Container for Consumer Goods with an Insert and Method of Manufacturing Such a Container

Abstract

A container for consumer goods includes an outer housing including a box portion and a hinged lid portion pivotable between open and closed positions, an inner package arranged within the outer housing, the inner package including an access opening an insert that can be pulled out of the container, including a front panel and at least a first side panel that are connected to each other, and wherein the front panel is arranged between a front wall of the inner package and a front wall of the box portion, and the first side panel is arranged between a first side wall of the inner package and a first side wall of the box portion, and the first side panel includes a first grasp portion that extends above the first side wall of the box portion in a longitudinal direction, when the insert is in a retracted position.

Claims

1. A container for consumer goods comprising: a. an outer housing comprising a box portion and a hinged lid portion for closing the container, wherein the hinged lid portion is pivotable between an open position and a closed position; b. an inner package for storing consumer goods, wherein the inner package is arranged within the outer housing and the inner package comprises an access opening through which consumer goods can be taken out; c. an insert that can be pulled out of the container, comprising a front panel and at least a first side panel, wherein the front panel and the first side panel are connected to each other, and wherein d. the front panel is arranged between a front wall of the inner package and a corresponding front wall of the box portion, and the first side panel is arranged between a first side wall of the inner package and a corresponding first side wall of the box portion; and e. the first side panel comprises a first grasp portion that extends above said first side wall of the box portion in a longitudinal direction, when the insert is in a retracted position.

2. The container according to claim 1, wherein the first grasp portion extends beyond a height of the front panel in said longitudinal direction and wherein the front panel is completely arranged below an upper edge of said front wall of the box portion, when the insert is in the retracted position.

3. The container according to claim 1, furthermore comprising a reclosable flap which is connected and moveable relative to the inner package, wherein the access opening can be covered by said reclosable flap for sealing the inner package.

4. The container according to claim 3, wherein the insert and the reclosable flap do not overlap, when the insert is in the retracted position.

5. The container according to claim 1, wherein the first grasp portion extends to an upper end of the inner package.

6. The container according to claim 1, wherein the insert further comprises a second side panel arranged at an opposite side to the first side panel and the front panel and the second side panel are connected to each other, wherein the second side panel is arranged between a second side wall of the inner package and a corresponding second side wall of the box portion.

7. The container according to claim 6, wherein the second side panel comprises a second grasp portion that extends above said second side wall of the box portion in said longitudinal direction, when the insert is in the retracted position.

8. The container according to claim 7, wherein the second grasp portion extends beyond the height of the front panel in said longitudinal direction.

9. The container according to claim 7, wherein the first grasp portion and/or the second grasp portion comprises an arch-shaped upper-front edge.

10. The container according to claim 7, wherein the first grasp portion and/or the second grasp portion comprises an indicium, indicating that the insert can be pulled out of the container.

11. An insert for insertion into a container for consumer goods, the insert comprising: a. a front panel and at least a first side panel, wherein b. the first side panel is connected to the front panel and the first side panel is arranged at an angle to the front panel; and c. the first side panel comprises a first grasp portion that extends beyond a height of the front panel in a longitudinal direction and is designed for pulling the insert out of a container.

12. The insert according to claim 11, further comprising a second side panel that is connected to the front panel at an opposite side to the first side panel.

13. A method of manufacturing a container for consumer goods, the method comprising the steps of: a. providing a charge of consumer goods; b. wrapping sheet material around the charge of consumer goods for forming an inner package; c. arranging a separate insert onto the inner package, the insert comprising a front panel and at least a first side panel, wherein the first side panel is connected to the front panel, and the first side panel and the front panel are arranged at an angle to each other, and the first side panel comprises a first grasp portion that extends beyond a height of the front panel in a longitudinal direction; and d. forming an outer housing of the container around the inner package and the insert such that the first side panel of the insert is arranged between a first side wall of the inner package and a first side wall of the outer housing and the front panel of the insert is arranged between a front wall of the outer housing and a front wall of the inner package.

14. The method according to claim 13, wherein: the step of arranging the separate insert is performed prior to the step of forming the outer housing.

15. The method according to claim 13, further comprising a step of applying a reclosable flap to the inner package (after arranging the insert onto the inner package.

16. The insert according to claim 12, wherein the second side panel comprises a second grasp portion that extends beyond the height of the front panel in said longitudinal direction.

