US20170313464A1

US20170313464A1 - Container having a lid lock assembly and methods of making same from a blank

Info

Publication number: US20170313464A1
Application number: US15/140,733
Authority: US
Inventors: Timothy L. MCCARTHY; Jeffrey S. James
Original assignee: WestRock Shared Services LLC
Current assignee: WestRock Shared Services LLC
Priority date: 2016-04-28
Filing date: 2016-04-28
Publication date: 2017-11-02

Abstract

A blank of foldable sheet material for forming a container includes a top panel comprising a front edge, and a tuck flap extending from the front edge of the top panel to an edge of the blank. The blank also includes at least one releasable locking assembly located along at least a portion of the front edge of the top panel. The at least one releasable locking assembly includes a first locking assembly panel coupled to a second locking assembly panel along an intermediate fold line. The intermediate fold line is offset from the front edge of the top panel towards the edge of the blank.

Description

BACKGROUND

The field of the disclosure relates generally to a container formed from a sheet of material, and more particularly to a container that includes at least one lid locking assembly having an upper and lower panel that extends along at least a portion of a front edge of a top panel of the container.
At least some known containers, such as containers for the food industry, do not include easily formed features that facilitate securing a lid to a base of the container when the container is closed. In addition, at least some known features that facilitate securing the lid to the base require additional material, such as additional flaps, to be included on a blank used to form the container. Moreover, it is well known in the food industry, including the pizza industry, to provide a food product to a consumer that is packaged in film, foil, paperwrap, a box, or a container. Such containers provide a convenient package to carry the food product from the producer of the food product to a table or other location for consumption by the consumer of the food product. However, if the container is sealed and unventilated and the food product contained within the container is hot, moisture captured within the container may make the drier parts of the food product soggy. Conversely, if the container is too ventilated, there will be excessive heat loss during product transfer. It is also convenient to place multiple containers in a heated bag so a customer and/or delivery person is able to carry those containers from the restaurant for consumption elsewhere. At least some of these containers may be time-consuming to form.

BRIEF DESCRIPTION

In one aspect, a blank of foldable sheet material for forming a container is provided. The blank includes a top panel comprising a front edge, and a tuck flap extending from the front edge of the top panel to an edge of the blank. The blank also includes at least one releasable locking assembly located along at least a portion of the front edge of the top panel. The at least one releasable locking assembly includes a first locking assembly panel coupled to a second locking assembly panel along an intermediate fold line. The intermediate fold line is offset from the front edge of the top panel towards the edge of the blank.
In certain aspects of the blank, the first locking assembly panel is rotatable into an oblique position with respect to the top panel and the second locking assembly panel is rotatable into an oblique position with respect to the tuck flap when a lid of the container is formed.
In certain aspects of the blank, the first locking assembly panel is rotatable into the oblique position with respect to the top panel to define a pair of first vent openings in the lid of the container on opposite sides of the first locking assembly panel, and the second locking assembly panel is rotatable into the oblique position with respect to the tuck flap to define a pair of second vent openings on opposite sides of the second locking assembly panel, when the lid of the container is formed.
In certain aspects of the blank, the first locking assembly panel is defined within the top panel and the tuck flap, and the second locking assembly panel is defined within the tuck flap.
In certain aspects of the blank, the second locking assembly panel extends from the tuck flap along a fold line defined within the tuck flap.
In certain aspects of the blank, opposing ends of the first and second locking assembly panels are defined by a pair of cut lines each defined in the tuck flap and the top panel.
In certain aspects of the blank, each of the pair of cut lines includes two segments that extend obliquely with respect to the intermediate fold line and define an apex.
In certain aspects of the blank, the first locking assembly panel is positionable such that the first locking assembly panel proximate the apex engages a free edge defined in the tuck flap by the cut line when the releasable lid locking assembly is positioned to secure a lid to a base of the container.
In certain aspects of the blank, the first locking assembly panel extends from the top panel along a first fold line, and the apex is spaced a distance from the first fold line that is approximately one-half to two-thirds of a distance between the first fold line and the intermediate fold line.
In certain aspects of the blank, the two segments of the cut line extend at opposite angles relative to the intermediate fold line, such that a respective magnitude of each angle is within a range of between 30 to 60 degrees.
In certain aspects the blank further comprises a first front panel; and at least one first receiving structure defined in the first front panel, the at least one first receiving structure positioned to align with the at least one releasable lid locking assembly to facilitate releasably locking a lid of the container when the container is formed.
In certain aspects of the blank, the first receiving structure comprises a punch-out panel defined by a fold line and a cut line defined in the first front panel.
In certain aspects of the blank, the first receiving structure comprises at least one of a cutout and a slot defined in the first front panel.
In certain aspects the blank further comprises a second front panel; and at least one second receiving structure defined in the second front panel, the at least one second receiving structure positioned to align with the at least one releasable lid locking assembly and the at least one first receiving structure to facilitate releasably locking the lid of the container when the container is formed.
