Resealable inner package for a container

Abstract

A container includes an inner package disposed within a housing. The inner package includes a first region that extends along a longitudinal axis of the inner package and includes first and second layers of a material that forms the inner package, and a second region adjacent the first region that also extends along the longitudinal axis. The second region includes only the first layer and not the second layer. The first region also includes a first line of weakness disposed in the first layer that defines a flap, and a second line of weakness disposed in the second layer that defines an access opening disposed in the first region. The access opening is covered by the flap when the flap is in a closed position and at least partially uncovered when the flap is in an open position.

Claims

1. A container for consumer goods, comprising: a housing comprising a box and a lid hingedly attached to the box, wherein the box comprises a front wall and a rear wall; an inner package disposed within the housing and at least partially defining an interior volume for housing the consumer goods, wherein the inner package is formed from a material comprising a first layer and a second layer attached to an inner surface of the first layer, wherein the inner package comprises: a first side wall, and a second side wall; a sealed portion in at least one of the first and second side walls disposed within a fold of the material of the inner package; a first region extending along a longitudinal axis of the inner package and comprising the first and second layers, wherein the first region longitudinally extends an entire length of the inner package when pre-assembled such that the first and second layers in the first region also extend the entire length of the inner package when pre-assembled, wherein the first region further comprises a first line of weakness disposed in the first layer that defines a flap, and a second line of weakness disposed in the second layer that defines an access opening disposed in the first region through which the consumer goods can be removed, wherein the access opening is covered by the flap when the flap is in a closed position, wherein the access opening is at least partially uncovered when the flap is in an open position, wherein the flap is attached to an inner surface of the lid; and a second region adjacent the first region and extending along the longitudinal axis, wherein the second region comprises only the first layer and not the second layer, wherein the second layer does not extend into the sealed portion.

2. The container of claim 1, wherein the flap is attached to the inner surface of the lid such that upon opening the lid the flap and a portion of the second layer attached to the flap are separated from the inner package along the first and second lines of weakness respectively to reveal the access opening.

3. The container of claim 2, wherein the flap is attached to the inner surface of the lid by a permanent adhesive.

4. The container of claim 1, wherein the inner package further comprises a top wall, bottom wall, front and back walls that extend between the top and bottom walls along the longitudinal axis, and the first and second side walls that are each disposed between the front and back walls, the access opening disposed in the first region is defined across a portion of the top wall and the front wall of the inner package.

5. The container of claim 1, wherein the inner package comprises a fold line disposed between the front wall and at least one side wall, and further wherein the second layer does not extend to the fold line.

6. The container of claim 1, wherein the second layer is attached to the inner surface of the first layer by a releasable adhesive.

7. The container of claim 6, wherein the releasable adhesive comprises a pressure-sensitive adhesive.

8. The container of claim 1, wherein the inner package further comprises a seal region formed between the first line of weakness and the second line of weakness, wherein the flap is adapted to overlap the access opening into the seal region such that the flap attaches to the second layer within the seal region when the flap is in the closed position.

9. The container of claim 8, wherein the seal region comprises an average width that extends from a perimeter of the access opening to the first line of weakness, wherein the average width is between about 2 mm and about 5 mm.

10. The container of claim 1, wherein at least a portion of an outer surface of the first layer of the inner package is permanently affixed to a corresponding portion of an inner surface of the rear wall of the box.

11. The container of claim 1, wherein at least a portion of the outer surface of the first layer of the inner package is permanently affixed to a corresponding portion of an inner surface of the front wall of the box.

12. The container of claim 1, further comprising an inner frame disposed within the box, wherein the inner frame comprises a front wall and a pair of opposed side walls.

13. The container of claim 12, wherein: the inner frame is disposed between the front wall of the box and the inner package; or the inner frame is disposed within the inner package.

14. The container of claim 1, further comprising the consumer goods, wherein the consumer goods are housed in the interior volume defined by the inner package.

