CN110650900B

CN110650900B - Container for consumer goods with reclosable flap and method

Info

Publication number: CN110650900B
Application number: CN201880032775.3A
Authority: CN
Inventors: 于尔根·金佩尔; 蒂姆·柯林斯; 延斯·弗兰岑; 加布里埃拉·格雷科; 罗伯特·阿利松; 米格尔·索里亚诺
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2017-05-18
Filing date: 2018-05-15
Publication date: 2021-08-13
Anticipated expiration: 2038-05-15
Also published as: EP3625150A1; JP2020519543A; CN110650900A; KR20200007928A; EA039723B1; JP7105253B2; US20200346846A1; CA3063490A1; EA201992449A1; WO2018210834A1

Abstract

The present invention relates to a container (1) for consumer goods, such as smoking articles, having an outer shell with a hinged flap (3) which houses an inner package (5) of consumer goods, and to a method of forming the container. The inner package (5) has an access opening (6) through which consumer goods can be taken out, and the access opening is covered by a reclosable flap (8) that is attached to a first flap panel (32) that is movable relative to a second flap panel (33) throughout rotation of the flap (3) between a flap open position and a flap closed position. When the hinged flap (3) is in the open position, a portion of the reclosable flap (8) is maintained in a substantially flat, tensioned configuration between the hinge line (7) of the reclosable flap and the hinged flap (3).

Description

Container for consumer goods with reclosable flap and method

Technical Field

The present invention relates to a container for consumer goods, in particular for smoking articles.

Background

Some cigarette containers comprise a rigid outer shell and a sealed inner package within which the cigarettes are contained, for example as described in WO 2008/142540. These containers have a resealable access opening in the sealed inner package that is selectively covered by a cover sheet. The cover sheet is attached to the hinged flap such that opening and closing the flap simultaneously opens and closes the cover sheet over the resealable access opening. The cover sheet is secured to the inner package using an adhesive that extends around the entire access opening so that the cover sheet can be detached from the inner package and secured back again. This may allow the cover sheet to seal the cigarettes within the inner package when the flap is closed.

In these conventional packaging structures, it is challenging to select the adhesive strength of the adhesive surface to be sufficient for a high quality seal throughout the life of the container and to allow the flap to be opened, especially when the container is first opened. If the bond strength is too strong, the first opening can lead to the flap being damaged, especially at the hinge and side panels, and if the bond strength is too weak, the attachment of the cover sheet to the inner package fails and may even wear out after multiple openings. Further, this choice must be made for each combination of cover sheet and inner wrapper or texture.

Several solutions to this problem have been proposed based on reducing the effective adhesion area. These solutions have still been found to be unsatisfactory because they are complex and still rely on an adhesive surface, thus only partially solving the problem.

Another problem found with these containers is that it is well known that once some cigarettes are removed from the inner package, the repositioning of the cover sheet to the inner package will be less precise, even leading to attachment problems.

In order to solve this problem, attempts have been made to use more complex and therefore expensive materials, in particular for the covering sheet, or to rigidify the inner package, for example by using a rigid inner frame which is located below the sealed package and almost completely surrounds the cigarettes. These solutions are still unsatisfactory because they are more expensive and increase manufacturing complexity.

Yet another problem is that loose tobacco fines may stick to the adhesive, which may be unpleasant for the user and may reduce the effectiveness of the adhesive. A further problem is that the seal provided by known cover sheets may, under certain atmospheric conditions, actually be detrimental to the preservation of tobacco in a smoking article. Yet another problem associated with these containers is the difficulty of opening them for the first time, especially when a seal or marker is provided at the closure line of the flap as evidence that the container has not been tampered with.

Another known container is described in WO 2012/089812. In this arrangement, the cover layer is provided with an embossed marker on the inner surface of the adhesive label. The imprinted markers are visible when the cover layer is moved from the closed position to the open position. However, movement of the cover sheet between the closed and open positions may cause distortion of the embossed markers, which may produce undesirable visual effects.

Disclosure of Invention

It is therefore an object of the present invention to provide an improved container for consumer goods with a reclosable flap. It is another object of the present invention to provide a blank for forming an outer shell of an improved container.