In another aspect, a container formed from a blank of foldable sheet material is provided. The container includes a lid that includes a top wall and a front wall emanating from a front edge of the top wall. The container also includes at least one releasable locking assembly located along at least a portion of the front edge of the top wall. The at least one releasable locking assembly includes a first locking assembly panel coupled to a second locking assembly panel along an intermediate fold line. The intermediate fold line protrudes outward from the front wall of the lid.
In certain aspects of the container, the first locking assembly panel is positioned obliquely with respect to the top wall and the second locking assembly panel is positioned obliquely with respect to the front wall of the lid.
In certain aspects of the container, a pair of first vent openings are defined in the lid on opposite sides of the first locking assembly panel, such that a cavity of the container is in flow communication with a surrounding environment outside the container through at least one of the pair of first vent openings.
In certain aspects of the container, a pair of second vent openings are defined in the lid on opposite sides of the second locking assembly panel, such that a cavity of the container is in flow communication with a surrounding environment outside the container through at least one of the pair of second vent openings.
In certain aspects of the container, the second locking assembly panel emanates from the front wall of the lid along a fold line defined within the front wall of the lid.
In certain aspects of the container, opposing ends of the first and second locking assembly panels are defined by a pair of free edges.
In certain aspects of the container, each of the pair of free edge of the first and second locking assembly panels includes two segments that extend obliquely with respect to the intermediate fold line and define an apex.
In certain aspects of the container, the first locking assembly panel proximate the apex engages a free edge defined in the front wall of the lid.
In certain aspects of the container, the first locking assembly panel emanates from the top wall along a first fold line, and the apex is spaced a distance from the first fold line that is approximately one-half to two-thirds of a distance between the first fold line and the intermediate fold line.
In certain aspects of the container, the two segments of the free edge of the first and second locking assembly panels extend at opposite angles relative to the intermediate fold line, such that a respective magnitude of each angle is within a range of between 30 to 60 degrees.
In certain aspects the container further includes a base comprising a front wall of the base comprising a first front panel; and at least one first receiving structure defined in the first front panel, the at least one first receiving structure positioned to align with the at least one releasable lid locking assembly to facilitate releasably locking the lid of the container.
In certain aspects of the container, the first receiving structure comprises a punch-out panel defined by a fold line and a cut line defined in the first front panel.
In certain aspects of the container, the first receiving structure comprises at least one of a cutout and a slot defined in the first front panel.
In certain aspects of the container, the front wall of the base further comprises a second front panel; and at least one second receiving structure defined in the second front panel, the at least one second receiving structure positioned to align with the at least one releasable lid locking assembly and the at least one first receiving structure to facilitate releasably locking the lid of the container.
In another aspect, a method of forming a container from a blank of sheet material is provided. The blank includes a top panel that includes a front edge, a tuck flap extending from the front edge of the top panel, and at least one releasable locking assembly located along at least a portion of the front edge of the top panel. The method includes rotating the tuck flap toward an interior surface of the top panel, such that the top panel forms a top wall of a lid of the container and the tuck flap forms a front wall of the lid. The method also includes rotating a first locking assembly panel and a second locking assembly panel of the at least one releasable locking assembly about an intermediate fold line, such that the intermediate fold line protrudes outward from the front wall of the lid.
In certain aspects of the method, rotating the first locking assembly panel and the second locking assembly panel includes rotating the first locking assembly panel into an oblique position with respect to the top wall and rotating the second locking assembly panel into an oblique position with respect to the front wall of the lid.
In certain aspects of the method, rotating the first locking assembly panel and the second locking assembly panel includes defining a pair of first vent openings in the lid on opposite sides of the first locking assembly panel, and defining a pair of second vent openings on opposite sides of the second locking assembly panel.
In certain aspects of the method, opposing ends of the first and second locking assembly panels are defined by a pair of cut lines each defined in the tuck flap and the top panel, each of the pair of cut lines includes two segments that extend obliquely with respect to the intermediate fold line and define an apex, and rotating the first locking assembly panel and the second locking assembly panel includes positioning the first locking assembly panel such that the first locking assembly panel proximate the apex engages a free edge defined in the front wall of the lid by the respective cut line.
In certain aspects of the method, the blank further includes a first front panel and at least one first receiving structure defined in the first front panel, and the method further includes aligning the at least one releasable locking assembly with the at least one first receiving structure to facilitate releasably securing the lid to a base of the container.
In certain aspects of the method, the at least one receiving structure includes an aperture that extends through the first front panel, and the method further includes receiving at least a portion of the first locking assembly panel and the second locking assembly panel proximate the protruding intermediate fold line in the aperture.
In certain aspects of the method, the blank further includes a second front panel and at least one second receiving structure defined in the second front panel, and the method further includes aligning the at least one second receiving structure with the at least one releasable locking assembly and the at least one first receiving structure to facilitate releasably securing the lid to the base of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a blank of sheet material for constructing a container according to an embodiment of the present disclosure.

