RESEALABLE CONTAINER INCLUDING INSERT AND METHOD OF MANUFACTURING
Methods include cutting an inner liner (30) that has an outer surface and an inner surface to form an opening (54) of an inner package. First, an insert (60) is applied to the outer surface of the inner liner. Thereafter, a resealable label (45) is applied over both a portion of the insert and a portion of the outer surface of the inner liner. The inner surface of the resealable label has a sealing area (46) and a non-sealing area (47) and only the non-sealing area is disposed on the insert. A bundle of consumer goods is formed by wrapping the consumer goods with the inner liner. A container (10) is formed around the bundle of consumer goods so that the insert is positioned between the inner liner and the container. Containers formed using such methods are also disclosed.
Resealable container that includes an accessible insert and methods of manufacturing the containers are disclosed. The container finds particular application as a container for elongate smoking articles such as cigarettes.
It is common in the industry to use inserts as a means of communication.
WO 2015/011621 shows a resealable pack that includes an insert, but the insert has a shape (at its top) that mirrors an offset seal on the lid. The mirrored portion of the insert affords a tab with which to gain access to the insert. Such a configuration would require the container and methods of making the container to be drastically modified.
WO 2015/045070 provides an inner liner with a fin seal across the front wall that creates a pocket on the front wall of the container to hold an insert. The pocket limits the size of the insert significantly.
With the above-discussed containers, as well a typically utilized resealable containers and more specifically automatically resealable containers, use of an insert is not possible because there is no space available to access additional components, like an insert.
One object of the invention is to provide a container that both affords automatic opening and resealing of an inside sealed package upon opening the outer lid and access to an insert. Another object of the invention is a method of making such containers.
In one aspect of the present invention, a container is described. The container comprises a housing that comprises a box and a lid that is hingedly attached to the box. The lid has an inner surface and an outer surface. The container also comprises an inner package disposed at least partially within the housing and at least partially defining an interior volume for housing consumer goods. The inner package has an outer surface and an inner surface and the inner surface is in contact with the inner surface of the box. The container also comprises a resealable label configured to open and close the inner package when the lid of the housing is opened and closed. The resealable label has an outer surface and an inner surface and the inner surface comprises a sealing area and a non-sealing area. The container also comprises an insert positioned between the inner surface of the box and the outer surface of the inner package. At least a portion of the insert is in contact with the non-sealing area of the inner surface of the resealable label.
In other aspects of the present invention, methods include cutting an inner liner that has an outer surface and an inner surface to form an opening of an inner package. An insert is applied to the outer surface of the inner liner. A resealable label is applied over both a portion of the insert and a portion of the outer surface of the inner liner. The inner surface of the resealable label has a sealing area and a non-sealing area and only the non-sealing area is disposed on the insert. A bundle of consumer goods is formed by wrapping the consumer goods with the inner liner. A container is formed around the bundle of consumer goods so that the insert is positioned between the inner liner and the container.
Various aspects of the present invention may provide one or more advantages relative to currently-available or previously-described containers and methods. For example, the present containers combine the feature of being automatically resealable with the use of inserts, which up until the present invention were unable to be combined. Further, by allowing the insert to be at least partially underneath the label, additional space for the insert is made available as compared to an insert without any overlap. This becomes particularly important for automatically resealable packs, where the lower edge of the label is attached to the inside of the lid. This inhibits the placement of an insert on the outside of the label, as it would otherwise interfere with the connection of label and lid. Advantageously, the additional space can be used for easier access to the insert. In addition, additional communication space is made available. Furthermore, the present containers afford the combination of two features but do not sacrifice proper functionality of the automatic closure of the inner feature. Furthermore, the methods disclosed herein can be undertaken using standard seal bundling process equipment and processes with little or no modification, thereby not increasing manufacturing complexity or costs but affording a functional resealable container with an insert.
The present invention is applicable to any suitable container for consumer goods such as for example elongate smoking articles. It is known to package consumer goods such as, for example, elongate smoking articles in containers formed from folded laminar blanks. For example, elongate smoking articles, such as cigarettes and cigars, are commonly sold in hinge lid packs having a box for housing the smoking articles and a lid connected to the box about a hinge line extending across the back wall of the container.
