A CONTAINER HAVING A SEALED COMPARTMENT

Abstract

There is provided a container (4) for consumer goods, the container (4) comprising a first substrate layer (8) and a second substrate layer (10) overlying the first substrate layer (8). A first portion (3) of the first substrate layer (8) and a first portion (5) of the second substrate layer (10) form a compartment region (7), wherein a perimeter (18) of the compartment region (7) is completely sealed to form a sealed compartment (16) for containing one or more consumer goods. A second portion (9) of the first substrate layer (8) and a second portion (11) of the second substrate layer (8) form an access region (13) directly adjacent to the compartment region (7). The access region (13) comprises an unsealed area (22), wherein a perimeter (20) of the access region (13) extends around the unsealed area (22). The first substrate layer (8) is attached to the second substrate layer (10) at the perimeter of the access region. The unsealed area (22) is separated from the sealed compartment (16) by the completely sealed perimeter (18) of the compartment region (7). The container (4) further comprises a first line of weakness (128) extending at least partially within the unsealed area (22) of the access region (13) in the first substrate layer (8) only, the container (4) further comprising a second line of weakness (131) in the second substrate layer (10) only. The second line of weakness (131) has a different shape to the first line of weakness (128), wherein the difference in shape between the first line of weakness (128) and the second line of weakness (131) defines a closure tab (143) in the second substrate layer (10) in the unsealed area (22) of the access region (13).

Claims

1-16. (canceled)

17. A container for consumer goods, the container comprising: a first substrate layer; a second substrate layer overlying the first substrate layer; wherein a first portion of the first substrate layer and a first portion of the second substrate layer form a compartment region, wherein a perimeter of the compartment region is completely sealed to form a sealed compartment for containing one or more consumer goods; wherein a second portion of the first substrate layer and a second portion of the second substrate layer form an access region directly adjacent to the compartment region, wherein the access region comprises an unsealed area, wherein a perimeter of the access region extends around the unsealed area, wherein the first substrate layer is attached to the second substrate layer at the perimeter of the access region, wherein the unsealed area is separated from the sealed compartment by the completely sealed perimeter of the compartment region; and wherein the container further comprises a line of weakness extending at least partially within the unsealed area of the access region, wherein the line of weakness is a first line of weakness in the first substrate layer only, the container further comprising a second line of weakness in the second substrate layer only, wherein the second line of weakness has a different shape to the first line of weakness, wherein the difference in shape between the first line of weakness and the second line of weakness defines a closure tab in the second substrate layer in the unsealed area of the access region, and wherein the difference in shape between the first line of weakness and the second line of weakness is such that a part of the first substrate layer may be tucked underneath the closure tab to retain the first substrate layer in a closed position.

18. A container according to claim 17, wherein the line of weakness extends between a first edge of the container and a second edge of the container.

19. A container according to claim 17, wherein the perimeter of the access region comprises at least one unsealed portion, and wherein the line of weakness extends across the at least one unsealed portion.

20. A container according to claim 19, wherein the at least one unsealed portion comprises a first unsealed portion and a second unsealed portion, wherein a first end of the line of weakness extends across the first unsealed portion and wherein a second end of the line of weakness extends across the second unsealed portion.

21. A container according to claim 17, wherein the line of weakness is linear.

22. A container according to claim 17, wherein at least a portion of the line of weakness is curved.

23. A container according to claim 17, wherein the second line of weakness at least partially overlies the first line of weakness.

24. A container according to claim 17, wherein the first portion of at least one of the first substrate layer and the second substrate layer comprises a recess, and wherein the recess at least partially defines the compartment for containing one or more consumer goods.

25. A container according to claim 17, wherein each of the first substrate layer and the second substrate layer comprises a laminate material, and wherein the laminate material comprises at least one layer of paper and at least one layer of a polymeric film.

26. A packaged aerosol-generating article comprising: a container according to claim 17; and an aerosol-generating article sealed within the compartment.