15. The container of claim 1, wherein the consumer goods are smoking articles.

16. A carton comprising the container of claim 1.

17. A pre-assembled inner package extending along a longitudinal axis, wherein the pre-assembled inner package is formed from a material comprising a first layer and a second layer attached to an inner surface of the first layer, wherein the pre-assembled inner package comprises: a plurality of side wall panels that form side walls of an inner package when assembled, wherein at least one of the side walls includes a sealed portion disposed within a fold of the material of the inner package when assembled; a first region extending along the longitudinal axis and comprising the first and second layers, wherein the first region longitudinally extends an entire length of the pre-assembled inner package such that the first and second layers in the first region also extend the entire length of the pre-assembled inner package, wherein the first region further comprises a first line of weakness disposed in the first layer that defines a flap, and a second line of weakness disposed in the second layer that defines an access opening disposed in the first region, wherein the access opening is covered by the flap when the flap is in a closed position, and further wherein the access opening is at least partially uncovered when the flap is in an open position; and a second region adjacent the first region and extending along the longitudinal axis, wherein the second region comprises only the first layer and not the second layer, wherein the second layer does not extend into the sealed portion.

18. The pre-assembled inner package of claim 17, further comprising a third region adjacent the first region and extending along the longitudinal axis, wherein the first region is disposed between the second and third regions, wherein the third region comprises only the first layer and not the second layer.

19. The pre-assembled inner package of claim 17, wherein the first region has a width measured in a transverse direction of between about 2 mm and about 20 mm.

20. The pre-assembled inner package of claim 17, wherein the second line of weakness is disposed on the pre-assembled inner package such that the access opening is defined across a portion of a top wall panel and a front wall panel of the pre-assembled inner package.

Description

(1) Referring now to the drawings, in which some aspects of the present invention are illustrated:

(2) FIG. 1 is a schematic perspective view of a container that includes a lid in an open position, where the container includes a housing and an inner package disposed within the housing.

(3) FIG. 2 is a schematic side cross-section view of the container of FIG. 1.

(4) FIG. 3 is a schematic perspective view of the container of FIG. 1 with the lid in a closed position.

(5) FIG. 4 is a schematic perspective view of the inner package of FIG. 1.

(6) FIG. 5 is a schematic cross-section view of a portion of the inner package of FIG. 1.

(7) FIG. 6 is a schematic plan view of a portion of the inner package of FIG. 1.

(8) FIG. 7 is a schematic plan view of a pre-assembled inner package.

(9) FIG. 8 is a schematic plan view of an inner frame.

(10) Referring to FIG. 1, a schematic perspective view of an embodiment of a container 10 for consumer goods is depicted. The container includes a housing 12 that includes a box 14 and a lid 20 hingedly attached to the box via a hinge line (not shown). The hinge line extends across a back 18 of the box 14 of the container 10 and acts to allow the lid 20 to be moved from a closed position (FIG. 3) to an open position as shown in FIG. 1. 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.

(11) Referring to FIGS. 4-6, the inner package 30 includes a top wall 38, bottom wall 39, front and back walls 32, 34 that extend between the top and bottom walls, a first side wall 36, and a second side wall 37, where each side wall is disposed between the front and back walls. The inner package 30 is formed from a material 31 that includes a first layer 40 and a second layer 50 attached to an inner surface 46 of the first layer 40 (FIG. 5). As illustrated in FIGS. 5-6, the inner package 30 also includes a first region 80 that extends along a longitudinal axis 2. The first region 80 includes the first and second layers 40, 50 of the material 31. The first region 80 also includes a first line of weakness 42 disposed in the first layer 40 that defines a flap 44. The first region 80 also includes a second line of weakness 52 disposed in the second layer 50 that defines an access opening 54 disposed in the first region 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 (FIG. 3). Further, the access opening 54 is at least partially uncovered when the flap 44 is in the open position (FIGS. 1-2).

(12) The inner package 30 also includes a second region 82 adjacent the first region 80 that extends along the longitudinal axis 2. The second region 82 includes only the first layer 40 and not the second layer 50. The inner package 30 also includes a third region 84 adjacent the first region 80 such that the first region is disposed between the second region 82 and the third region 84. The third region 84 also extends along the longitudinal axis 2. The third region 84 includes only the first layer 40 and not the second layer 50.