FIG. 2 is a perspective view of a container formed from the blank shown in FIG. 1.

FIG. 3 is a top plan view of a blank of sheet material for constructing a container according to another embodiment of the present disclosure.

FIG. 4 is a perspective view of a container formed from the blank shown in FIG. 3.

DETAILED DESCRIPTION

The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.
The present disclosure provides a stackable, collapsible container that includes a top panel and at least one releasable lid locking assembly located along at least a portion of a front edge of the top panel. In certain embodiments, the at least one releasable locking assembly provides enhanced ventilation for a food product contained within the container while also facilitating securing a lid of the container to a base of the container. The lockable container is constructed from a blank of sheet material. The blank is formed by a machine that imparts fold lines, cut lines, and other lines of weakness to the blank. In one embodiment, the lockable container is fabricated from a paperboard material. The lockable container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.
In the example embodiment, the blank used to make the lockable container includes at least one marking thereon including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. “Printing,” “printed,” and/or any other form of “print” as used herein may include, but is not limited to including, ink jet printing, laser printing, screen printing, giclee, pen and ink, painting, offset lithography, flexography, relief print, rotogravure, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings herein provided. In another embodiment, the blank is devoid of markings, such as, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. Furthermore, the lockable container may have any suitable size, shape and/or configuration, i.e., any suitable number of sides having any suitable size, shape and/or configuration as described and/or illustrated herein. In one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates packaging a food item, a shape that facilitates transporting the container, and/or a shape that facilitates stacking and/or arrangement of a plurality of containers.
Examples of at least some useful benefits of the releasable lid locking assembly described herein include securing the lid of the container to the base of the container without requiring additional blank material to be added the top front and/or bottom front panel to create a locking member. In addition, in some embodiments, the lid locking assembly described herein facilitates forming at least one vent serving to release steam generated by a heated food product contained within the container to prevent the food product from becoming soggy and undesirable, while retaining heat to prevent the food product from becoming cold too quickly.
Referring now to the drawings, and more specifically to FIGS. 1 and 2, although as described above a container may have any suitable size, shape, and/or configuration, FIGS. 1 and 2 illustrate the construction or formation of an embodiment of the lockable container. Specifically, FIG. 1 is a top plan view of a first example embodiment of a blank 100 of sheet material. FIG. 2 is a perspective view of a first example embodiment of a container 200 formed from blank 100 shown in FIG. 1.
Referring to FIG. 1, blank 100 has a first or interior surface 112 and an opposing second or exterior surface 114. Further, blank 100 defines a leading edge 116 and a trailing edge 118. Blank 100 includes, in series from leading edge 116 to trailing edge 118, a front tuck flap 134, a top panel 120, a back panel 122, a bottom panel 124, a second front panel 142, and a first front panel 136, coupled together along preformed, generally parallel, fold lines 126, 128, 130, 132, and 148 respectively. More specifically, top panel 120 extends from front tuck flap 134 along fold line 126, back panel 122 extends from top panel 120 along fold line 128, bottom panel 124 extends from back panel 122 along fold line 130, second front panel 142 extends from bottom panel 124 along fold line 132, and first front panel 136 extends from second front panel 142 along fold line 148. In particular, fold line 126 defines, and is also referred to as, front edge 126 of top panel 120. Fold lines and/or hinge lines as described herein may include any suitable line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided.
Blank 100 further includes a releasable lid locking assembly 150 located along at least a portion of front edge 126. Releasable lid locking assembly 150 includes a first locking assembly panel 194 coupled to a second locking assembly panel 196 along an intermediate fold line 160. Intermediate fold line 160 is substantially parallel to, and offset towards leading edge 116 from, front edge 126 of top panel 120. First locking assembly panel 194 is defined within top panel 120 and front tuck flap 134, and second locking assembly panel 196 is defined within front tuck flap 134.
More specifically, in the example embodiment, second locking assembly panel 196 extends from front tuck flap 134 along a fold line 158 defined within front tuck flap 134 substantially parallel to, and offset from, leading edge 116. First locking assembly panel 194 extends from second locking assembly panel 196 along intermediate fold line 160. More specifically, first locking assembly panel 194 extends from intermediate fold line 160 to top panel 120, and is coupled to top panel 120 along a first fold line 170 that is substantially parallel to intermediate fold line 160. First fold line 170 is offset from front edge 126 of top panel 120 in a direction away from leading edge 116. Opposing ends of locking assembly panels 194 and 196 are defined by a pair of cut lines 198 each defined in front tuck flap 134 and top panel 120.
First locking assembly panel 194 is rotatable into an oblique position with respect to top panel 120, and second locking assembly panel 196 is rotatable into an oblique position with respect to front tuck flap 134, when a lid of the container is formed, as will be described herein. Moreover, in certain embodiments, first locking assembly panel 194 positioned obliquely with respect to top panel 120 defines a pair of first vent openings in a lid of the container on opposing sides of first locking assembly panel 194, and/or first locking assembly panel 194 positioned obliquely with respect to top panel 120 and second locking assembly panel 196 positioned obliquely with respect to front tuck flap 134 define a pair of second vent openings in the lid of the container on opposing sides of first locking assembly panel 194 and second locking assembly panel 196, as will be described herein.
In the illustrated embodiment, each cut line 198 includes two segments that extend obliquely with respect to intermediate fold line 160 and define an apex 188. First locking assembly panel 194 is positionable such that first locking assembly panel 194 proximate apex 188 engages a free edge defined in front tuck flap 134 by cut line 198 when releasable lid locking assembly 150 is positioned to secure a lid to a base of container 200, as will be described herein. In certain embodiments, apex 188 is spaced a distance from first fold line 170 that is approximately one-half to two-thirds of a distance between first fold line 170 and intermediate fold line 160, such that first locking assembly panel 194 has a greater width than second locking assembly panel 196. For example, the two segments of cut line 198 extend at equal but opposite angles relative to intermediate fold line 160. In some such embodiments, a respective magnitude of each angle is within a range of between 30 to 60 degrees. In alternative embodiments, the two segments of at least one cut line 198 are co-linear, such that cut line 198 forms a straight line substantially perpendicular to intermediate fold line 160 and apex 188 is not defined. In other alternative embodiments, apex 188 is spaced any suitable distance from first fold line 170 and/or the two segments of cut lines 198 extend at any suitable respective angles that enable releasable lid locking assembly 150 to function as described herein.