According to a first aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing comprising a box and a hinged flap rotatable between an open position and a closed position, wherein a lower front edge of the flap abuts a free edge of the front wall of the box when the flap is in the closed position; an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed; a reclosable flap movable about a hinge line relative to the inner package and arranged to cover the access opening, the reclosable flap having a free end attached to the hinged flap; wherein, in the open position with the flip top wall disposed substantially perpendicular to the box back wall, the lower flip front edge is a first distance from the line of articulation; wherein a second distance is measured along the length of the reclosable flap between the hinge line and its free end; wherein the ratio between the first distance and the second distance is comprised between 70% and 100%.

In this way, the reclosable flap can be held in tension when the hinged flap is in the open position. This is achieved because the second distance is either equal to the first distance or slightly longer than the first distance. This minimizes the likelihood of any slack in the reclosable flap when the flip is in the open position. Advantageously, this may assist the movement of the hinged flap from the open position towards the closed position. Furthermore, this may improve the positioning of the reclosable flap against the inner package when the hinged flap is moved from the open position to the closed position. In particular, this may improve the positioning of the reclosable flap along the top wall of the inner package to ensure that an effective seal is created and to help preserve the consumer goods.

The ratio may be at least 75%, such as at least 80%, such as at least 85%. It has been found that these proportions can provide a desired amount of tension to the reclosable flap when the hinged flap is in the open position.

The proportion may be not more than 95%, for example not more than 90%. It has been found that these ratios provide a desired amount of tension to the reclosable flap when the hinged flap is in the open position, while limiting the risk of damage to the reclosable flap or to the inner package (e.g., tearing the inner package).

In one arrangement, the hinge line may be positioned at the top wall of the inner package at a distance of at least 20% of the distance from the top rear edge of the inner package to the top front edge of the inner package. This distance may be at least 25%, for example at least 30%. This relative distance may provide a desired amount of tension to the reclosable flap when the hinged flap is in the open position. By positioning the hinge line at the top wall of the inner package at a distance from the top rear edge of the inner package to the top front edge of the inner package of not more than 40%, accessibility of the consumer goods is facilitated. This distance may be no greater than 35% to provide further accessibility to the consumer goods, especially for consumer goods stacked in three rows between the rear surface and the front surface of the inner package. Where the consumer articles are smoking articles, the smoking articles may be positioned in three rows between the front and rear surfaces of the inner wrapper, and it is advantageous to position the hinge line proximate the interface between the rear row of smoking articles and the intermediate row of smoking articles.

When the container has dimensions similar to those of a conventional smoking article container, the hinge line may be positioned at the top wall of the inner package at a distance of at least 5mm, such as at least 6mm, such as at least 7mm from the top rear edge of the inner package. Likewise, the hinge line may be positioned at a distance of no more than 9mm, for example no more than 8 mm.

Thus, the hinge line may be positioned further away from the top rear edge of the inner package than has typically been considered. This may advantageously increase the tension in the reclosable flap when the hinged flap is in the open position, while still allowing easy access to the consumer goods through the access opening.

The reclosable flap can be attached to the inner package such that during movement of the flap, a portion of the reclosable flap is movable relative to the inner package while another portion of the reclosable flap is not movable during movement of the flap. For example, the non-removable portion of the reclosable flap may be attached to the inner package by a permanent adhesive, preferably by one or more strips of permanent adhesive. In this arrangement, the hinge line defines a movable portion and a non-movable portion of the reclosable flap.

In another configuration, the access opening may be provided by a cut line or a line of weakness defining a flap in the outer surface of the inner package. The hinge line of the reclosable flap may substantially coincide with the hinge line of the flap in the outer surface of the inner package. Thus, the hinge line may substantially coincide with the rear edge of the access opening.

In this case, the inner package may comprise an adhesive label adhered to its inner surface at the portion of the reclosable lid sheet overlying the adhesive label. The access opening may then be provided in the adhesive label, for example by a cut or a line of weakness, or by a cut line defining a flap covering the access opening.

A reclosable flap can be attached to a first flap panel of the hinged flap and the first flap panel can be movable relative to a second flap panel during movement of the flap between the open and closed positions.