(13) The flap 44 is attached to the first layer 40 along a hinge line 49 (FIG. 2). The flap 44 is also attached to an inner surface 22 (FIG. 2) of the lid 20 such that upon opening the lid the flap and a portion 55 (FIG. 1) of the second layer 50 attached to the flap are separated from the inner package 30 along the first and second lines of weakness 42, 52 respectively to reveal the access opening 54.

(14) The container 10 also includes an inner frame 70 disposed within the inner package 30. The inner frame 70 can include a reinforcing element 72 disposed between the inner frame and an inner surface 17 (FIG. 2) of a front wall 16 the box 14.

(15) Referring to FIG. 2, a schematic cross-section view of the container 10 of FIG. 1 is depicted with the lid 20 and the flap 44 in the open position. The inner package 30 is shown disposed within the box 14 of housing 12, and the inner frame 70 is disposed within the inner package. In one or more embodiments, the flap 44 is attached to the lid 20. In the open position, the flap 44 forms an S-shape. The geometry of the container 10 is such that the flap 44 is automatically resealed to the inner package 30 when the flap (and the lid 20) is returned to the closed position.

(16) At least a portion of an outer surface 48 of the first layer 40 of the inner package 30 is permanently affixed to a corresponding portion of an inner surface 19 of the rear wall 18 of the box 14, thereby affixing the inner package to the inner surface of the rear wall of the box in a first region 24. Further, at least a portion of the outer surface 48 of the first layer 40 of the inner package 30 is permanently affixed to a corresponding portion of an inner surface 17 of the front wall 16 of the box 14, thereby affixing the inner package to the inner surface of the front wall of the box in a second region 26. By permanently affixing at least a portion of the inner package 30 to one or both of the front wall 16 and the rear wall 18 of the box 14, the structural resilience of the inner package may be further improved. The inner package 30 may be permanently affixed using, for example, hot melt adhesive, solvent based adhesive, water based adhesive, solvent-free adhesive, pressure-sensitive adhesive, conductive type sealing, and inductive type sealing. In a preferred embodiment, the inner package 30 is permanently attached to the box 14 using a hot melt adhesive.

(17) Referring to FIG. 3, a schematic perspective view of the container 10 of FIG. 1 is depicted. The lid 20 of the container 10 and the flap 44 of the inner package 30 are in the closed position. The flap 44 is attached to the second layer 50 (FIG. 5) when the flap is in the closed position.

(18) Referring to FIG. 4, a schematic perspective view of the inner package 30 of FIG. 1 is depicted. In one or more embodiments, the inner package 30 also includes adhesive 94 disposed on the flap 48 such that the flap can be attached to the inner surface 22 of the lid 20 (FIG. 2). The inner package 30 further includes a sealed portion 90 on the first side wall 36. Although not shown, the inner package 30 can also include an additional sealed portion disposed on the second side wall 37. The sealed portion 90 can be disposed within a fold 92 of the material 31 of the inner package 30 to hold the fold in place. The fold 92 of inner package 30 is an envelope fold. The second layer 50 of the material 31 of the inner package 30 does not extend into the sealed portion 90 (FIG. 6).

(19) Referring to FIG. 5, a schematic cross-section view of a portion of the inner package 30 of FIG. 1 is depicted. The first region 80 of the inner package 30 includes the first line of weakness 42 disposed in the first layer 40 that defines the flap 44. The second layer 50 is attached to the inner surface 46 of the first layer 40 with adhesive 60. The first region 80 includes the second line of weakness 52 disposed in the second layer 50 that defines an access opening 54 disposed in the first region. As shown in FIG. 5, the access opening 54 is covered by the flap 44 when the flap is in the closed position. The flap 44 is adapted to be attached to the second layer 50 when the flap is in the closed position.

(20) A seal region 62 is formed between the first line of weakness 42 and the second line of weakness 52. The flap 44 is adapted to overlap the access opening 54 into the seal region 62 such that the flap attaches to the second layer 50 within the seal region when the flap is in the closed position. In one or more embodiments, the seal region 62 has a constant width along a perimeter of the access opening 54. In one or more embodiments, the seal region 62 has a width that varies along a perimeter of the access opening 54.