The container may take any suitable form for housing consumer goods. For example, as already mentioned, the container may comprise a housing that can be described as a hinge-lid container having one or more hinged lids connected to a box housing the consumer goods. In one or more embodiments, the container may be a slide and shell container having an inner slide for housing the consumer goods mounted within an outer shell. Where the container is a slide and shell container, the outer shell or the inner slide may include one or more hinge lids. The container may be formed from any suitable materials including, but not limited to, cardboard, paperboard, plastic, metal, other materials, or combinations thereof. The cardboard may have a weight of between about 100 grams per square meter and about 350 grams per square meter.
Containers described herein will generally have the same or a similar shape as the housing. As such, housings according to the invention may be in the shape of a rectangular parallelepiped, with right-angled longitudinal and right-angled transverse edges. Alternatively, the housing may comprise one or more rounded longitudinal edges, rounded transverse edges, bevelled longitudinal edges, or bevelled transverse edges, other types of edges, or combinations thereof. For example, the housing according to the invention may comprise, without limitation, one or more of the following features:
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- one or two longitudinal rounded or bevelled edges on at least one of the front wall and the back wall;
- one or two transverse rounded or bevelled edges on at least one of the front wall and the back wall;
- one longitudinal rounded edge and one longitudinal bevelled edge on the front wall, or one transverse rounded edge and one transverse bevelled edge on the back wall;
- one longitudinal rounded edge and one longitudinal bevelled edge on the front wall, and one transverse rounded edge and one transverse bevelled edge on the back wall;
- one or two transverse rounded or bevelled edges on the front wall and one or two longitudinal rounded or bevelled edges on the front wall; and
- two longitudinal rounded or bevelled edges on a first side wall or two transverse rounded or bevelled edges on the second side wall.
Where the housing comprises one or more rounded edges, preferably the blanks forming the housing comprise three, four, five, six, or seven scoring lines or creasing lines to form each rounded edge in the assembled container. The scoring lines or creasing lines may be either on the inside of the housing or on the outside of the housing. Preferably, the scoring lines or creasing lines are spaced from each other by between about 0.3 millimetres (mm) and 4 mm.
Preferably, the spacing of the creasing lines or scoring lines is a function of the thickness of the laminar blank. Preferably, the spacing between the creasing lines or scoring lines is between about 0.5 and about 4 times larger than the thickness of the laminar blank.
Where the housing comprises one or more bevelled edges, preferably the bevelled edge has a width of between about 1 mm and about 10 mm, preferably between about 2 mm and about 6 mm. In one or more embodiments, the housing may comprise a double bevel formed by three parallel creasing or scoring lines that are spaced such that two distinct bevels are formed on the edge of the container. Where the housing comprises a bevelled edge, the bevel may be formed by two parallel creasing lines or scoring lines in the laminar blank from which the container is formed. The creasing lines or scoring lines may be arranged symmetrically to the edge between a first wall and a second wall. Alternatively, the creasing lines or scoring lines may be arranged asymmetrically to the edge between the first wall and the second wall, such that the bevel reaches further into the first wall of the container than into the second wall of the housing.
Alternatively, the housing may have a non-rectangular transverse cross section, for example, polygonal such as triangular or hexagonal, or oval, semi-oval, circular or semi-circular.
Containers according to the invention find particular application as packs for elongate smoking articles such as, for example, cigarettes, cigars or cigarillos. In other embodiments, the consumer goods may be aerosol-generating articles such as articles that heat but not burn tobacco. It will be appreciated that through appropriate choices of the dimensions thereof, containers according to the invention may be designed for different numbers of conventional size, king size, super-king size, slim or super-slim cigarettes. Through an appropriate choice of the dimensions thereof, containers or housings according to the invention may be designed to hold different total numbers of smoking articles, or different arrangements of smoking articles. For example, through an appropriate choice of the dimensions thereof, containers or housings according to the invention may be designed to hold a total of between ten and thirty smoking articles.
As well as housing a bundle of smoking articles, the container may further comprise other consumer goods, for example, matches, lighters, extinguishing means, breath-fresheners, or electronics. The other consumer goods may be attached to the outside of the container, contained within the container along with the smoking articles, in a separate compartment of the container, or any combination thereof.