17. The method according to claim 13, wherein: the step of arranging the separate insert is performed after the step of forming the outer housing and performed by fitting the insert between the inner package and the outer housing.

Description

4. SHORT DESCRIPTION OF THE DRAWINGS

[0032] In the following, preferred embodiments of the invention are disclosed by reference to the accompanying figures, in which shows:

[0033] FIG. 1 a three-dimensional view of an embodiment of an open container indicating a partially hidden insert in the retracted position;

[0034] FIG. 2 a three-dimensional view of an embodiment of an open container with a first embodiment of an insert in the retracted position;

[0035] FIG. 3 a three-dimensional view of the first embodiment of an insert;

[0036] FIGS. 4a, 4b schematic three-dimensional views of the arrangement of the first embodiment of an insert in the retracted position in an embodiment of a container;

[0037] FIGS. 5a, 5b three-dimensional views of an embodiment of an open container with a second embodiment of an insert in the retracted position;

[0038] FIG. 6 a three-dimensional view of the second embodiment of an insert;

[0039] FIGS. 7a, 7b three-dimensional views of the arrangement of the second embodiment of an insert in the retracted position in an embodiment of a container;

[0040] FIGS. 8a, 8b a third embodiment of an insert in a schematic illustration (FIG. 8a) and in an overlay illustration with a contour of the first embodiment of an insert (FIG. 8b);

[0041] FIG. 9 a schematic illustration of a fourth embodiment of an insert;

[0042] FIGS. 10-10c a fifth embodiment of an insert similar to the first embodiment (FIG. 10a) and similar to the fourth embodiment (FIG. 10b) in a schematic illustration, and in an overlay illustration with a contour of the first embodiment (FIG. 10c);

[0043] FIGS. 11a-11d schematic illustrations of manufacturing steps arranging the first embodiment of an insert on an embodiment of an inner package from different perspectives;

[0044] FIGS. 12a-12d illustrations of an embodiment of a manufactured container with the first embodiment of an insert from different perspectives;

[0045] FIGS. 13a-13e illustrations of manufacturing steps arranging the second embodiment of an insert on an embodiment of an inner package from different perspectives;

[0046] FIGS. 14a-14d illustrations of an embodiment of a manufactured container with the second embodiment of an insert from different perspectives; and

[0047] FIG. 15 a schematic illustration of a manufacturing facility.

5. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0048] In the following, preferred embodiments of the invention are described in detail with respect to the figures.

[0049] FIG. 1 shows an embodiment of a container 1 comprising an insert 30. The container 1 has a generally cuboid shape. Its outer housing 10 is preferably made of stronger paper sheets or cardboard in order to provide a stable structure to the container 1 and to protect the consumer goods 5 inside.

[0050] The size of the container 1 comprises a height in longitudinal direction L of about 70 to 120 mm and a width of about 40 to 72 mm between a first lateral side 15a and a second lateral side 15b, and a thickness of about 16 to 25.5 mm from the front wall 13 of the container to its back wall.

[0051] The outer housing 10 of the container 1 further comprises a box portion 12 and a lid portion 14. The lid portion 14 is hingedly attached to the box portion 12 at the back side of the container 1 and can be brought manually from a closed position into an open position, as shown in FIG. 1. Thereby, the hinge of the lid portion 14 is made of a fold of the paper or cardboard of the outer housing 10 and can be easily manufactured. In the closed position the consumer goods 5 are fully protected inside the container 1, wherein in the open position access to the consumer goods 5 is given and for example a cigarette can be taken out from the container 1.

[0052] When the lid portion 14 and, thus, the container 1 is in the closed position, the insert 30 is not visible. Thus, for example surprising messages can be written to the insert 30 which are revealed not until the container 1 is opened and the insert 30 is pulled out by the consumer. The insert 30 of this embodiment comprises a front panel 33 and one side panel 35a having a grasp portion 36a at its upper end. When the lid portion 14 is in its open position and the insert 30 is in its retracted position, only the grasp portion 36a, 36b of the insert 30 is visible (see FIG. 2 and FIGS. 5a, 5b). The front panel 33 of the insert 30, however, is not visible and does not hinder a free access to the access opening 22 of the inner package 20. Thus, consumer goods 5 can be taken out easily from the inner package 20 and the container 1, respectively.

