At a step 230, the carton may be transported. For example, carton 100, 102 or 104 may be picked up and carried.
At a step 235, the carton may be opened using the foldable lid flaps of the carton to access the contents thereof. For example, the two foldable lid end flaps 120 and the two foldable lid end flaps 126 of carton 100, 102 or 104 may be opened to access the contents thereof.
At a step 240, the carton may be reclosed using the foldable lid flaps of the carton to resecure the contents thereof. For example, carton 100, 102 or 104 may be reclosed using the two foldable lid end flaps 120 and the two foldable lid end flaps 126 to secure the contents thereof.
In summary and referring now again to FIG. 1 through FIG. 15 , cartons 100, 102, 104, and method 200 provide container body 110 for holding any desired contents (e.g., food items), two foldable lid end flaps 120, and two foldable lid end flaps 126.
Further, in some embodiments, cartons 100, 102, 104 and method 200 may provide container body 110, two foldable lid end flaps 120, and two foldable lid end flaps 126 further including any number, arrangements, and/or combinations of vent openings 150, which may be hole openings, vent punchouts, and/or vent flaps 165 for preventing the buildup of excessive moisture inside the cartons 100, 102, 104 and thereby helping to keep the food contents crisp and not soggy.
Following long-standing patent law convention, the terms “a,” “an,” and “the” refer to “one or more” when used in this application, including the claims. Thus, for example, reference to “a subject” includes a plurality of subjects, unless the context clearly is to the contrary (e.g., a plurality of subjects), and so forth.
The terms “comprise,” “comprises,” “comprising,” “include,” “includes,” and “including,” are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that may be substituted or added to the listed items.
Terms like “preferably,” “commonly,” and “typically” are not utilized herein to limit the scope of the claimed embodiments or to imply that certain features are critical or essential to the structure or function of the claimed embodiments. These terms are intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.
The term “substantially” is utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation and to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
Various modifications and variations of the disclosed methods, compositions and uses of the invention will be apparent to the skilled person without departing from the scope and spirit of the invention. Although the subject matter has been disclosed in connection with specific preferred aspects or embodiments, it should be understood that the subject matter as claimed should not be unduly limited to such specific aspects or embodiments.
For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing amounts, sizes, dimensions, proportions, shapes, formulations, parameters, percentages, quantities, characteristics, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about” even though the term “about” may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are not and need not be exact, but may be approximate and/or larger or smaller as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art depending on the desired properties sought to be obtained by the presently disclosed subject matter. For example, the term “about,” when referring to a value can be meant to encompass variations of, in some embodiments ±100%, in some embodiments ±50%, in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate to perform the disclosed methods or employ the disclosed compositions.
Further, the term “about” when used in connection with one or more numbers or numerical ranges, should be understood to refer to all such numbers, including all numbers in a range and modifies that range by extending the boundaries above and below the numerical values set forth. The recitation of numerical ranges by endpoints includes all numbers, e.g., whole integers, including fractions thereof, subsumed within that range (for example, the recitation of 1 to 5 includes 1, 2, 3, 4, and 5, as well as fractions thereof, e.g., 1.5, 2.25, 3.75, 4.1, and the like) and any range within that range.
Although the foregoing subject matter has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be understood by those skilled in the art that certain changes and modifications can be practiced within the scope of the appended claims.

Claims

That which is claimed:

1. A carton, comprising:

a. a floor panel;

b. a plurality of side panels extending about a periphery of the floor panel, the plurality of side panels comprising a front side panel, an opposing rear side panel, a first side end panel, and an opposing second side end panel;

c. corner gussets extending between adjacent side panels, wherein the floor panel, side panels, and corner gussets are configurable to form a compartment region;

d. a closure portion, wherein the closure portion is configured to secure a top opening of the container portion; and

e. an arrangement of vent openings.

2. The carton of claim 1, wherein the closure portion comprises, closure flaps extending from an uppermost edge of the side panels forming a moveable joint where the closure flaps and corresponding side panels intersect.

3. The carton of claim 2, wherein a first closure flap and a second closure flap are adapted to engage with one another when in a folded closed position.

4. The carton of claim 3, wherein the first closure flap and the second closure flap are configured to interlock with one another via a tab formed on one of the first closure flap or the second closure flap and a corresponding slot formed in the other of the first closure flap or the second closure flap.

5. The carton of claim 1, wherein one or more of the vent openings are formed substantially in the closure portion of the carton.

6. The carton of claim 1, wherein the vent openings are of a generally semi-circular shape.

7. The carton of claim 2, wherein a bottom edge of one or more of the vent openings are formed along one or more of the fold lines.

8. The carton of claim 2, wherein a bottom edge portion of one or more of the vent openings extends slightly below one or more of the fold lines, and the remaining portion extends into its respective closure flap.

9. The carton of claim 2, wherein one or more of the vent openings are formed in one or more of the closure flaps.

10. The carton of claim 2, wherein one or more of the vent openings are configured as any one or more of a through-hole, a punchout, or a vent flap.

11. The carton of claim 10, wherein the one or more vent openings, when configured in the through-hole configuration, are defined by an opening devoid of material.

12. The carton of claim 10, wherein the one or more vent openings, when configured in the punchout configuration, are defined by a perforated line or a score line formed about a part of, or all of, a periphery of the vent openings, and wherein the vent openings are partially or fully removable about the perforated line or the score line.

13. The carton of claim 10, wherein the one or more vent openings, when configured in the vent flap configuration, are defined by a perforated line or a score line formed about a part of a periphery of the vent openings, and wherein the vent openings are partially removable about the perforated line or the score line.

14. The carton of claim 1, wherein the carton comprises a single piece of material comprising a plurality of fold lines, and wherein the plurality of fold lines are configured to allow the carton to be transformed from a flat pre-folded first configuration to an assembled folded second configuration.

15. The vented carton of claim 2, wherein one or more of the moveable joints are weakened, and wherein one or more of the closure flaps are configured to be removable from its respective side panel by tearing along a respective one of the weakened moveable joints.

16. The carton of claim 1, wherein the corner gussets are configured to be foldable and securable to an inner surface or outer surface of one of their adjacent side panels, wherein securing the corner gussets to their corresponding adjacent side panels secures the compartment region in its formed state.

17. A method of using a vented carton, the method comprising:

a. providing a vented carton, comprising:

i. a floor panel;

ii. a plurality of side panels extending about a periphery of the floor panel, the plurality of side panels comprising a front side panel, an opposing rear side panel, a first side end panel, and an opposing second side end panel;

iii. corner gussets extending between adjacent side panels, wherein the floor panel, side panels, and corner gussets are configurable to form a compartment region;

iv. a closure portion, wherein the closure portion is configured to secure a top opening of the container portion; and

v. an arrangement of vent openings;

b. placing contents into the compartment region;

c. closing the top opening of the compartment region using the closure portion; and

d. venting the carton via the vent openings.

18. The method of claim 17, wherein venting the carton comprises partially or fully removing material covering one or more of the vent openings.