Disclosed containers comprise a housing. The housing has an inner surface and an outer surface. The housing also has a rear wall, a front wall and two side walls. The housing comprises a lid and a box.
The lid of the housing is hingedly attached to the box and is adapted to be manipulated between an open position and a closed position. In the open position, the consumer can access the consumer goods disposed within the housing. The lid is hingedly attached to the box along a hinge line that extends across the rear wall or the upper edge of the rear wall of the housing. A hinge line may be, for example, a fold line or a score line in the panel forming the back wall of the housing. The lid and box are further defined by an opening line. The opening line refers to the delineation between the lid and the box which begins at one end of the hinge line traverses the right side of the housing, the front of the housing then the left side of the housing, or vice versa, and ends at the other end of the hinge line.
Preferably, the box comprises a box front wall, a box left side wall, a box right side wall, a box back wall, and a box bottom wall. The box has an inner surface and an outer surface. The front wall of the box has an upper edge, which when closed meets the bottom edge of the lid.
Preferably, the lid comprises a lid front wall, a lid left side wall, a lid right side wall, a lid back wall, and a lid top wall. The lid has an inner surface and an outer surface. The front wall of the lid also has a bottom edge.
The container also comprises an inner package. The inner package is disposed at least partially within the housing of the container. The inner package can be configured to house consumer goods. Illustrative consumer goods can include smoking articles such as elongate smoking articles. Specific illustrative elongate smoking articles can include for example cigarettes, cigars, cigarillos, consumer goods such as aerosol-generating articles that heat but not burn tobacco, or combinations thereof.
The inner package can be made of any suitable materials, for example, polymeric materials, metal foils, other materials, or combinations thereof. The inner package preferably comprises polymeric materials such as polyethylene films, polyolefin films, poly lactic acid (PLA) films, or some combination thereof. Preferably, the inner package can comprise a first layer and a second layer that are attached, at least at their peripheries to form a package with an interior volume.
The inner package comprises an access opening that affords access to the consumer goods housed inside when the inner package is opened. The flap of the inner package covers the access opening when the container and the flap are in a closed position. The access opening is at least partially uncovered when the container and the flap are in the open position. The access opening can be cut during manufacturing, for example. Preferably, the flap forms an S-shape curve, a curve with at least two turning points, when the flap is open.
The inner package also comprises a flap. Preferably, the first layer of a multilayer inner package comprises a flap. The flap can be attached to the inner surface of the lid with a resealable label comprising one or more adhesive regions.
The resealable label can be configured to attach the flap to the inner surface of the lid as well as reseal the inner package. In such an embodiment, when opening the lid and the inner package, the flap and a portion of the second layer attached to the flap, the sealing region, are separated from each other along first and second cut lines respectively to reveal the access opening. The resealable label can be attached to the lid using any suitable techniques, for example, mechanical attachment, adhesive, thermal, or ultrasonic bonding. Preferably, the resealable label can be attached to the lid using an adhesive, more preferably a permanent adhesive. The flap, via the resealable label can be configured to be re-attached to the second layer when the flap and the lid of the container are in the closed position.
As mentioned above, advantageously, the additional space can be used for easier access to the insert. In addition, additional communication space is made available. The resealable label allows for repeated opening and closing of the inner package to access the consumer goods individually. The resealable label preferably provides sufficient adhesion for the flap to be re-attached at least as many times as there are consumer goods within the inner package. The resealable label preferably enables a consumer to open and reseal the inner package until the package is empty.
The resealable label has an inner surface and an outer surface. The outer surface of the resealable label can be configured to permanently attach the label and the flap of the inner package to the inner surface of the front wall of the lid.