27. A method of forming a packaged aerosol-generating article, the method comprising: providing a first web of substrate material; positioning an aerosol-generating article on the first web of substrate material; providing a second web of substrate material; positioning the second web of substrate material over the aerosol-generating article and the first web of substrate material; securing a first portion of the first web of substrate material to a first portion of the second web of substrate material to form a compartment region, wherein a perimeter of the compartment region is completely sealed to form a sealed compartment, and wherein the aerosol-generating article is contained within the sealed compartment; securing a second portion of the first web of substrate material to a second portion of the second web of substrate material to form an access region directly adjacent to the compartment region, wherein the access region comprises an unsealed area, wherein a perimeter of the access region extends around the unsealed area, wherein the first substrate layer is attached to the second substrate layer at the perimeter of the access region, and wherein the unsealed area is separated from the sealed compartment by the completely sealed perimeter of the compartment region; forming a line of weakness extending at least partially within the unsealed area of the access region, wherein the line of weakness is a first line of weakness in the first substrate layer only, the container further comprising a second line of weakness in the second substrate layer only, wherein the second line of weakness has a different shape to the first line of weakness, wherein the difference in shape between the first line of weakness and the second line of weakness defines a closure tab in the second substrate layer in the unsealed area of the access region, and wherein the difference in shape between the first line of weakness and the second line of weakness is such that a part of the first substrate layer may be tucked underneath the closure tab to retain the first substrate layer in a closed position; and cutting the first web of substrate material and the second web of substrate material to form a packaged aerosol-generating article, the packaged aerosol-generating article comprising the aerosol-generating article and a container comprising a first substrate layer, a second substrate layer, the compartment region, the access region and the line of weakness.

28. A method according to claim 27, wherein each of the first substrate layer and the second substrate layer comprises a laminate material, and wherein the laminate material comprises at least one layer of paper and at least one layer of a polymeric film.

Description

[0128] Examples will now be further described with reference to the figures in which:

[0129] FIG. 1 shows a top view of a packaged aerosol-generating article according to a first embodiment of the present disclosure;

[0130] FIGS. 2 to 4 show a cross-sectional view of the packaged aerosol-generating article of FIG. 1 taken along line 1-1;

[0131] FIG. 5 shows a top view of a packaged aerosol-generating article according to a second embodiment of the present disclosure;

[0132] FIG. 6 shows a bottom view of the packaged aerosol-generating article of FIG. 5;

[0133] FIG. 7 shows a cross-sectional view of the packaged aerosol-generating article of FIGS. 5 and 6 taken along line 5-5;

[0134] FIGS. 8 to 10 show an enlarged view of the portion of the packaged aerosol-generating article of FIG. 7 circled by line 7-7;

[0135] FIGS. 11 to 13 show a plug assist apparatus for thermoforming a recess in a web of substrate material;

[0136] FIG. 14 shows the steps of a plug assist thermoforming process according to an embodiment of the present disclosure; and

[0137] FIG. 15 shows the steps of a method of forming a packaged aerosol-generating article according to an embodiment of the present disclosure.

[0138] FIGS. 1 to 4 show a packaged aerosol-generating article 2 according to a first embodiment of the present disclosure. The packaged aerosol-generating article 2 comprises a container 4 and an aerosol-generating article 6 received within the container 4. The container 4 comprises a first substrate layer 8 and a second substrate layer 10 overlying the first substrate layer 8. Each of the first substrate layer 8 and the second substrate layer 10 is formed from a laminate material comprising a layer of paper forming an outer surface of the substrate layer and a layer of a polymeric film forming an inner surface of the substrate layer.

[0139] A first portion 3 of the first substrate layer 8 and a first portion 5 of the second substrate layer 10 form a compartment region 7, wherein a perimeter 18 of the compartment region 7 is completely sealed by a continuous thermal weld to form a sealed compartment 16 in which the aerosol-generating article 6 is positioned. The first portion 3 of the first substrate layer 8 comprises a first recess 12 and the first portion 5 of the second substrate layer 10 comprises a second recess 14, wherein the first recess 12 and the second recess 14 together define the compartment 16.

[0140] A second portion 9 of the first substrate layer 8 and a second portion 11 of the second substrate layer 10 form an access region 13 directly adjacent to the compartment region 7, wherein the access region 13 comprises an unsealed area 22 and wherein a perimeter 20 of the access region 13 extends around the unsealed area 22. The first substrate layer 8 is attached to the second substrate layer 10 along part of the access region perimeter 20 The access region perimeter 20 comprises two unsealed portions 15 on opposite sides of the unsealed area 22 at which the first substrate layer 8 is not attached to the second substrate layer 10. The unsealed area 22 is separated from the sealed compartment 16 by the completely sealed perimeter 18 of the compartment region 7.

