BACKGROUND

[0001] Clamshell cartons are utilized in food service industries to hold various food items, such as hamburgers and hot dogs. Typical cartons are made from cardboard. Printing may be provided on one side of the carton to identify the food item within the carton.

[0002] During normal usage, a server may place a sandwich, hamburger or other food item into the carton and then close the carton. A consumer typically removes the food item by reaching around the side of the food item and into the carton to grasp the bottom of the food item.

BRIEF SUMMARY

[0003] In one aspect, a carton includes a top portion and a bottom portion. Each portion includes a front wall, a rear wall, and opposing sidewalls extending therebetween. The top portion and bottom portion include respective top and bottom surfaces. The rear walls of the top and bottom portions are hingedly connected to another along respective outer edges. When closed, the top portion and bottom portion define a cavity for storing an item. The carton also includes a separation region defined on the top and bottom portions that extends from an outside edge of the front wall of the top portion, around the top portion and the bottom portion, to an outside edge of the front wall of the bottom portion. The separation region is configured to facilitate controlled separation of the carton into first and second side portions and to prevent liquid flow through separation region.

[0004] In a second aspect, a method for manufacturing a carton includes providing a planar material. The material is cut to remove excess material. A separation region is formed along a major axis of the cut planar material. The separation region is configured to facilitate controlled separation of the carton, when assembled, into first and second side portions and to prevent liquid flow through separation region.

[0005] Other features and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional features and advantages included within this description be within the scope of the claims, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the design. Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.

[0007] Figs. 1 A and 1 B are perspective views of an exemplary carton that includes a tear strip in both closed and open configurations;

[0008] Figs. 2A and 2B illustrate exemplary plan views of first and second planar sheet embodiments that may be formed into the carton of Figs. 1 A and 1 B;

[0009] Figs. 3A and 3B illustrate removal of the tear strip and separation of the carton into left and right portions; and

[0010] Fig. 4 is a flow diagram illustrating exemplary operations involved in the production of the carton.

DETAILED DESCRIPTION

[0011] The exemplary embodiments below describe a food carton that includes an integrated tear strip feature. The tear strip facilitates vertically parting the food carton into two halves. The tear strip may include a group of perforations. A barrier material may be applied over the perforations to prevent liquid from flowing through the perforations. After parting, a consumer may grasp a food item stored therein in a manner that minimizes the likelihood of his hands becoming messy.

[0012] Figs. 1 A and 1 B illustrate perspective views of a clamshell carton 100 in both closed and open configurations. The carton 100 includes a top portion 105A and a bottom portion 105B. Each portion (105AB) includes a front wall 1 10AB, a rear wall 1 15AB, and opposing sidewalls (120AB and 125AB). A top surface 107A and bottom surface 107B extend respectively between the walls of the top portion 105A and the bottom portion 105B.

[0013] The top portion 105A and bottom portion 105B are hingedly attached to one another along a shared top edge of the rear walls (1 15AB). The front wall 1 1 0A of the top portion 1 05A and the front wall 1 1 0B of the bottom portion define, respectively, a pair of outwardly extending fingers (1 30 and 135) that extend from respective edges of the front walls 1 1 0AB. The fingers (1 30 and 1 35) are configured to engage one another to secure the top portion 1 05A and bottom portion 1 05B of the carton together and thereby maintain the carton 1 00 in the closed configuration of Fig. 1 A.

[0014] The tear strip 140 is defined along both the top portion and bottom portion 1 05AB. The tear strip 140 extends between outside edges of the front walls 1 1 0AB. That is, the tear strip 140 is defined along the front wall 1 1 0A, top surface 1 07A, and rear wall 1 1 5A, of the top portion 1 05A, and the front wall 1 1 0B, bottom surface 1 07B, and rear wall 1 1 5B of the bottom portion 1 05B. A pull-tab 140A is provided on the section of the tear strip 140 that is defined on the front wall 1 1 0A of the top portion 1 05A.

[0015] Figs. 2A and 2B illustrate exemplary plan views of first and second planar sheet embodiments 200AB that may be formed into the carton 1 00 of Fig.

1 . The sheets 200AB may be cut out from a larger sheet of material, such as a corrugated paper material, cardboard, paperboard, plastic or any other material that may be creased, folded and bonded, as described above, that is suitably rigid for storing food items.

[0016] Referring to Fig. 2A, the sheet 200A includes a series of creases 270a- q that define a plurality of planar regions 21 2a-r that define the carton 1 00. Also shown are a series of regions 205 to which an adhesive may be applied. The adhesive is utilized to bond the plurality of planar regions 21 2a-r to one another. During production, the planar regions 212a-r are folded about the creases 270a-q resulting in the assembled carton configuration shown in Fig. 1 A. For example, referring to Fig. 1 A, the front surface 1 1 0A of the carton 1 00 in the assembled configuration includes the three planar regions 21 2abn, shown on the top of Fig.

2. In this case, the right and left upper planar regions 21 2b and 21 2n are disposed behind the center planar region 21 2a when the carton 1 00 is assembled.