[0053] In case the inner package 20 is additionally sealed by a reclosable flap 40, the insert 30 does not overlay the reclosable flap 40 because the grasp portions 36a, 36b are arranged at first and second sides 15a, 15b of the box portion 12, only. The front panel 33 of the insert 30, however, is interposed between front walls 13, 23 of the box portion 12 and the inner package 20 when in its retracted position, and not visible to the consumer. Preferably, the front panel 33 is arranged fully below an upper edge 16 of the front wall 13 of the box portion 12.

[0054] A consumer may pay attention to a grasp region 36a, 36b due to its remarkable coloring. Any suitable contrast between the appearance of the grasp portion 36a, 36b and the appearance of the inner package 20 can be used in order to increase visibility of the grasp portion 36a, 36b. The contrast can be, for example, a color contrast or a finishing contrast, e.g. a matt inner package 20 and a glossy grasp portion 36a, 36b. Furthermore, a consumer may also pay attention to a grasp region 36a, 36b due to an indicium 50, that is applied to the grasp region 36a, 36b (see FIGS. 3, 4a, 6, 7a and 7b).

[0055] The indicium 50 can be provided by a printing medium, by one or more protrusions, by one or more depressions or a combination thereof. The indicium 50 can preferably be text, a symbol, an image, a pattern or a combination thereof.

[0056] The insert 30 is preferably made of paper material such that it is thin enough for fitting in-between the front walls 13, 23 of the box portion 12 and the inner package 20. On the other hand, the insert 30 must be strong enough to be pulled out from the container 1 without tearing. The insert 30 is preferably loosely arranged inside the container 1. Because of its flexibility, each grasp portion 36a, 36b of the insert can be easily bent outwards by a consumer for better grasping said grasp region 36a, 36b, which increases user friendliness. Protrusions or impressions on the grasp region 36a, 36b further facilitate outward bending and grasping.

[0057] Although the insert 30 is preferably made of thin paper material, the insert 30 comprises a stable three-dimensional structure which facilitates removal, due to a first bending 37a on at least a first side, which forms a first side panel 35a. The stability of the insert's structure during manufacturing can be furthermore increased by a second bending 37b of the insert 30 on a second side, which forms a second side panel 35b (see FIGS. 6 to 7b). In case the forming of a second side panel 35b is not desired, it might be already sufficient for improving the stability of the structure to provide a small second bending 37b as can be seen in FIGS. 3 to 4b.

[0058] FIGS. 8a and 8b show a third embodiment of an insert 30. In this embodiment, compared to the insert 30 of the first embodiment, a lower portion of the first bending portion 37a is cut off at cut line 32. Thus, the first bending portion 37a and the lower left area of the front panel 33 comprises an upwardly inclined border line 32 that decreases the height of the insert 30 in this area. Such a configuration may be more advantageous compared to the first and second embodiment because the insert 30 comprises a natural tendency to tilt because of an eccentric pulling force applied by a consumer when he pulls at one grasp portion 36a, 36b. The lower part 37a* of the first bending portion 37a is cut off as this part 37a* would interfere with the outer housing 10 during said tilting motion of the insert 30. The shape of the insert 30 of the third embodiment shown in FIG. 8a promotes the insert's 30 natural tilting during extraction from a container 1. In the shown third embodiment, approximately 50% of the height of the first bending portion 37a are cut off, as can be seen best in the comparative illustration between the first (dotted line) and the third embodiment (straight line) as it is shown in FIG. 8b. As a result, extraction of the insert 30 is improved while said third embodiment does not reduce manufacturing stability nor reduce communication space on the front panel 33 of the insert 30.

[0059] Furthermore, FIG. 9 shows a fourth embodiment of an insert 30. In this embodiment the cut, and respectively cut line 32, is diagonally extended into the lower part of front panel 33. This extended cut line 32 further improves an insert 30 removal by tilting the front panel and maintains stability during manufacturing. However, the communication area on the front panel 33 of the insert 30 is slightly reduced.

[0060] In FIGS. 10a-10c a fifth embodiment of an insert 30 is shown. In this embodiment the second bending portion 37b is removed due to its interference with the above-mentioned tilting motion. However, the removal of the second bending portion 37b* will have an impact on the stability of the insert 30 during manufacturing. Thus, it is suggested in this case to apply some adhesive between the front panel 33 of the insert 30 and the front wall 23 of the inner package 20 to stabilize the insert 30 during manufacturing (e.g. during step 104). Thereby, it is important that the adhesive strength is selected to withstand manufacturing forces and allow its removal by a user as it will be described below with reference to the manufacturing process.