In the example embodiment, blank 100 also includes a first top side panel 162 and a second top side panel 164 extending from top panel 120 along respective fold lines 166 and 168. Fold lines 166 and 168 define, and are also referred to as, opposing side edges of top panel 120. In the example embodiment, blank 100 also includes a first bottom side panel 176 and a second bottom side panel 178 extending from bottom panel 124 along respective fold lines 180 and 182. Fold lines 180 and 182 define, and are also referred to as, opposing side edges of bottom panel 124. Fold line 132 defines a front edge of bottom panel 124, and fold line 130 defines a back edge of bottom panel 124. Fold lines 166, 168, 180, and 182 are substantially parallel to each other and substantially perpendicular to fold lines 126, 128, 130, 132, and 148.
Each of first bottom side panel 176 and second bottom side panel 178 extends between a respective pair of opposing fold lines 146 and 186. A side flap 138 extends from each of first bottom side panel 176 and second bottom side panel 178 along fold line 146, and a back tab 184 extends from each of first bottom side panel 176 and second bottom side panel 178 along fold line 186. Each side flap 138 is separated from second front panel 142 and first front panel 136 by a respective cut line 152. Each back tab 184 is separated from back panel 122 by a cut line 190, and separated from an adjacent one of top side panels 162 and 164 by a cut line 192. In an alternative embodiment (not shown), each back tab 184 is coupled to one of top side panels 162 and 164 by a fold line, and a cut line separates each back tab 184 from one of bottom side panels 176 and 178.
In certain embodiments, blank 100 includes at least one first receiving structure 154 defined in first front panel 136. Moreover, in some such embodiments, blank 100 includes at least one second receiving structure 156 defined in second front panel 142. Receiving structures 154 and 156 are positioned to align with lid locking assembly 150 to facilitate releasably locking a lid of container 200 when container 200 is formed, as will be described herein. For example, in the example embodiment, first receiving structure 154 includes a punch-out panel defined by a fold line 151 and a cut line 153 defined in first front panel 136, and second receiving structure 156 is a punch-out panel defined by a fold line 155 and a cut line 157 defined in second front panel 142. When container 200 is formed, fold line 151 aligns with fold line 155, and cut line 153 aligns with cut line 157, such that punch-out panels 154 and 156 are rotatable out of plane from first front panel 136 and second front panel 142 to create an aperture to receive lid locking assembly 150.
In an alternative embodiment (not shown), at least one of first receiving structure 154 and second receiving structure 156 is defined as a cut-out. In other alternative embodiments (not shown), blank 100 does not include second receiving structure 156. For example, first receiving structure 154 is defined as a slot (not shown) in first front panel 136 positioned to align with intermediate fold line 160 of lid locking assembly 150 to facilitate locking a lid of container 200 when container 200 is formed. In other alternative embodiments, blank 100 does not include first receiving structure 154 and second receiving structure 156. For example, intermediate fold line 160 of lid locking assembly 150 bears against first front panel 136 in a friction fit to facilitate locking a lid of container 200 when container 200 is formed.
With reference to FIGS. 1 and 2, in the example embodiment, to construct container 200 from blank 100, a base 202 of container 200 and a lid 206 of container 200 are formed. Bottom panel 124 forms a bottom wall 210 of base 202 of container 200. To form base 202, bottom side panels 176 and 178 are rotated about respective fold lines 180 and 182 toward interior surface 112 to form first and second side walls 212 and 216, respectively, of base 202. Side walls 212 and 216 are substantially perpendicular to bottom wall 210. Side flaps 138 and back tabs 184 are rotated concurrently with bottom side panels 176 and 178. Side flaps 138 also are rotated about respective fold lines 146 toward interior surface 112 of respective bottom side panels 176 and 178. After rotation, side flaps 138 are aligned with fold line 132 and are substantially perpendicular to side walls 212 and 216. For example, in the example embodiment, bottom edges of side flaps 138 contact fold line 132.
Second front panel 142 and first front panel 136, which have an approximately identical width and length, are rotated along respective fold lines 132 and 148 toward interior surface 112, causing first front panel 136 to be adjacent to second front panel 142 in a face-to-face relationship, with side flaps 138 located in between second front panel 142 and first front panel 136, to form front wall 214 of base 202. More specifically, second front panel 142 forms an exterior portion of front wall 214 and first front panel 136 forms an interior portion of front wall 214.
In the example embodiment, second front panel 142 includes tabs 159 along fold line 132. Tabs 159 include at least partially free edges between bottom panel 124 and second front panel 142. First front panel 136 includes tabs 144 along trailing edge 118 that each align with a respective tab 159. Each pair of tabs 159 and 144 have approximately identical width and length. When second front panel 142 and first front panel 136 are rotated interiorly along respective fold lines 132 and 148, tabs 144 insert into a slot opening created when tabs 159 are rotated outwardly, such that tabs 144 and 159 extend downwardly into and/or below bottom wall 210. In certain embodiments, tabs 144 extend to a different depth than tabs 159.
In the example embodiment, back tabs 184 are rotated about respective fold lines 186 toward interior surface 112 of respective bottom side panels 176 and 178, such that back tabs 184 are parallel to fold line 130. Back panel 122 is rotated about fold line 130 toward interior surface 112 into a position perpendicular to bottom wall 210. Back panel 122 aligns with back tabs 184 to form a back wall 218 of base 202. Bottom wall 210, side walls 212 and 216, front wall 214, and back wall 218 cooperate to define a cavity 204 of base 202.
To construct lid 206 of container 200, in the example embodiment, top side panels 162 and 164 are rotated about respective fold lines 166 and 168 toward interior surface 112 to form first and second side walls 222 and 226 of lid 206. Top panel 120 forms a top wall 220 of lid 206. Front tuck flap 134 is rotated about fold line 126 toward interior surface 112 to form a front wall 224 of lid 206. Front wall 224 and side walls 222 and 226 are substantially perpendicular to top wall 220. It should be understood that lid 206 may be formed before base 202 is formed and/or at least partially concurrently with base 202.
As front tuck flap 134 is rotated toward interior surface 112, releasable lid locking assembly 150 is caused to rotate out of plane from top panel 120 and front tuck flap 134. More specifically, first locking assembly panel 194 and second locking assembly panel 196 rotate about intermediate fold line 160, such that each of first locking assembly panel 194 and second locking assembly panel 196 projects outwardly relative to front wall 224, and intermediate fold line 160 is spaced a distance away from front wall 224. Thus, intermediate fold line 160 protrudes outward relative to front wall 224 of lid 206. For example, because intermediate fold line 160 is offset from front edge 126 of top panel 120 towards leading edge 116, first locking assembly panel 194 is caused to rotate about first fold line 170 toward interior surface 112 into an oblique position with respect to top wall 220, such that intermediate fold line 160 protrudes outward from front wall 224 of lid 206. Similarly, second locking assembly panel 196 is caused to rotate about fold line 158 toward exterior surface 114 of front tuck flap 134 into an oblique position with respect to front wall 224 of lid 206. In certain embodiments, first locking assembly panel 194 proximate at least one apex 188 bears against a free edge 225 defined in front wall 224 by respective cut line 198, which facilitates stiffening intermediate fold line 160 in the protruding position. In alternative embodiments, releasable lid locking assembly 150 does not include apex 188 and/or apex 188 does not bear against free edge 225.