[0017] Each of the three regions 212abn includes locking finger regions 1 35 which, when assembled, correspond to the locking fingers 1 35, shown in Fig. 1 . Similarly, the bottom three regions 21 2ghl include locking finger regions 1 30 which, when assembled, correspond to the locking fingers 1 30 extending from the bottom portion 1 1 5 of the carton 1 00. [0018] As illustrated, the tear strip 140 is generally defined along the major axis of the sheet 200A. The outline that defines the tear strip 140 may correspond to a pattern of repeated 9/16 inch segments that are separated by a 1 /16 inch perforation. The length of the segments and the perforation between them may be different. For example, the segments may be 3/8 inch, 1 /16 inch or a different length. The distance between the segments may be 1 /32 inch or a different distance. Factors to be considered when determining the length of the segments and the distance between them include the desired ease with which the tear strip can be removed, the loss of structural integrity that results from the perforations, and possible seepage of juices through the perforations. The various dimensions above have been determined to optimally balance these considerations.

[0019] To further limit or prevent seepage through the perforations, a barrier coating may be applied over the perforations to prevent seepage of liquids (e.g., water, oil, grease or sauces) contained in the food items. For example, a barrier coating may be applied over the perforations. Such a barrier coating effectively seals the perforations without adversely affecting the ease with which the tear strip 140 may be removed.

[0020] In alternative implementations, creases or partial scoring of the working material may be utilized rather than or in combination with the perforations to control the separation of the tear strip. For example, creasing and partial scoring of the working material may be provided in those regions where juices are more likely to seep, such as one or more of the front wall 1 10B, bottom surface 107B, and rear wall 1 15B of the bottom portion 105B.

[0021] The width of the tear strip 140 may be generally uniform across the length of the sheet 200. For example, the width may be about ¼ inch. As illustrated in Fig. 2B, in alternative embodiments, the width of the tear strip may be about ¼ inch, along a section of the sheet 200B that corresponds to the top portion 105A of the carton 100, and then taper into a single perforated or creased section along a second section of the sheet 200B that corresponds to the second portion 105B.

[0022] As illustrated in Figs. 3A and 3B, the tear strip 140 facilitates controlled separation of the carton 100 along a vertical parting line through the carton 100 into left and right portions 305AB. Separation is accomplished by pulling on the pull-tab 140A section of the tear strip 140 until the tear strip is completely severed from the left and right portions 305AB.

[0023] During normal usage, a server may place a sandwich, hamburger or other food item into the carton 100 and then close the carton 100, as illustrated in Fig. 1 A. As illustrated in Fig. 3A, a consumer may open the carton by pulling on the front wall 1 10A of the top portion. Alternatively, the consumer may rotate that carton so that the tear strip 140 is generally horizontal and then remove the tear strip 140 by pulling on the pull-tab 140A until the carton 100 separates into the left and right portions 305AB illustrated in Fig. 3B. Because the carton was initially rotated, the open side of the left portion 305A will be facing upward, and about half of the food item (e.g., hamburger) will protrude above the open side. The consumer may then place the left portion 305A of the carton 100 on a counter and proceed to remove the food item. In the case of a hamburger, sandwich, etc., the consumer may remove the food item while grasping only the outside portions of the food item (e.g., buns, slices of bread). That is, the consumer can remove the food item without getting the condiments on his hands, which can tend to happen with conventional clamshell cartons which require the consumer to reach around the side of the food item and into the carton to grasp the bottom of the food item. Alternatively, the consumer may simply grasp the left portion 305A of the carton and eat the portion of the food item that protrudes from the open side thereof. This is particularly advantageous for food items that drip juices or condiments. Thus, the carton 100 provides a more cleanly eating experience. This in turn saves the food service cost in terms of cleanup. For example, fewer napkins are necessary. This also results in less trash and is, therefore, friendlier for the environment.

[0024] Fig. 4 is a flow diagram of exemplary operations carried out during the production of the carton 100 of Fig. 1 . At block 400, decorations and other details may be printed on the form. For example, a description of a food item carried in the carton and nutritional information may be printed on the form. In addition, prize information may be printed on the prize information tab.

[0025] At block 405, an unassembled carton form is punched from a larger piece of working material. For example, the carton form may correspond to the carton form 200 shown in Fig. 2. The punch may simultaneously cut out material that is not needed, crease the working material to define regions of the carton, and perforate or crease the working material to define the tear strip, as described above.

[0026] At block 407, a barrier material may be applied to at least the perforated areas of the tear strip to prevent liquid from flowing through the perforations.

[0027] At block 410, the various regions defined in the form may be folded along the creases to provide the carton 100 shown in Fig. 1 B.

[0028] At block 415, an adhesive may be applied to various regions of the form. The adhesive may be utilized to bond the various regions to one another.

[0029] While the carton and method for assembling the carton have been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope. For example, the carton described above may be utilized for items other than food. In addition, the operations in manufacturing the carton may be done in a different order. For example, decorations and other details may be printed on the carton form after the carton form is punched from the working material, or the glue dots may be applied earlier than the other operations.

[0030] In addition, many modifications may be made to adapt a particular situation or material to the teachings without departing from its scope. Therefore, it is intended that the present method and system not be limited to the particular embodiment disclosed, but that the method and system include all embodiments falling within the scope of the appended claims.