[0141] A line of weakness 28 comprising a perforation line is provided in the first substrate layer 8 and the second substrate layer 10, the line of weakness 28 extending between a first edge 24 of the container 4 and a second edge 26 of the container 4.

[0142] Although the first substrate layer 8 is not secured to the second substrate layer 10 at the unsealed area 22, the attachment of the first substrate layer 8 to the second substrate layer 10 along part of the length of the access region perimeter 20 makes it difficult to separate the first substrate layer 8 from the second substrate layer 10. Therefore, the attachment of the first substrate layer 8 to the second substrate layer 10 along part of the length of the access region perimeter 20 reduces the risk of the container 4 being opened accidentally.

[0143] Opening of the container 4 to remove the aerosol-generating article 6 from the container 4 is a two-step process.

[0144] Firstly, a user tears, snaps or breaks the container 4 along the entire length of the line of weakness 28 to detach a portion of the container 4 comprising part of the access region perimeter 20. The outcome of this step is shown in FIG. 3.

[0145] Secondly, a user separately grasps the first substrate layer 8 and the second substrate layer 10 at the unsealed area 22 and pulls the first substrate layer 8 and the second substrate layer 10 away from each other to detach the first substrate layer 8 from the second substrate layer 10 at the sealed compartment region perimeter 18. This step is illustrated in FIG. 4. Once the first substrate layer 8 has been detached from the second substrate layer 10 across at least part of the sealed compartment region perimeter 18 the aerosol-generating article 6 may be removed from the compartment 16.

[0146] FIGS. 5 to 10 show a packaged aerosol-generating article 102 according to a second embodiment of the present disclosure. The packaged aerosol-generating article 102 is similar to the packaged aerosol-generating article 2 described with reference to FIGS. 1 to 4, and like reference numerals are used to designate like parts.

[0147] The packaged aerosol-generating article 102 comprises a container 4 and an aerosol-generating article 6 received within the container 4. The container 4 comprises a first substrate layer 8 and a second substrate layer 10 overlying the first substrate layer 8. Each of the first substrate layer 8 and the second substrate layer 10 is formed from a laminate material comprising a layer of paper forming an outer surface of the substrate layer and a layer of a polymeric film forming an inner surface of the substrate layer.

[0148] A first portion 3 of the first substrate layer 8 and a first portion 5 of the second substrate layer 10 form a compartment region 7, wherein a perimeter 18 of the compartment region 7 is completely sealed by a continuous thermal weld to form a sealed compartment 16 in which the aerosol-generating article 6 is positioned. The first portion 3 of the first substrate layer 8 comprises a first recess 12 and the first portion 5 of the second substrate layer 10 comprises a second recess 14, wherein the first recess 12 and the second recess 14 together define the compartment 16.

[0149] A second portion 9 of the first substrate layer 8 and a second portion 11 of the second substrate layer 10 form an access region 13 directly adjacent to the compartment region 7, wherein the access region 13 comprises an unsealed area 22 and wherein a perimeter 20 of the access region 13 extends around the unsealed area 22 and is completely sealed. The unsealed area 22 is separated from the sealed compartment 16 by the completely sealed perimeter 18 of the compartment region 7.

[0150] A first line of weakness 128 is provided in the first substrate layer 10 and comprises a perforation line 129 extending across part of the unsealed area 22. The first line of weakness 128 also comprises a first cut line 135 extending across the sealed compartment region perimeter 18 between a first end of the perforation line 129 and a first edge 24 of the container 4. The first line of weakness 128 also comprises a second cut line 137 extending across the sealed compartment region perimeter 18 between a second end of the perforation line 129 and a second edge 26 of the container 4.

[0151] A second line of weakness 131 comprising a perforation line is provided in the second substrate layer 10 and extends across part of the unsealed area 22. The second line of weakness 131 has a different shape to the first line of weakness 128 so that the second line of weakness 131 only partially overlies the first line of weakness 128. In particular, end portions of the second line of weakness 131 overlie corresponding end portions of the perforation line 129 of the first line of weakness 128. However, a central portion of the second line of weakness 131 is shaped to define a tab 143. The function of the tab 143 is described in further detail below.

[0152] Although the first substrate layer 8 is not secured to the second substrate layer 10 at the unsealed area 22, the completely sealed access region perimeter 20 makes it difficult to separate the first substrate layer 8 from the second substrate layer 10. Therefore, the completely sealed access region perimeter 20 reduces the risk of the container 4 being opened accidentally.