The inner surface of the resealable label can comprise at least a sealing area and a non-sealing area. The sealing area can be such that movement of the lid between open and closed positions simultaneously moves the flap and the access opening of the inner package between opened and closed positions. In the closed position, the flap and label cover the access opening of the inner package and is resealably attached to the inner package by the resealable adhesive of the sealing area. In the open position, the flap and label are at least partially detached from the inner package and the access opening of the inner package is at least partially uncovered or opened. The sealing area of the label can utilize an adhesive for example, preferably a pressure sensitive adhesive. The non-sealing area of the inner surface of the label can be positioned on the resealable label, so that it will be positioned towards the bottom edge of the lid when attached to the lid. The non-sealing area can allow for the adhesive region to be more easily opened. It should be noted that the non-sealing area can include an adhesive, but such an adhesive does not contribute to the sealing of the inner package. The adhesive in such an embodiment is preferably used to attach the insert to the label so that opening the label pulls the insert away from the container.
The container also comprises an insert. The insert can be utilized for communication. The insert can comprise or be made of any suitable materials. For example, the insert can comprise cardboard, paperboard, paper, plastic, metal, or combinations thereof. The insert can be printed thereon for example using any known printing techniques. The insert can be folded in order to increase the available communication space. The insert can be folded longitudinally or transversally or both longitudinally and transversally. Preferably, at least one dimension of the insert (whether in total or once folded), for example, the height of the insert, can be less than the height of the front wall of the box. Preferably, the length of the insert is between the length of the longest longitudinal length of the front wall and the length of the front wall in the area of the access region. Such configurations afford the use of the maximum length of the insert. Preferably, the other dimension of the insert (whether in total or once folded), for example the width of the insert, can be less than the width of the front of the box. Because of the ability to fold the insert, once, twice, or more often the overall surface area of the insert can be larger than the front wall of the box.
The insert is positioned between the inner surface of the front wall of the box and the outer surface of the front wall of the inner package. At least a portion of the insert is in contact with the non-sealing area of the inner surface of the resealable label. The insert can be but need not be affixed to the outer surface of the inner package. This can be accomplished using any suitable technique, for example, mechanical attachment, adhesive, thermal, ultrasonic bonding, the use of micro-suction features, or any combination thereof. Preferably, the insert is affixed to the outer surface of the inner package using adhesive, micro-suction features, or some combination thereof.
The container can also comprise an optional inner frame disposed within the box. The inner frame can be disposed inside the front wall of the box. Alternatively, the inner frame can be disposed within the inner liner. Advantageously, an inner frame with a large surface area provided adjacent the front wall of the box increases the structural strength of the container. This is particularly advantageous for subsequent use when the container is no longer full. A container can also optionally include an inner liner. The inner liner can wrap the consumer goods. The inner liner and the consumer goods can collectively be referred to as an inner package. A carton that includes a lid and at least one sidewall can contain multiple containers as described herein.
Also disclosed herein are methods of making containers. As mentioned above, advantageously, the construction in which the label over lies at least partially the insert, additional space for the insert is made available as compared to an insert without any overlap. In particular, as the lower edge of the label is attached to the inside of the lid, the insert cannot overlie the label. This would otherwise interfere with the connection of label and lid. However, today, in like containers as available in the market, the label is pre-applied to the inner liner at a converter and is provided during the making of the container on bobbins this makes the application of an insert that underlies the label complicated.
The disclosed methods can be utilized in combination with any processes for forming bundled packages of consumer goods and forming containers there around. For example, disclosed methods can be utilized with standard seal bundling processes, machines and systems for carrying out such processes. In some embodiments, disclosed methods can utilize two labellers, one to apply the insert to the inner package and a second to apply the resealable label to the inner package to insert combination.
Disclosed methods can include various steps that can be carried out in various orders and may or may not include other steps. Various steps can be accomplished simultaneously with, before, or after transport of the item of interest along a conveying belt or conveying system. Various steps can also be accomplished by or in combination with electronic, or robotic control of the item along a conveying system to carry out disclosed methods. Other known processes of control and movement can also be utilized in combination with the specific steps discussed herein. Any step or steps disclosed herein can be accomplished on a single machine or using a system of one or more machines that have been configured to work together to carry out the step or steps.
In some illustrative methods, one step includes cutting an inner liner, which will ultimately be folded to form an inner package to form an opening. Illustrative methods could also include a step of cutting the inner liner from a continuous roll of inner liner material. These two steps of cutting (as well as any others) may occur at the same or a different time. Any suitable technique or combination of techniques can be utilized to cut the inner liner. For example, cutting the inner liner or a continuous roll of inner liner (or both) can be performed using a rotating wheel having one or more blades attached to the rotating wheel, using a die-cutting tool or tools, or other suitable cutting machinery, separating machinery, or both cutting machinery and separating machinery, for example.