[0061] Finally, the fifth embodiment can be provided similar to the first embodiment with only a first bending portion 37a (see FIG. 10a), or similar to the fourth embodiment with an extended cut line 32 (see FIG. 10b). For the latter case, FIG. 10c shows an overlay illustration between the first embodiment (dotted line) and the fifth embodiment (straight line) with the cut-off parts 37a* and 37b*. As a result, said insert 30 of the fifth embodiment is easy to extract, but comprises a reduced communication space at the front panel 33 and a reduced stability during manufacturing.

[0062] Altogether, the embodiments of an insert 30 shown in FIGS. 3 to 10c comprise a front panel 33 having a height H in a longitudinal direction L of the container 1. Preferably, the height H of the front panel 33 is preferably between 40% and 100% of the height of the front wall 13 of the box portion 12, for example between 50% and 95%. In the described embodiments of an insert 30, the height H of the front panel 33 is about 50% of the height of the front wall 13 of the box portion 12. The grasp regions 36a, 36b extend significantly beyond this height H in said direction L. By this structure it is secured that the grasp portions 36a, 36b are visible inside the container 1, while the front panel 33 can be fully hidden in-between the front walls 13, 23 of the box portion 12 and the inner package 20.

[0063] The width W of the front panel 33, i.e. the maximum extension of the front panel 33 along a transversal direction T, is preferably between 40% and 100% of the width of the front wall 13 of the box portion 12, for example between 50% and 90%. In the described embodiments, the width of the front panel 33 is about 85% of the width of the front wall 13 of the box portion 12. Thereby, some space at the front side is left for the bending portions 37a, 37b.

[0064] Preferably, the overall height of the insert 30 from a bottom edge of the front panel 30 to a peak point 39 of the grasp region 36a, 36b is between 50% and 100% of the height of the inner package 20 in said direction L. In some embodiments, the overall height of the insert 30 from a bottom edge of the front panel 30 to a peak point 39 of the grasp region 36a, 36b can substantially correspond to a height of the inner package 20 in said direction L, as shown in FIG. 1. In other embodiments, the overall height of the insert 30 from a bottom edge of the front panel 30 to a peak point 39 of the grasp region 36a, 36b is between 55% and 85% of the height of the inner package 20 in said direction L, preferably between 65% and 75%, as shown in FIGS. 11-14.

[0065] During manufacturing of the container 1 in one embodiment of the manufacturing process the first or second embodiment of an insert 30 (FIG. 11a, 13a) is applied onto an embodiment of an inner package 20. Particularly the embodiment of an insert 30 can be at first applied onto the front wall 23 of the inner package 20 (FIG. 11b, 13c). Afterwards, the first and second side panels 35a, 35b of the insert 30 are bent around the inner package 20 to abut against it (see FIGS. 11c, 11d, 13b, 13d and 13e). Thereby, the insert 30 is arranged at a distance to the reclosable flap 40 (see FIGS. 11b, 13c). After that, the outer housing 10 is wrapped around the inner package 20 with the insert 30 to form a container 1 (FIGS. 12a-12d and 14a-14d).

[0066] In FIG. 15 an embodiment of a packaging facility 100 for the manufacturing of a container 1 is illustrated. The packaging facility 100 essentially comprises six production lines PL-1 to PL-6. A first production line PL-1 provides the sheet material 30s of the inserts 30. The sheet material can be provided on a continuous supply sheet. Thereby, in step 102 one of the inserts 30 is removed from the supply sheet and individualized.

[0067] At a second production line PL-2 bundles of consumer goods 5, here cigarettes, are wrapped 106 into a different sheet material 20S that forms the inner package 20. This sheet material can be for instance a metallized plastics laminate film or aluminized paper. The bundle of consumer goods 5 is held together by means of a series of inner frames, that are arranged around a number of pieces of consumer goods 5, here cigarettes. The wrapping is preferably done by rollers. Thereby, the production of the inner package is performed via several folding states 20*. The folding of the inner package can be performed during further transportation of the inner package inside the manufacturing facility 100.