[0153] Opening of the container 4 to remove the aerosol-generating article 6 from the container 4 is a two-step process.

[0154] Firstly, a user bends the container 4 to break the first substrate layer 8 along the first line of weakness 128 and to break the second substrate layer 10 along the second line of weakness 131. The outcome of this step is shown in FIG. 8.

[0155] Secondly, a user separately grasps the first substrate layer 8 and the second substrate layer 10 at the unsealed area 22 and pulls the first substrate layer 8 and the second substrate layer 10 away from each other to detach the first substrate layer 8 from the second substrate layer 10 at the sealed compartment region perimeter 18. The first cut line 135 and the second cut line 137 in the first substrate layer 8 facilitate detachment of the first substrate layer 8 from the second substrate layer 10 at the sealed compartment region perimeter 18. This step is illustrated in FIG. 9. Once the first substrate layer 8 has been detached from the second substrate layer 10 across at least part of the sealed compartment region perimeter 18 the aerosol-generating article 6 may be removed from the compartment 16.

[0156] FIG. 10 illustrates the function of the tab 143 formed by the second substrate layer 10 when the second substrate layer 10 is broken along the second line of weakness 131. The tab 143 facilitates reclosing of the container 4 by allowing a user to position part of the first substrate layer 8 at the unsealed area 22 under the tab 143. For example, when the aerosol-generating article 6 has been used, the user may reinsert the aerosol-generating article 6 into the compartment 16 and reclose the container 4 by positioning part of the first substrate layer 8 at the unsealed area 22 under the tab 143. The used aerosol-generating article 6 may then be carried in the container 4 until the user can dispose of the used aerosol-generating article 6 and the container 4 together.

[0157] FIGS. 11 to 13 show a plug assist apparatus 200 for thermoforming a recess in a web of substrate material. The plug assist apparatus 200 may be used to thermoform the first recess 12 and the second recess 14 of the first substrate layer 8 and the second substrate layer 10 described with reference to FIGS. 1 to 10.

[0158] The plug assist apparatus 200 comprises a plug 202 comprising a plug body 204 formed from stainless steel and an elastomeric cover 206 extending over a portion of the plug body 204. The plug body 204 has a rounded cuboid shape.

[0159] The plug assist apparatus 200 also comprises a mold 208 formed from stainless steel and positioned opposite the plug 202. Each of the plug 202 and the mold 208 is arranged for linear movement along a forming direction 210.

[0160] In a first configuration shown in FIG. 11 the plug 202 and the mold 208 are spaced apart from each other and a web of substrate material 212 is positioned between the plug 202 and the mold 208. The web of substrate material is arranged for linear movement along a machine direction 214 orthogonal to the forming direction 210.

[0161] To form a recess 216 in the web of substrate material 212 the plug 202 and the mold 208 are advanced towards each other along the forming direction 210. The elastomeric cover 206 of the plug 202 engages the web of substrate material 212 and deforms the web of substrate material 212 into the mold 208. The plug 202 and the mold 208 are then withdrawn from the web of substrate material 212 along the forming direction 210 to leave the formed recess 216 in the web of substrate material 212.

[0162] FIG. 14 shows the steps of a plug assist thermoforming process 300 according to an embodiment of the present disclosure. The process of FIG. 14 is described with reference to the plug assist apparatus 200 of FIGS. 11 to 13, but the skilled person will appreciate that the process may be carried out using any apparatus comprising a mold and a plug comprising a plug body and an elastomeric cover.

[0163] The plug assist thermoforming process 300 comprises providing 302 the mold 208 and the plug 202 comprising the plug body 204 and the elastomeric cover 206 extending over a portion of the plug body 204.

[0164] The plug assist thermoforming process 300 also comprises heating 304 the web of substrate material 212. The heating step may be carried out by passing the web of substrate material 212 across at least one of a heated roller and a heated plate, impinging heated air or a heated gas on a surface of the web of substrate material, passing the web of substrate material through an oven, and combinations thereof.

[0165] The plug assist thermoforming process 300 also comprises positioning 306 the heated web of substrate material 212 between the mold 208 and the plug 202. For example, the heated web of substrate material 212 may be positioned between the mold 208 and the plug 202 by advancing the heated web of substrate material 212 in the machine direction 214.

