RESEALABLE CONTAINER INCLUDING INSERT AND METHOD OF MANUFACTURING

Abstract

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.

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.

Description

[0052] Referring now to the drawings, in which some aspects of the present invention are illustrated.

[0053] FIG. 1 is a schematic perspective view of a container in an open position, where the container comprises an access region comprising a line of weakness and an insert.

[0054] FIG. 2 is a schematic cross-section view of the side of the container of FIG. 1 in an open position.

[0055] FIG. 3 is a schematic perspective view of the front of the container of FIG. 1 in a closed position.

[0056] FIG. 4 is a cross-section view of a portion of a container showing only a portion of the inner package, resealable label and insert.

[0057] FIG. 5 is a schematic perspective view of a container in an open position, where the insert is adhered to the inner package.

[0058] FIG. 6 is a schematic perspective view of the container of FIG. 5 with the insert removed from the container.

[0059] Referring to FIGS. 1 and 2, a schematic perspective view (and a cross section view in FIG. 2) 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 box has a front wall 16 and a rear wall 18. The front wall of the box has an upper edge 21. The box also has an inner surface 17 and an outer surface 19. The hinge line extends across the back wall 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. The lid 20 has a front wall 24 that has an inner surface 22 and an outer surface 26 (FIG. 2).

[0060] 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 FIG. 2). The inner package 30 includes an outer surface 33. The inner package also includes a first layer 40 and a second layer 50 attached to an inner surface of the first layer.

[0061] 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 (FIG. 3). Further, the access opening 54 is at least partially uncovered when the flap 44 is in the open position. The flap can be attached to the inner surface of the lid with a resealable label 45. The resealable label 45 includes an inner surface and an outer surface. The inner surface includes a sealing area and a non-sealing area (shown in more detail in FIG. 4). The flap 44 can be 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 front wall 24 of the lid 20 such that upon opening the lid the flap and a portion 55 of the second layer 50 attached to the flap are separated from the inner package 30 along first and second lines of weakness (not shown herein) to reveal the access opening 54. The flap 44 is adapted to overlap the access opening 54 into a sealing region 72 such that the flap attaches to the second layer 50 within the sealing region 72 when the flap is in the closed position.

[0062] 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. 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.

[0063] 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.

[0064] Referring to FIG. 3, a schematic perspective view of an embodiment of a container that is closed is shown. As seen from this view, the label 45 is inside the lid and in contact with the inner surface of the lid. The inner surface of the label includes a sealing area 46 and a non-sealing area 47. As seen from this view, the insert 60 which is between the inner liner and the container is only in contact with the non-sealing area 47 of the label 45 not the sealing area 46.

[0065] Referring to FIG. 4, a cross-sectional view of a portion of a container is depicted. The portion shown includes an inner liner 30, an insert 60 and a resealable label 45. As seen from FIG. 4, the insert 60 is positioned between the inner liner 30 and the resealable label 45. The resealable label 45 has an inner surface 53 and an outer surface 51. The insert 60 is in contact with the inner surface 53. Only the non-sealing area 47 of the label 45 is in contact with the insert 60, with the sealing area 43 being in contact with the inner liner 30. It is also noted that the sealing area 43 is on the inner surface 53 while the outer surface 51 includes the permanent adhesive area 52 that attaches the resealable label 45 to the inner surface of the lid 24.

[0066] FIG. 5 depicts a schematic perspective view of an embodiment of a container 10 for consumer goods that includes some of the same features as that seen in FIGS. 1 and 2 but also includes an insert adhesive portion 71 that functions to attach the insert to the inner liner. It is noted that the insert adhesive portion 71 is located between the inner liner and the insert. This adhesive could have been applied in order to maintain the insert in contact with the inner liner during manufacturing. Preferably, the adhesive (or other fixative) is not so strong or long lasting that it does not allow the insert to be removed from the container. FIG. 6 depicts the same container with the insert removed from the container and shows that the insert 64 can be optionally folded.