Wrap-around carton with improved locking means

A wrap-around carrier, comprising:

• opposite side panels connected to a top panel and a bottom panel;
• the bottom panel being comprised of an outer bottom panel flap connected to one of the side panels and an inner bottom panel flap connected to the opposite side panel, the outer bottom panel flap partially overlapping the inner bottom panel flap;
• at least one locking tab connected to the outer bottom panel flap by a fold line, the locking tab having an outer portion and a base portion extending beyond the fold line;
• a locking opening in the inner bottom panel flap associated with the locking tab, the locking opening including a first edge adjacent the base tab portion and a second edge opposite the first edge;
• a locking opening flap connected to the second edge of the locking opening by a fold line and at least partially covering the locking opening;
• and
• the inner bottom panel flap including a secondary opening associated with the locking opening;
• the base portion of the locking tab underlying the inner bottom panel flap adjacent the first edge of the locking opening to form a primary lock and the outer portion of the locking tab extending through the secondary opening into the interior of the carton to form a secondary lock.

A blank for forming a wrap-around carrier, comprising:

• a centrally located top panel section;
• a side panel section connected to opposite edges of the top panel section;
• an outer bottom panel flap connected to one of the side panel sections and an inner bottom panel flap connected to the other side panel section;
• at least one locking tab connected to the outer bottom panel flap by a fold line, the locking tab having an outer portion and a base portion extending beyond the fold line;
• a locking opening in the inner bottom panel flap, the locking opening including a first edge and a second edge inwardly spaced therefrom;
• a locking opening flap connected to the second edge of the locking opening by a fold line and at least partially covering the locking opening;
• and
• the inner bottom panel flap including a secondary opening adjacent the locking opening flap fold line;
• the base portion of the locking tab underlying the inner bottom panel flap adjacent the first edge of the locking opening in a carrier formed from the blank to form a primary lock and the outer portion of the locking tab extending through the secondary opening into the interior of such a carrier to form a secondary lock.

A method of forming a mechanical lock in a carton formed from a blank having an outer flap at one end thereof and an inner flap at the opposite end thereof, the outer and inner flaps having opposite end edges, comprising:

• providing at least one locking tab connected to and extending outwardly from the end edge of the outer flap by a fold line, the locking tab having a base portion and an outer portion;
• providing a locking opening in the inner flap, the locking opening including a first edge spaced from and substantially parallel to the end edge of the inner flap, and a second edge opposite the first edge;
• providing a locking opening flap connected to the second edge of the locking opening by a fold line, the locking opening flap at least partially covering the locking opening;
• providing the inner flap with a secondary opening associated with the locking opening;
• positioning the inner and outer flaps so that their end edges are closely spaced apart;
• folding back the locking tab and the locking opening flap;
• exerting a force against the folded back locking tab and an oppositely directed force against the folded back locking opening flap to move the connected inner and outer flaps into partially overlapping condition;
• and
• causing the base portion of the locking tab to underlie the inner flap adjacent the first edge of the locking opening to form a primary lock and the outer portion of the locking tab to extend through the secondary opening into the interior of the carton to form a secondary lock.