In the example embodiment, first locking assembly panel 194 positioned obliquely with respect to top wall 220 defines a pair of first vent openings 230 in lid 206 on opposing sides of first locking assembly panel 194. Additionally, first locking assembly panel 194 positioned obliquely with respect to top wall 220 and second locking assembly panel 196 positioned obliquely with respect to front wall 224 define a pair of second vent openings 232 in lid 206 on opposing sides of second locking assembly panel 196.
To close container 200, lid 206 is rotated toward base 202 along fold line 128, such that first side wall 222 of lid 206 is aligned with and substantially adjacent to first side wall 212 of base 202, second side wall 226 of lid 206 is aligned with and substantially adjacent to second side wall 216 of base 202, and front wall 224 of lid 206 is aligned with and substantially adjacent to front wall 214 of base 202. Moreover, protruding intermediate fold line 160 of lid locking assembly 150 cooperates with at least one of first receiving structure 154, second receiving structure 156, and front wall 214 of base 202 to releasably secure lid 206 to base 202.
For example, in the example embodiment, at least a portion of first locking assembly panel 194 and second locking assembly panel 196 proximate protruding intermediate fold line 160 is received in an aperture 240 that extends through front wall 214. Aperture 240 is created by rotation of punch-out panels 154 and 156 out of plane from front wall 214 of base 202. In an alternative embodiment (not shown), aperture 240 is defined by complete removal of first receiving structure 154 and second receiving structure 156 each defined as a cut-out.
In another alternative embodiment (not shown), aperture 240 is defined only through first front panel 136, and thus only partially through front wall 214, by complete removal of first receiving structure 154 defined as a cut-out, and blank 100 does not include second receiving structure 156. In still another alternative embodiment (not shown), blank 100 does not include second receiving structure 156, and aperture 240 is defined only partially through front wall 214 by first receiving structure 154 defined as a slot. In other alternative embodiments, blank 100 does not include first receiving structure 154 and second receiving structure 156, and protruding intermediate fold line 160 bears against front wall 214 in a friction fit.
In certain embodiments, side walls 222 and 226 of lid 206 are positioned against respective side walls 212 and 216 of base 202 in a friction fit, further defining a releasably secure closure of lid 206 and base 202. In alternative embodiments, at least one of side walls 222 and 226 of lid 206 are positioned against respective side walls 212 and 216 of base 202 in a clearance fit and/or a non-contact fit.
In some embodiments, when container 200 is closed, the protruding locking assembly 150 functions as a pushable release mechanism to facilitate unlocking lid 206 from base 202. For example, but not by way of limitation, a user (not shown) directly, or indirectly through a push panel that defines first or second receiving structures 154 and 156, presses locking assembly 150 adjacent intermediate fold line 160 toward cavity 204, such that locking assembly 150 disengages from aperture 240. Lid 206 may then be opened with reduced interference from an interaction between locking assembly 150 and front wall 214.
Prior to closing container 200, a product, such as a food product, may be placed within cavity 204 of base 202. As such, when lid 206 engages base 202, the product is secured within cavity 204 by lid 206 and base 202. In certain embodiments, first and second vent openings 230 and 232 facilitate enhanced ventilation for a food product contained within cavity 204 when lid 206 is closed. For example, cavity 204 is in flow communication with a surrounding environment outside container 200 through at least one first vent opening 230. Additionally or alternatively, cavity 204 is in flow communication with a surrounding environment outside container 200 through at least one second vent opening 232 and, optionally, aperture 240. Alternatively, a product, other than a food product, that benefits from enhanced ventilation is placed within cavity 204. Alternatively, a product that does not benefit from enhanced ventilation is placed within cavity 204.
As such, in an embodiment, the following steps are performed to form container 200 from blank 100: (1) rotate side flaps 138 about respective fold lines 146 toward interior surface 112; (2) rotate bottom side panels 176 and 178 about respective fold lines 180 and 182 toward interior surface 112 to form side walls 212 and 216 of base 202; (3) rotate second front panel 142 and first front panel 136 about respective fold lines 132 and 148 towards interior surface 112, such that first front panel 136 contacts second front panel 142, with side flaps 138 located in between second front panel 142 and first front panel 136, tabs 144 on first front panel 136 are inserted into partially free edges of tabs 159, and front panels 136 and 142 are substantially perpendicular to bottom wall 210 of base 202 to form front wall 214 of base 202; (4) rotate top side panels 162 and 164 about respective fold lines 166 and 168 toward interior surface 112 to side walls 222 and 226 of 206; and (5) rotate front tuck flap 134 about fold line 126 toward interior surface 112 to form front wall 224 of lid 206, such that releasable locking assembly 150 is rotated out of plane with top wall 220 and front wall 224 of lid 206 and intermediate fold line 160 protrudes outwardly from front wall 224 of lid 206. In alternative embodiments, steps (1)-(5) are performed in any suitable sequence that enables container 200 to be formed as described herein.
FIG. 3 is a top plan view of a first example embodiment of a blank 300 of sheet material. FIG. 4 is a perspective view of a first example embodiment of a container 400 formed from blank 300 shown in FIG. 3. As described above, in alternative embodiments, container 400 and, correspondingly, blank 300 may have any suitable size, shape, and/or configuration.
Referring to FIG. 3, blank 300 has a first or interior surface 312 and an opposing second or exterior surface 314. Further, blank 300 defines a leading edge 316 and a trailing edge 318. Blank 300 includes, in series from leading edge 316 to trailing edge 318, a first side panel 334, a first end panel 320, a second side panel 322, a second end panel 324, and a glue panel 342, coupled together along preformed, generally parallel, fold lines 326, 328, 330, and 332 respectively. First end panel 320 and second end panel 324 also are referred to as front panel 320 and rear panel 324, respectively. More specifically, front panel 320 extends from first side panel 334 along fold line 326, second side panel 322 extends from front panel 320 along fold line 328, rear panel 324 extends from second side panel 322 along fold line 330, and glue panel 342 extends from rear panel 324 along fold line 332.
In the example embodiment, blank 300 also includes a first top side panel 362 and a first bottom side panel 364 extending from first side panel 334 along respective fold lines 366 and 368. Fold lines 366 and 368 define, and are also referred to as, opposing top and bottom edges of first side panel 334. In the example embodiment, blank 300 also includes a second top side panel 336 and a second bottom side panel 338 extending from second side panel 322 along respective fold lines 348 and 352. Fold lines 348 and 352 define, and are also referred to as, opposing top and bottom edges of second side panel 322.