In some embodiments, in the first open position, the hinged flap can be rotated through substantially 180 ° from the closed position such that the rear wall of the hinged flap is substantially parallel to the rear wall of the box. In the closed position, the rear wall of the hinged flap may be parallel to the rear wall of the box. In the first open position, the rear wall of the hinged flap can be folded back relative to the rear wall of the box such that the rear wall of the hinged flap is parallel to and adjacent to the rear wall of the box.

The rear wall of the hinged flap may be in contact with the rear wall of the box in the second open position. Preferably, the second open position of the hinged flip cover corresponds to a "fully open" position of the hinged flip cover, which is the extreme end of normal operational movement of the flip cover. Likewise, the closed position of the hinged flip preferably corresponds to a "fully closed" position at the other extreme of normal operational movement of the flip. The first open position is thus disposed between the closed position and the second open position.

The angle between the first flip panel and the front wall of the hinged flip may decrease as the hinged flip is rotated from the first open position to the second open position. Preferably, the angle may decrease from substantially 90 °. Thus, the first flip panel may be substantially perpendicular to the front wall of the hinged flip when the hinged flip is in the first open position. This has been found to assist in tensioning the reclosable flap in the first open position.

For example, the first flip panel can be hingedly connected (e.g., via a crease line) to the second flip panel. In this case, the first flip panel can be substantially perpendicular to the second flip panel in the first open position, and the first flip panel can rotate toward the second flip panel when the flip is rotated away from the closed position through the open position.

In some embodiments, the hinge line may be positioned at the top wall of the inner package at a distance from the top rear edge of the inner package that is about the same length as or shorter than the length of the first flap panel. The ratio between the length of the first flip panel and the distance between the hinge line and the top rear edge of the inner package is preferably comprised between 1 and 3. It has been found that this provides a sufficient amount of tension to assist movement of the reclosable flap from the open position towards the closed position, while limiting the risk of damage to the inner package or reclosable flap due to excessive tension in the open position.

To further improve the closing of the reclosable flap, the ratio of the length of the first flip panel to the distance between the hinge line and the top rear edge of the inner package may be at least 1.1, such as at least 1.2, such as at least 1.3, such as at least 1.4.

To further reduce the risk of damage to the inner package or the reclosable flap, the ratio of the length of the first flip panel to the distance between the hinge line and the top rear edge of the inner package may be no greater than 2.5, such as no greater than 2.2, such as no greater than 2, such as no greater than 1.8.

Preferably, a portion of the reclosable flap is maintained in a substantially flat, tensioned configuration between the hinge line and the hinged flap when the hinged flap is in the first open position. The length of the substantially flat portion of the reclosable flap can increase as the hinged flap is rotated from the first open position to the second open position. The ratio of the length of the substantially flat portion of the reclosable flap in the second open position to the length of the substantially flat portion of the reclosable flap in the first open position may be at least 1.5, such as at least 2, and such as at least 2.5. It has been found that this increases the accessibility of the contents of the inner package.

The substantially flat portion of the reclosable flap can be adjacent to, and possibly include, the flap attachment portion of the reclosable flap. It has been found that this arrangement further helps to improve the repositioning of the reclosable flap.

The length of the flat, tensioned portion of the reclosable flap can be at least 50% of the distance measured along the reclosable flap between the reclosable flap hinge line and the free end of the reclosable flap in the second open position. This has been found to further increase access to the contents of the inner package.

The length of the flat, tensioned portion of the reclosable flap can be no greater than 80% of the distance measured along the reclosable flap between the reclosable flap hinge line and the free end of the reclosable flap in the second open position. By limiting the length of the flat, tensioned portion to this value, the risk of tearing the inner package in the fully open position is mitigated. This is particularly true where the access opening includes a cut line that defines a flap in the inner package that covers the access opening.

When the container has dimensions similar to those of a conventional smoking article container, the length of the flat, tensioned portion of the reclosable flap can be at least about 10mm, for example at least about 12 mm. The minimum length of the flat, tensioned portion may correspond to the length of the reclosable flap that is in contact with the first flip panel (which may be at least about 6 mm); this may correspond to a minimum glue area. In the second open position, the length of the flat, tensioned portion of the reclosable flap can be at least about 20mm, such as at least about 25mm, such as at least about 30mm, such as at least about 35 mm.