[0166] The plug assist thermoforming process 300 also comprises engaging 308 the elastomeric cover 206 of the plug 202 with the heated web of substrate material 212 and inserting 310 the plug 202 into the mold 208 to form the heated web of substrate material 212 to the shape of the mold 208.

[0167] The plug assist thermoforming process 300 may also comprises withdrawing 312 the mold 208 and the plug 202 from the heated web of substrate material 212 and advancing the heated web of substrate material 212 to position a different portion of the heated web of substrate material 212 between the mold 208 and the plug 202. The steps 308, 310 and 312 may be repeated in a loop to form a series of recesses 216 in the heated web of substrate material 212.

[0168] FIG. 15 shows the steps of a method 400 of forming a packaged aerosol-generating article according to an embodiment of the present disclosure. The packaged aerosol-generating article formed according to the method 400 may be a packaged aerosol-generating article 2 described with reference to FIGS. 1 to 4, a packaged aerosol-generating article 102 described with reference to FIGS. 5 to 10, or a different packaged aerosol-generating article.

[0169] The method 400 comprises providing 402 a first web of substrate material and forming 404 a first recess in the first web of substrate material. The step of forming 404 a first recess in the first web of substrate material may be carried out using a plug assist thermoforming process. The plug assist thermoforming process may be the plug assist thermoforming process 300 described with reference to FIG. 14.

[0170] The method 400 also comprises providing 406 a second web of substrate material and forming 408 a second recess in the second web of substrate material. The step of forming 408 a second recess in the second web of substrate material may be carried out using a plug assist thermoforming process. The plug assist thermoforming process may be the plug assist thermoforming process 300 described with reference to FIG. 14.

[0171] The method 400 also comprises a step of positioning 410 an aerosol-generating article in the first recess of the first web of substrate material.

[0172] The method 400 further comprises positioning 412 the second web of substrate material over the aerosol-generating article and the first web of substrate material so that the second recess of the second web of substrate material overlies the aerosol-generating article.

[0173] The method 400 also comprises securing 414 a first portion of the first web of substrate material to a first portion of the second web of substrate material to form a compartment region, wherein a perimeter of the compartment region is completely sealed to form a sealed compartment, and wherein the aerosol-generating article is contained within the sealed compartment. The sealed compartment comprises the first recess and the second recess. Preferably, the step of securing 414 the second of web of substrate material to the first web of substrate material is carried out using a thermal weld.

[0174] The method 400 also comprises securing 416 a second portion of the first web of substrate material to a second portion of the second web of substrate material to form an access region directly adjacent to the compartment region, wherein the access region comprises an unsealed area, wherein a perimeter of the access region extends around the unsealed area, wherein the first substrate layer is attached to the second substrate layer at the perimeter of the access region, and wherein the unsealed area is separated from the sealed compartment by the completely sealed perimeter of the compartment region. Preferably, the step of securing 416 the second of web of substrate material to the first web of substrate material is carried out using a thermal weld.

[0175] It will be appreciated that the step of securing 416 the second web of substrate material to the first web of substrate material to form the access region may be carried out before the step of securing 414 the second web of substrate material to the first web of substrate material to form the compartment region.

[0176] It will be appreciated that the step of securing 416 the second web of substrate material to the first web of substrate material to form the access region may be carried out simultaneously with the step of securing 414 the second web of substrate material to the first web of substrate material to form the compartment region.

[0177] The method 400 also comprises forming 418 a line of weakness in at least one of the first web of substrate material and the second web of substrate material, wherein the line of weakness extends at least partially within the unsealed area of the access region.

[0178] It will be appreciated that the step of forming 418 a line of weakness may be carried out before any of the preceding steps.

[0179] The step of forming 418 a line of weakness may comprise forming a first line of weakness in the first web of substrate material and forming a second line of weakness in the second web of substrate material. In embodiments in which the step of forming 418 a line of weakness is carried out before step 412, the method 400 may comprise separate steps of forming a first line of weakness in the first web of substrate material and forming a second line of weakness in the second web of substrate material.

[0180] The method 400 also comprises cutting 420 the first web of substrate material and the second web of substrate material to form a packaged aerosol-generating article. The packaged aerosol-generating article comprises the aerosol-generating article and a container comprising a first substrate layer, a second substrate layer, the compartment region, the access region and the line of weakness.

[0181] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A±10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.