Also in the example embodiment, blank 300 also includes a rear top panel 372 and a rear bottom panel 374 extending from rear panel 324 along respective fold lines 384 and 386. Fold lines 384 and 386 define, and are also referred to as, opposing top and bottom edges of rear panel 324. Also in the example embodiment, blank 300 includes a top tuck flap 376 extending from rear top panel 372 along a fold line 390, and a bottom tuck flap 378 extending from rear bottom panel 374 along a fold line 392. In particular, fold line 390 defines, and is also referred to as, front edge 390 of rear top panel 372. Top tuck flap 376 extends from front edge 390 of rear top panel 372 to an opposite free edge 391 of blank 300. Fold lines 366, 368, 348, 352, 384, 386, 390, and 392 and free edge 391 are substantially parallel to each other and substantially perpendicular to fold lines 326, 328, 330, and 332.
Blank 300 also includes a releasable lid locking assembly 350 located along at least a portion of front edge 390. Releasable lid locking assembly 350 is substantially identical to releasable lid locking assembly 150 shown in FIGS. 1 and 2. More specifically, releasable lid locking assembly 350 includes a first locking assembly panel 394 coupled to a second locking assembly panel 396 along an intermediate fold line 360, and intermediate fold line 360 is substantially parallel to, and offset towards free edge 391 from, front edge 390 of rear top panel 372. First locking assembly panel 394 is defined within rear top panel 372 and top tuck flap 376, and second locking assembly panel 396 is defined within top tuck flap 376.
More specifically, in the example embodiment, second locking assembly panel 396 extends from top tuck flap 376 along a fold line 358 defined within top tuck flap 376 substantially parallel to, and offset from, free edge 391. First locking assembly panel 394 extends from second locking assembly panel 396 along intermediate fold line 360. More specifically, first locking assembly panel 394 extends from intermediate fold line 360 to rear top panel 372, and is coupled to rear top panel 372 along a first fold line 370 that is substantially parallel to intermediate fold line 360. First fold line 370 is offset nfrom front edge 390 of rear top panel 372 in a direction away from free edge 391. Opposing ends of locking assembly panels 394 and 396 are defined by a pair of cut lines 398 each defined in top tuck flap 376 and rear top panel 372.
As described above with respect to releasable lid locking assembly 150, In the illustrated embodiment, each cut line 398 includes two segments that extend obliquely with respect to intermediate fold line 360 and define an apex 388. First locking assembly panel 394 is positionable such that first locking assembly panel 394 proximate apex 388 engages a free edge defined in top tuck flap 376 by cut line 398 when releasable lid locking assembly 350 is positioned to secure a lid to a base of container 400, as will be described herein. In certain embodiments, apex 388 is again spaced a distance from first fold line 370 that is approximately one-half to two-thirds of a distance between first fold line 370 and intermediate fold line 360, such that first locking assembly panel 394 has a greater width than second locking assembly panel 396. For example, the two segments of cut line 398 extend at equal but opposite angles relative to intermediate fold line 360. In some such embodiments, a respective magnitude of each angle is within a range of between 30 to 60 degrees. In alternative embodiments, the two segments of at least one cut line 398 are co-linear, such that cut line 398 forms a straight line substantially perpendicular to intermediate fold line 360 and apex 388 is not defined. In other alternative embodiments, apex 388 is spaced any suitable distance from first fold line 370 and/or the two segments of cut lines 398 extend at any suitable respective angles that enable releasable lid locking assembly 350 to function as described herein.
In certain embodiments, blank 300 includes at least one first receiving structure 356 defined in front panel 320. Receiving structure 356 is positioned to align with lid locking assembly 350 to facilitate releasably locking a lid of container 400 when container 400 is formed, as will be described herein. For example, in the example embodiment, receiving structure 356 is defined as a cut-out in front panel 320, such that receiving structure 356 receives lid locking assembly 350 when container 400 is formed and a lid of container 400 is closed. In an alternative embodiment similar to that shown for receiving structure 156 in FIG. 1, receiving structure 356 includes a punch-out panel defined in front panel 320, and the punch-out panel is rotatable out of plane from front panel 320 to create an aperture to receive lid locking assembly 350 when container 400 is formed and a lid of container 400 is closed. In another alternative embodiment (not shown), receiving structure 356 is defined as a slot (not shown) in front panel 320 positioned to align with intermediate fold line 360 of lid locking assembly 350 to facilitate locking a lid of container 400 when container 400 is formed. In other alternative embodiments, blank 300 does not include receiving structure 356. For example, intermediate fold line 360 of lid locking assembly 350 bears against front panel 320 in a friction fit to facilitate locking a lid of container 400 when container 400 is formed.
With reference to FIGS. 3 and 4, in the example embodiment, to construct container 400 from blank 300, a base 402 of container 400 and a lid 406 of container 400 are formed. To form base 402, first side panel 334 is rotated about fold line 326 towards interior surface 312 of front panel 320 into a substantially perpendicular relationship with front panel 320. Front panel is rotated about fold line 328 towards interior surface 312 into a substantially perpendicular relationship with second side panel 322. Second side panel 322 is rotated about fold line 330 towards interior surface 312 into a substantially perpendicular relationship with rear panel 324. Glue panel 342 is rotated about fold line 332 towards interior surface 312 into a substantially perpendicular relationship with rear panel 324 and a face-to-face relationship with first side panel 334. For example, but not by way of limitation, exterior surface 314 of glue panel 342 is in face-to-face relationship with interior surface 312 of first side panel 334. Glue panel 342 is coupled to first side panel 334 in any suitable fashion to form a manufacturing joint.
Moreover, first bottom side panel 364 is rotated about fold line 368 towards interior surface 312 of first side panel 334 into a substantially perpendicular relationship with first side panel 334, and second bottom side panel 338 is rotated about fold line 352 towards interior surface 312 of second side panel 322 into a substantially perpendicular relationship with second side panel 322. In addition, rear tuck flap 378 is rotated about fold line 392 towards interior surface 312 of rear bottom panel 374 into a substantially perpendicular relationship with rear bottom panel 374, and rear bottom panel 374 is rotated about fold line 386 towards interior surface 312 into a substantially perpendicular relationship with rear panel 324, such that rear bottom panel 374 is in face-to-face relationship with first and second bottom side panels 364 and 338, and such that rear tuck flap 378 is in a face-to-face relationship with front panel 320. For example, but not by way of limitation, exterior surface 314 of first and second bottom side panels 364 and 338 is in face-to-face relationship with interior surface 312 of rear bottom panel 374, and exterior surface 314 of rear tuck flap 378 is in face-to-face relationship with interior surface 312 of front panel 320.
Rear bottom panel 374 and first and second bottom side panels 364 and 338 form a bottom wall 410 of base 402. First side panel 334 and glue panel 342 form a first side wall 412 of base 402. Front panel 320 and rear tuck flap 378 form a first end wall 414, second side panel 322 forms a second side wall 416, and rear panel 324 forms a second end wall 418 of base 402. First end wall 414 and second end wall 418 are also referred to as front wall 414 and rear wall 418, respectively. Bottom wall 410, side walls 412 and 416, front wall 414, and back wall 418 cooperate to define a cavity 404 of base 402.