(21) The inner package 30 also includes the portion 55 of the second layer 50 that remains attached to the flap 44 when the flap is moved from the closed position to the open position. In other words, upon opening the flap 44 (FIGS. 1-2), the flap and the portion 55 of the second layer 50 attached to the flap are separated from the inner package 30 along the first and second lines of weakness 42, 52 respectively to reveal the access opening 54.

(22) Referring to FIG. 6, a schematic plan view of a portion of the inner package 30 of FIG. 1 is depicted. Fold lines 96 and 98 are formed to provide an envelope fold in both the first and second side walls 36, 37, portions of which being illustrated in FIG. 6. The fold lines 96, 98 can be disposed between the front wall 32 and side walls 36, 37 of the inner package 30, or between the back wall 34 and the side walls. Tabs of the envelope folds (for example, envelope fold 90 of FIG. 4) formed in the first and second side walls 36, 37 can be attached together to form the sealed portion 92 in the first side wall 36 (FIG. 4) and a sealed portion in the second side wall 37 (not shown). In one or more embodiments, a first edge 58 of the second layer 50 does not extend to the fold line 96 in the first side wall 36. Further, a second edge 59 of the second layer 50 does not extend to the fold line 98 in the second side wall 37. As a result, the second layer 50 does not extend into the sealed portions formed when tabs of the envelope fold are attached together in the first and second side walls 36, 37.

(23) Referring to FIG. 7, a schematic plan view of a pre-assembled inner package 100 is depicted. The pre-assembled inner package 100 extends along a longitudinal axis 102 and is formed from a material that includes a first layer 140 and a second layer 150 attached to an inner surface of the first layer (not shown). The pre-assembled inner package 100 further includes a first region 180 that extends along the longitudinal axis 102 and includes the first and second layers 140, 150. The first region 180 further includes a first line of weakness 142 disposed in the first layer 140 that defines a flap 144, and a second line of weakness 152 disposed in the second layer 150 that defines an access opening 154 disposed in the first region. The access opening 154 is covered by the flap 144 when the flap is in a closed position, and the access opening is at least partially uncovered when the flap is in an open position. The pre-assembled inner package 100 also includes a second region 182 adjacent the first region 180 that extends along the longitudinal axis 102. The second region 182 includes only the first layer 140 and not the second layer 150. The pre-assembled inner package 100 also includes a third region 184 adjacent the first region 180 that extends along the longitudinal axis 102 such that the first region 180 is disposed between the second region 182 and the third region. The third region 184 includes only the first layer 140 and not the second layer 150.

(24) The first region 180 can longitudinally extend an entire length of the pre-assembled inner package 100. In one or more embodiments, the first region 180 longitudinally extends between a first transverse portion 186 and a second transverse portion 188. Each of the first and second transverse portions 186, 188 includes only the first layer 140 and not the second layer 150.

(25) The pre-assembled inner package 100 shown in FIG. 7 also includes a front wall panel 101 that forms a front wall (for example, front wall 32 of inner package 30 of FIG. 4) of the inner package when assembled, two wall panels 104 and 106 that form a back wall (for example, back wall 34 of inner package 30 of FIG. 4) of the inner package when assembled, a top wall panel 108, and a bottom wall panel 110. The pre-assembled inner package 100 also includes a plurality of side wall panels 118 that form side walls (for example, first and second side walls 36, 37 of FIG. 4). As can be seen in FIG. 7, the second line of weakness 152 is disposed on the pre-assembled inner package 100 such that the access opening 154 is defined across a portion of the top wall panel 108 and the front wall panel 102. The preassembled inner package 100 can also include a reinforcing element 119. The reinforcing element 119 can include any suitable reinforcing element described herein regarding the inner frame 70 of FIGS. 1-2.

(26) FIG. 8 shows the pre-assembled inner frame 120. As described herein, the inner frame 120 includes a front wall 122 and two opposed side walls 124 and 126. The outer surface of the front wall 122 is provided with a reinforcing element 128. As described herein, a cut-out 130 is provided at the top of the front wall panel of the inner frame. The cut-out 130 is provided to allow the consumer goods housed within the container to be accessed more easily. The cut-out 130 is provided such that it aligns with the access opening 54 (FIG. 1) provided in the inner package 30.

(27) The dashed lines in the above described figures indicate fold lines.