Some illustrative methods can also include steps of embossing the inner liner. This step can be accomplished before, after, or both, the inner liner is cut. The step of embossing the inner liner can be utilized to provide crease lines which will be utilized in forming the inner package around the consumer goods. Also, the embossing may be designed to form a pattern that may improve or control the opening and closing forces of the resealable label. Any suitable technique or combination of techniques can be utilized to emboss the inner liner if such a step is done.
In some illustrative methods, an insert is applied onto the outer surface of the inner liner. This step can be accomplished before or after the inner liner has been cut to form an opening. Preferably, this step is undertaken after the inner liner has been cut to form an opening. Any suitable technique or combination of techniques can be utilized to apply the insert to the outer surface of the inner liner. The purpose of this step is to avoid having the insert fall off of the inner liner during the remaining manufacturing process. As such, this step can be accomplished with or combined with the use of adhesive (either permanent or temporary), micro-suction features (either on the insert or the inner liner, or both), natural cohesive forces between the two (for example, static electricity, etc.), or any combination thereof. Any suitable technique or combination of techniques can be utilized to apply the insert to the outer surface of the inner liner. The particular technique(s) utilized may depend at least in part on the particular way, if any, the insert and the inner liner are to remain in contact (for example, adhesive, micro-suction features or combinations thereof).
In some embodiments, the insert can be applied to the inner liner using a labeller. The labeller places the insert on the outer surface of the inner liner, or more preferably on a portion of the outer surface of the inner liner that will ultimately be the front panel of the inner package. In some embodiments, the labeller can be configured along with a process or machine to affect a method of maintaining contact between the insert and the inner liner. It should be noted that the adhesion between the insert and the inner liner should be strong enough so that contact is maintained during manufacturing, but not so strong or so long lasting (or both) that the insert cannot be removed from the outer surface of the inner liner during use. For example, adhesive (either permanent or temporary) could be placed between the insert and the inner liner, either on the insert, on the inner liner, or some combination thereof. Alternatively, one or both of the inner liner and the insert could have micro-suction features formed therein or thereon. Alternatively, a drop of a liquid, for example water, could be placed on the insert, the inner liner, or both and van-der-Waals forces from the interaction of the liquid and the insert, inner liner or both could maintain the contact of the insert an inner liner until the liquid evaporates. Preferably, the liquid that is utilized to induce the van-der-Waals forces is one that does not substantially degrade the insert, the inner liner, or both.
A next step includes applying a resealable label to the insert to inner liner combination. This step can be accomplished after the insert is applied onto the outer surface of the inner liner. The resealable label is applied over a portion of the outer surface of the inner liner and a portion of the insert. Only the non-sealing area of the resealable label is disposed on or is in contact with the insert. Preferably, the resealable label can be applied to the inner liner to insert combination using a labeller. The labeller places the inner surface of the resealable label, more preferably it places the sealing area of the resealable label on the outer surface of the inner liner, or even more preferably on a portion of the outer surface of the inner liner that is ultimately attached to the inner surface of the lid of the container. In some embodiments, the labeller can be configured along with a process or machine (or both) to affect placement of the resealable label. It should be noted that the resealable label may be provided to the manufacturing process with a release liner (such as paper or a similar material that has been coated with a release material or a non-adherent material) in contact with at least the sealing area of the inner surface of the resealable label. Methods disclosed herein can also optionally include removing such release liners before the resealable label is placed in contact with the insert and inner liner.
Once the inner liner to insert to label combination has been formed a bundle of consumer goods can be formed by wrapping the consumer goods with the inner liner to insert to label combination. The bundle is formed so that the insert to label is on the outside of the bundle. This step can be accomplished using any suitable technique or combination of techniques including cutting techniques, folding techniques, wrapping techniques or combinations thereof. After the bundle of consumer goods has been formed, a container can be formed around the bundle. The container ultimately includes a box and a lid that is hingedly attached to the box. This step can be accomplished using any suitable technique or combination of techniques including cutting techniques, folding techniques, wrapping techniques, etc.