To construct lid 406 of container 400, in the example embodiment, top tuck flap 376 is rotated about fold line 390 toward interior surface 112 of rear top panel 372 into a substantially perpendicular relationship with rear top panel 372. Rear top panel 372 forms a top wall 420 of lid 406, and top tuck flap 376 forms a front wall 424 of lid 406. As top tuck flap 376 is rotated toward interior surface 312, releasable lid locking assembly 350 is caused to rotate out of plane from rear top panel 372 and top tuck flap 376. More specifically, first locking assembly panel 394 and second locking assembly panel 396 rotate about intermediate fold line 360, such that each of first locking assembly panel 394 and second locking assembly panel 396 projects outwardly relative to front wall 424, and intermediate fold line 360 is spaced a distance away from front wall 424. Thus, intermediate fold line 360 protrudes outward relative to front wall 424 of lid 406. For example, because intermediate fold line 360 is offset from front edge 390 of rear top panel 372 towards free edge 391, first locking assembly panel 394 is caused to rotate about first fold line 370 toward interior surface 312 into an oblique position with respect to top wall 420, such that intermediate fold line 360 protrudes outward from front wall 424 of lid 406. Similarly, second locking assembly panel 396 is caused to rotate about fold line 358 toward exterior surface 314 of top tuck flap 376 into an oblique position with respect to front wall 424 of lid 406. In certain embodiments, first locking assembly panel 394 proximate at least one apex 388 bears against a free edge 425 defined in front wall 424 by respective cut line 398, which facilitates stiffening intermediate fold line 360 in the protruding position. In alternative embodiments, releasable lid locking assembly 350 does not include apex 388 and/or apex 388 does not bear against free edge 425.
In the example embodiment, first locking assembly panel 494 positioned obliquely with respect to top wall 420 defines a pair of first vent openings 430 in lid 406 on opposing sides of first locking assembly panel 394. Additionally, first locking assembly panel 394 positioned obliquely with respect to top wall 420 and second locking assembly panel 396 positioned obliquely with respect to front wall 424 define a pair of second vent openings 432 in lid 406 on opposing sides of second locking assembly panel 396.
To close container 400, first top side panel 362 is rotated about fold line 366 towards interior surface 312 of first side panel 334 into a substantially perpendicular relationship with first side panel 334, and second top side panel 336 is rotated about fold line 348 towards interior surface 312 of second side panel 322 into a substantially perpendicular relationship with second side panel 322. In addition, lid 406 is rotated toward base 402 along fold line 384, such that top wall 420 of lid 406 is in face-to-face relationship with first and second top side panels 362 and 336. For example, but not by way of limitation, exterior surface 314 of first and second top side panels 362 and 336 is in face-to-face relationship with interior surface 312 of rear top panel 372. Moreover, protruding intermediate fold line 360 of lid locking assembly 350 cooperates with at least one of receiving structure 356 and front wall 414 of base 402 to releasably secure lid 406 to base 402.
For example, in the example embodiment, at least a portion of first locking assembly panel 394 and second locking assembly panel 396 proximate protruding intermediate fold line 360 is received in an aperture 440 that extends through front wall 414. Aperture 440 is created by the cutout that defines receiving structure 356. In an alternative embodiment (not shown), aperture 440 is created by rotation of punch-out panels (not shown) out of plane from front wall 414 of base 402, similar to aperture 240 shown in FIG. 2.
In another alternative embodiment (not shown), aperture 440 is defined by receiving structure 356 defined as a slot. In other alternative embodiments, blank 300 does not include receiving structure 356, and protruding intermediate fold line 360 bears against front wall 414 in a friction fit.
In some embodiments, when container 400 is closed, the protruding locking assembly 350 functions as a pushable release mechanism to facilitate unlocking lid 406 from base 402. For example, but not by way of limitation, a user (not shown) directly, or indirectly through a push panel that defines receiving structure 356, presses locking assembly 350 adjacent intermediate fold line 360 toward cavity 404, such that locking assembly 350 disengages from aperture 440. Lid 406 may then be opened with reduced interference from an interaction between locking assembly 350 and front wall 414.
Prior to closing container 400, a product, such as a food product, may be placed within cavity 404 of base 402. As such, when lid 406 engages base 402, the product is secured within cavity 404 by lid 406 and base 402. In certain embodiments, first and second vent openings 430 and 432 facilitate enhanced ventilation for a food product contained within cavity 404 when lid 406 is closed. For example, cavity 404 is in flow communication with a surrounding environment outside container 400 through at least one first vent opening 430. Additionally or alternatively, cavity 404 is in flow communication with a surrounding environment outside container 400 through at least one second vent opening 432 and, optionally, aperture 440. Alternatively, a product, other than a food product, that benefits from enhanced ventilation is placed within cavity 404. Alternatively, a product that does not benefit from enhanced ventilation is placed within cavity 404.
As such, in an embodiment, the following steps are performed to form container 200 from blank 100: (1) rotate first side panel 334, front panel 320, second side panel 322, rear panel 324, and glue panel 342 about parallel fold lines 326, 328, 330, and 332, respectively, such that first side panel 334 and second side panel 322 are substantially parallel to each other and substantially orthogonal to front panel 320 and rear panel 324, and such that glue panel 342 is in face-to-face relationship with first side panel 334 to form side walls 412 and 416, front wall 414, and back wall 418; (2) couple glue panel 342 to first side panel 334 to form a manufacturing joint; (3) rotate rear tuck flap 378 about fold line 392 into substantially perpendicular relationship with rear bottom panel 374, and rotate first and second bottom side panels 364 and 338 and rear bottom panel 374 into substantially orthogonal relationship to side walls 412 and 416, front wall 414, and back wall 418 to form bottom wall 410; and (4) rotate top tuck flap 376 into substantially perpendicular relationship to rear top panel 372 to form top wall 420 and front wall 424 of lid 406, such that releasable locking assembly 350 is rotated out of plane with top wall 420 and front wall 424 of lid 406 and intermediate fold line 360 protrudes outwardly from front wall 424 of lid 406. In alternative embodiments, steps (1)-(4) are performed in any suitable sequence that enables container 400 to be formed as described herein.
Embodiments of the above-described container are easily constructed from a flexible unitary blank of paperboard. Further, embodiments of the above-described container include an easily formed releasable locking assembly for a lid and a base. The releasable locking assembly is at least partially defined on a tuck flap on the glid, and does not require additional blank material to be added to the tuck flap and/or front panel. In some embodiments, when the container is closed, the protruding locking assembly functions as a pushable release mechanism to facilitate unlocking the lid from the base. Moreover, in certain embodiments, the releasable locking assembly defines at least one vent opening that facilitates enhanced ventilation for a food product within the container when the lid is closed.
Example embodiments of a container have been described above in detail. The container is not limited to the specific embodiments described herein, but rather, components of the container and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. Further, the described components and/or method steps can also be defined in, or used in combination with, other apparatus and/or methods, and are not limited to practice with only the apparatus and method as described herein.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims

