Gusseted Carton Having Upper and Lower Storage Compartments

Abstract

Cartons, carton blanks, and methods for manufacturing cartons are described herein. In one implementation, a carton formed from a carton blank includes a lower storage compartment having at least one panel. The carton also includes a lid connected to a first panel of the lower storage compartment, where the lid is configured to be pivotable with respect to the lower storage compartment. The carton further includes an upper storage compartment that is formed within the lid. The lid comprises a lower lid panel that separates the lower storage compartment from the upper storage compartment.

1 . A carton formed from a carton blank, the carton comprising:
 a lower storage compartment having at least one panel;   a lid connected to a first panel of the lower storage compartment, the lid configured to be pivotable with respect to the lower storage compartment; and   an upper storage compartment formed within the lid;   wherein the lid comprises a lower lid panel that separates the lower storage compartment from the upper storage compartment.   
   
   
       2 . The carton of  claim 1 , wherein the lower storage compartment comprises a substantially water-tight receptacle. 
   
   
       3 . The carton of  claim 2 , wherein the water-tight receptacle allows the lower storage compartment to be substantially water tight up to a first height. 
   
   
       4 . The carton of  claim 3 , wherein the first height is greater than about  20 % of the height of the carton. 
   
   
       5 . The carton of  claim 1 , wherein the lid is pivotable between a closed position and an opened position. 
   
   
       6 . The carton of  claim 5 , wherein, in the closed position, items stored in the upper storage compartment are at least partially separated from items in the lower storage compartment by the lower lid panel. 
   
   
       7 . The carton of  claim 5 , wherein, in the opened position, the upper storage compartment and lower storage compartment are accessible for storing or removing items. 
   
   
       8 . The carton of  claim 1 , further comprising a first handle and a second handle, wherein the first handle and second handle are positioned at substantially opposite ends of the carton. 
   
   
       9 . A carton blank comprising:
 a plurality of adjoining panels connected together by a plurality of fold lines, the plurality of adjoining panels capable of being formed into a lower storage compartment of a carton;   a lower lid panel having a first panel, a second panel, and an intermediate panel, the first panel foldably connected to a first end of the intermediate panel, the second panel foldably connected to a second end of the intermediate panel; and   an upper lid panel having a pivot panel and a spacer panel;   wherein the pivot panel is positioned for overlapping the first panel of the lower lid in response to predetermined folding along at least a first fold line of the plurality of fold lines; and   wherein the spacer panel includes a portion thereof positioned for overlapping the second panel of the lower lid in response to predetermined folding along at least a second fold line of the plurality of fold lines.   
   
   
       10 . The carton blank of  claim 9 , wherein the plurality of adjoining panels comprises:
 a bottom panel;   a front panel foldably connected to the bottom panel;   a back panel foldably connected to the bottom panel;   first and second end panels foldably connected to the bottom panel;   a first gusset foldably connected to the first end panel and the front panel;   a second gusset foldably connected to the front panel and the second end panel;   a third gusset foldably connected to the second end panel and the back panel; and   a fourth gusset foldably connected to the back panel and the first end panel.   
   
   
       11 . The carton blank of  claim 10 , further comprising a fold line between the pivot panel and the back panel. 
   
   
       12 . The carton blank of  claim 9 , further comprising:
 first and second longitudinal panels foldably connected to the back panel in a longitudinal direction; and   third and fourth longitudinal panels foldably connected to the front panel in a longitudinal direction.   
   
   
       13 . The carton blank of  claim 12 , further comprising:
 first and second outer handle panels foldably connected to the first and second longitudinal panels, respectively; and   first and second inner handle panels foldably connected to the third and fourth longitudinal panels, respectively.   
   
   
       14 . The carton blank of  claim 9 , wherein the lower lid panel is cut and removed from the single planar sheet with no fold lines connecting the lower lid panel to adjoining panels. 
   
   
       15 . A method of manufacturing a carton, the method comprising:
 cutting a carton blank from a sheet of material, the carton blank comprising a plurality of adjoining panels, an upper lid panel, and a lower lid panel;   attaching the lower lid panel to the upper lid panel to at least partially form an upper storage compartment of the carton; and   folding the plurality of adjoining panels along respective fold lines to form a lower storage compartment of the carton.   
   
   
       16 . The method of  claim 15 , wherein the lower lid panel is at least partially struck from at least one of the plurality of panels and the upper storage compartment is at least partially further formed in response to the folding step. 
   
   
       17 . The method of  claim 15 , wherein the carton blank further comprises outer handle panels and inner handle panels, the method further comprising:
 adhering the inner handle panels to first portions of the outer handle panels.   
   
   
       18 . The method of  claim 17 , wherein the plurality of adjoining panels includes end panels, the method further comprising:
 adhering second portions of the outer handle panels to portions of the end panels.   
   
   
       19 . The method of  claim 15 , further comprising:
 forming a fold line along a first edge of the upper lid panel; and   forming tear lines along other edges of the upper lid panel.   
   
   
       20 . The method of  claim 19 , further comprising:
 tearing the tear lines along the other edges of the upper lid panel to thereby allow the upper lid panel to be pivoted along the fold line along the first edge.