The term “inner surface” is used throughout the specification to refer to the surface of a component of the assembled container that is facing towards the interior of the container, for example towards the consumer goods, when the container is in the closed position. For example, the outer film comprises an inner surface that is facing the housing of the container.
The term “outer surface” is used throughout the specification to refer to the surface of a component of the container that is facing towards the exterior of the container. For example, the outer film comprises an outer surface that is facing away from the housing of the container. It should be noted that the inside or outside surface is not necessarily equivalent to a certain side of a blank used in assembly of the container. Depending on how the blank is folded around the consumer goods, areas that are on the same side of the container can either face towards the inside or the towards the outside of the container.
The terms “front,” “back,” “upper,” “lower,” “top,” “bottom,” and “side” refer to the relative positions of portions of containers according to the invention and components thereof when the container is in an upright position with the lid of the housing in the closed position and the hinge line at the rear of the container. When describing containers according to the present invention, these terms are used irrespective of the orientation of the container being described. The rear or back wall of the container includes the hinge line.
Referring now to the drawings, in which some aspects of the present invention are illustrated.
Referring to
An inner package 30 is disposed within the housing 12. The inner package 30 at least partially defines an interior volume for housing consumer goods. The inner package 30 is made from a barrier material or materials to hermetically seal the consumer goods before the container is opened for the first time. The barrier material may be a metal foil or a plastic and metal laminate. The inner package 30 includes a front wall 32 and a back wall 34 (seen in
The inner package 30 includes an access opening 54 through which the consumer goods (not shown) can be removed. The access opening 54 is covered by the flap 44 when the flap is in the closed position (
Referring to
All of the figures also show an insert 60. The insert 60 is positioned between the inner surface 17 of the front wall 18 of the box and the outer surface 32 of the front wall 31 of the inner package 30. The insert has an upper edge 35 that is accessible via an access region 62. The insert can be made of any useful material, can have any useful dimensions, and can optionally be folded either transversally or longitudinally. The insert is positioned entirely below the sealing region 72 of the second layer 50. If the insert were positioned above the sealing region 72, the adhesive portion of the label that functions to close the inner package would be adhered to the insert and the inner package would no longer be resealable.
Referring to
Referring to
Claims
1-15. (canceled)
16. A method comprising:
- cutting an inner liner to form an opening (54) of an inner package (30), the inner liner comprising an outer surface (33) and an inner surface;
- first applying an insert (60) onto the outer surface of the inner liner;
- thereafter applying a resealable label (45) so as to cover the cut forming the opening over both a portion of the insert and a portion of the outer surface of the inner liner, wherein the resealable label has an inner surface (53) and an outer surface (51) and the inner surface comprises a sealing area (46) and a non-sealing area (47), and wherein only the non-sealing area of the inner surface is disposed on the insert;
- wrapping consumer goods with the inner liner to form a bundle of consumer goods; and
- forming a container (10) around the bundle of consumer goods wherein the insert is positioned between the inner liner and the container, and wherein the container comprises a box (14) and a lid (20) hingedly attached to the box.
17. The method according to claim 16, wherein the step of applying an insert onto the outer surface of the inner liner comprises application of an adhesive.
18. The method according to claim 16, wherein the step of applying an insert onto the outer surface of the inner liner comprises use of micro-suction features.
19. The method according to claim 18, wherein the micro-suction features are on the inner liner.
20. The method according to claim 18, wherein the micro-suction features are on the insert.
21. The method according to claim 16, wherein the insert is applied to the outer surface of a front wall (32) of the inner liner.
22. The method according to claim 16 further comprising embossing the inner liner before the opening is cut.
23. The method according to claim 16 further comprising attaching the outer surface of the resealable label to an inner surface (22) of the lid.
24. The method according to claim 16 further comprising forming an inner frame around the consumer goods before the bundle is formed with the inner liner.
Type: Application
Filed: Oct 17, 2016
Publication Date: Oct 25, 2018
Inventors: Arjen Hamilcar Slooff (Oosterbeek), Timothee Cailleaux (Divonne-les-Bains)
Application Number: 15/769,172