What is claimed is:

1. A blank of foldable sheet material for forming a container, said blank comprising:

a top panel comprising a front edge;

a tuck flap extending from the front edge of the top panel to an edge of the blank; and

at least one releasable locking assembly located along at least a portion of the front edge of the top panel, the at least one releasable locking assembly comprising a first locking assembly panel coupled to a second locking assembly panel along an intermediate fold line, wherein the intermediate fold line is offset from the front edge of the top panel towards the edge of the blank.

2. A blank in accordance with claim 1, wherein the first locking assembly panel is rotatable into an oblique position with respect to the top panel and the second locking assembly panel is rotatable into an oblique position with respect to the tuck flap when a lid of the container is formed.

3. A blank in accordance with claim 2, wherein the first locking assembly panel is rotatable into the oblique position with respect to the top panel to define a pair of first vent openings in the lid of the container on opposite sides of the first locking assembly panel, and the second locking assembly panel is rotatable into the oblique position with respect to the tuck flap to define a pair of second vent openings on opposite sides of the second locking assembly panel, when the lid of the container is formed.

4. A blank in accordance with claim 1, wherein the first locking assembly panel is defined within the top panel and the tuck flap, and the second locking assembly panel is defined within the tuck flap.

5. A blank in accordance with claim 1, wherein the second locking assembly panel extends from the tuck flap along a fold line defined within the tuck flap.

6. A blank in accordance with claim 1, wherein opposing ends of the first and second locking assembly panels are defined by a pair of cut lines each defined in the tuck flap and the top panel.

7. A blank in accordance with claim 6, wherein each of the pair of cut lines includes two segments that extend obliquely with respect to the intermediate fold line and define an apex.

8. A blank in accordance with claim 7, wherein the first locking assembly panel is positionable such that the first locking assembly panel proximate the apex engages a free edge defined in the tuck flap by the cut line when the releasable lid locking assembly is positioned to secure a lid to a base of the container.

9. A blank in accordance with claim 7, wherein the first locking assembly panel extends from the top panel along a first fold line, and the apex is spaced a distance from the first fold line that is approximately one-half to two-thirds of a distance between the first fold line and the intermediate fold line.

10. A blank in accordance with claim 7, wherein the two segments of the cut line extend at opposite angles relative to the intermediate fold line, such that a respective magnitude of each angle is within a range of between 30 to 60 degrees.

11. A blank in accordance with claim 1, further comprising:

a first front panel; and

at least one first receiving structure defined in the first front panel, the at least one first receiving structure positioned to align with the at least one releasable lid locking assembly to facilitate releasably locking a lid of the container when the container is formed.

12. A blank in accordance with claim 11, wherein the first receiving structure is defined in the first front panel and comprises at least one of cutout, a slot, and a punch-out panel defined by a fold line and a cut line.

13. A container formed from a blank of foldable sheet material, said container comprising:

a lid comprising a top wall and a front wall emanating from a front edge of the top wall; and

at least one releasable locking assembly located along at least a portion of the front edge of the top wall, the at least one releasable locking assembly comprising a first locking assembly panel coupled to a second locking assembly panel along an intermediate fold line, wherein each of the first and second locking assembly panels project outwardly relative to the front wall of the lid, such that the intermediate fold line is spaced a distance away from the front wall of the lid.

14. A container in accordance with claim 13, wherein the first locking assembly panel is positioned obliquely with respect to the top wall and the second locking assembly panel is positioned obliquely with respect to the front wall of the lid.

15. A container in accordance with claim 13, wherein a pair of first vent openings are defined in the lid on opposite sides of the first locking assembly panel, such that a cavity of the container is in flow communication with a surrounding environment outside the container through at least one of the pair of first vent openings.

16. A container in accordance with claim 13, wherein a pair of second vent openings are defined in the lid on opposite sides of the second locking assembly panel, such that a cavity of the container is in flow communication with a surrounding environment outside the container through at least one of the pair of second vent openings.

17. A container in accordance with claim 13, wherein the second locking assembly panel emanates from the front wall of the lid along a fold line defined within the front wall of the lid.

18. A container in accordance with claim 13, wherein opposing ends of the first and second locking assembly panels are defined by a pair of free edges.

19. A container in accordance with claim 18, wherein each of the pair of free edge of the first and second locking assembly panels includes two segments that extend obliquely with respect to the intermediate fold line and define an apex.

20. A container in accordance with claim 19, wherein the first locking assembly panel proximate the apex engages a free edge defined in the front wall of the lid.

21. A container in accordance with claim 19, wherein the first locking assembly panel emanates from the top wall along a first fold line, and the apex is spaced a distance from the first fold line that is approximately one-half to two-thirds of a distance between the first fold line and the intermediate fold line.

22. A container in accordance with claim 19, wherein the two segments of the free edge of the first and second locking assembly panels extend at opposite angles relative to the intermediate fold line, such that a respective magnitude of each angle is within a range of between 30 to 60 degrees.

23. A container in accordance with claim 13, further comprising a base comprising:

a front wall of the base comprising a first front panel; and

at least one first receiving structure defined in the first front panel, the at least one first receiving structure positioned to align with the at least one releasable lid locking assembly to facilitate releasably locking the lid of the container.

24. A container in accordance with claim 23, wherein the first receiving structure is defined in the first front panel and comprises at least one of a cutout, a slot, and a punch-out panel defined by a fold line and a cut line.

25. A method of forming a container from a blank of sheet material, the blank including a top panel comprising a front edge, a tuck flap extending from the front edge of the top panel, and at least one releasable locking assembly located along at least a portion of the front edge of the top panel, the method comprising:

rotating the tuck flap toward an interior surface of the top panel, such that the top panel forms a top wall of a lid of the container and the tuck flap forms a front wall of the lid; and

rotating a first locking assembly panel and a second locking assembly panel of the at least one releasable locking assembly about an intermediate fold line, such that each of the first and second locking assembly panels project outwardly relative to the front wall of the lid and the intermediate fold line is spaced a distance away from the front wall of the lid.