[0068] After that, in production line PL-3, an individualized insert 30 is applied onto an inner package 20 in step 104. Thereby, the flat inserts 30 are applied onto the front wall 23 of the inner package 20. Subsequent to the application of the insert 30 onto the inner package 20 in step 104 at least the first side panel 35a of the insert 30 is bent around the inner package 20. In case the insert 30 comprises also a second side panel 35b, this second side panel 35b is simultaneously bent around the inner package 20. However, in case no second side panel 35b and/or no second bending portion 37b is provided to the insert 30, it may be favorable to apply some adhesive between the front panel 33 of the insert 30 and the front wall 23 of the inner package 20 to stabilize the insert 30 during manufacturing, e.g. during step 104. When doing so, it is important that the adhesive strength is selected to withstand manufacturing forces but to allow the removal of the insert 30 by a consumer. Manufacturing forces can be, for example, acceleration forces during transportation through the manufacturing facility. If the adhesive strength would be too high, the consumer would be unable to remove the insert. If the adhesive strength would be too low, then the insert might not be stable during manufacturing and jam the manufacturing facility 100.

[0069] Thereby, the bending of the side panels 35a, 35b can be performed during further transportation of the inner package 20 through the manufacturing facility 100. This saves time and increases the production volume.

[0070] In one embodiment of the manufacturing process, a reclosable flap 40 is applied to the inner package prior to the application of the insert, i.e. between steps 106 and 104. In another embodiment of the production process, said reclosable flap 40 is applied to the inner package after step 104 and before step 108.

[0071] A fourth production line PL-4 provides sheets of flat cardboards 10s from a corresponding supply to a transportation line of the inner package 20 with the insert 30. Therefore, in step 108 one cardboard 10s is associated to each inner package 20 with the insert 30.

[0072] Thereafter, in production line PL-5 the cardboard 10s passes through several bending stages 10* and is glued at appropriate edges to finally form the outer housing 10 and the container 1, respectively. Finally, the container 1 may be wrapped in a transparent plastic foil for a water-proof and integrity sealing.

[0073] In a last production line PL-6 the finished containers 1 are transported to successive facilities (not shown) preferably by a conveyor belt, usually for packaging large numbers of containers into larger packets for shipping. In between these steps the products or intermediate products are checked several times and damaged ones are rejected. The packaging process usually is fully automatic.

[0074] In another embodiment of the manufacturing of a container 1, however, step 104 is replaced by an insert introduction step, which is performed after forming the complete container 1 without wrapping in plastic foil. The introduction of the insert 30 is performed by means of appropriate tools, which slightly widen the container 1 in the respective regions, i.e. between the front walls 13, 23 of the box portion 12 and the inner package 20 and at least the first side walls 15a, 25a of the box portion and the inner package 20, in order to facilitate the introduction of the insert 30. In this embodiment, step 106 is directly followed by step 108 without step 104 in-between. The insert introduction step is then performed preferably between production lines PL-5 and PL-6.

LIST OF REFERENCE SIGNS

[0075] 1 container [0076] 5 consumer goods [0077] 10 outer housing [0078] 10s cardboard [0079] 10* intermediate steps [0080] 12 box portion [0081] 13 front wall [0082] 14 lid portion [0083] 15a first side wall [0084] 15b second side wall [0085] 16 upper edge [0086] 20 inner package [0087] 20s sheet material [0088] 20* intermediate steps [0089] 22 access opening [0090] 23 front wall [0091] 24 upper end [0092] 25a first side wall [0093] 25b second side wall [0094] 30 insert [0095] 30s sheet material [0096] 32 cut line [0097] 33 front panel [0098] 34 upper edge [0099] 35a first side panel [0100] 35b second side panel [0101] 36a first grasp portion [0102] 36b second grasp portion [0103] 37a first bending portion [0104] 37a* cut-off part of first bending portion [0105] 37b second bending portion [0106] 37b* cut-off part of second bending portion [0107] 38 upper-front edge [0108] 39 peak point [0109] 40 reclosable flap [0110] 42 attachment portion [0111] 44 non-adhesive region [0112] 46 adhesive region [0113] 50 indicium [0114] 100 packaging facility [0115] 102 insert forming step [0116] 104 insert application step [0117] 106 sheet material application step [0118] 108 cardboard application step [0119] H height [0120] L longitudinal direction [0121] PL-X production line X (X=1 to 6) [0122] T transversal direction [0123] W width