According to a second aspect of the present invention there is provided a method of forming a container for consumer goods, the method comprising the steps of: providing an inner package of consumer goods, the inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap, the reclosable flap being movable relative to the inner package about a hinge line; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap such that a lower front edge of the flap abuts a free edge of the front wall of the box portion when the flap is in the closed position; attaching the free end of the reclosable flap to the hinged flap such that a ratio between a first distance measured along a straight line between the lower flap front edge and the hinge line when the hinged flap is in the open position and a second distance along the reclosable flap between the hinge line and the free end of the reclosable flap is comprised between 70% and 100%.

According to a third aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing comprising a box and a hinged flap rotatable between an open position and a closed position, wherein the hinged flap comprises a first flap panel and a second flap panel, wherein the first flap panel is movable relative to the second flap panel during movement of the flap between the open position and the closed position; an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed; and a reclosable flap movable about a hinge line relative to the inner package and arranged to cover the access opening, a portion of the reclosable flap being attached to the first flip panel; wherein the first flip panel is substantially perpendicular to the flip front wall when the hinged flip is in a first open position in which the flip top wall is disposed substantially perpendicular to the box back wall.

This minimizes the likelihood of any slack in the reclosable flap when the flip is in the open position. Advantageously, this may assist the movement of the hinged flap from the open position towards the closed position. Furthermore, this may improve the positioning of the reclosable flap against the inner package when the hinged flap is moved from the open position to the closed position. In particular, this may improve the positioning of the reclosable flap along the top wall of the inner package to ensure that an effective seal is created and to help preserve the consumer goods. It has been found that the substantially flat portion of the reclosable flap helps to ease access to the contents of the inner package.

In some embodiments, the hinge line may be positioned at the top wall of the inner package at a distance from the top rear edge of the inner package that is about the same as or shorter than the length of the flap attachment portion of the reclosable flap. Preferably, the ratio between the length of the flap attachment portion of the reclosable flap and the distance between the hinge line and the top rear edge of the inner package is comprised between 1 and 3. This provides a sufficient amount of tension to assist in the movement of the reclosable flap from the open position towards the closed position while limiting the risk of damage to the inner package or reclosable flap due to excessive tension in the open position.

To further improve the re-positioning of the reclosable flap, the ratio of the length of the flap attachment portion of the reclosable flap to the distance between the hinge line and the top rear edge of the inner package may be at least 1.1, such as at least 1.2, such as at least 1.3, such as at least 1.4.

To further reduce the risk of damage to the inner package or the reclosable flap, the ratio of the length of the flap attachment portion of the reclosable flap to the distance between the hinge line and the top rear edge of the inner package may be not more than 2.5, such as not more than 2.2, such as not more than 2, such as not more than 1.8.

According to a fourth aspect of the present invention there is provided a method of forming a container for consumer goods, the method comprising the steps of: providing an inner package of consumer goods, the inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap, the reclosable flap being movable relative to the inner package about a hinge line; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap in such a way that the first flap panel is movable relative to the second flap panel when the container is in use; the free end of the reclosable flap is attached to the first flip panel such that the first flip panel is substantially perpendicular to the flip front wall when the hinged flip is in a first open position in which the flip top wall is disposed substantially perpendicular to the box back wall.

According to a fifth aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing including a hinged flap rotatable between an open position and a closed position; a consumer product package within the housing comprising an access opening through which the consumer product can be removed, the access opening covered by a reclosable flap, wherein the reclosable flap is attached to the hinged flap such that a portion of the reclosable flap is substantially coplanar with the planar wall of the hinged flap when the hinged flap is moved between the open and closed positions; and the indicia are disposed on a portion of the reclosable flap that is coplanar with the planar wall.

The reclosable flap may be maintained in a flat or planar configuration by the planar walls of the hinged flap. By placing the marker on the reclosable flap at this location, the marker can be displayed without any distortion that might otherwise be introduced by curved or non-planar surfaces. Such distortion may lead to undesirable visual effects of the marker, which are avoided by the current arrangement.

"marker (indigo)" is the singular form of the word "marker (indigo)" and is used herein to refer to an independent design element that provides a representation of information or decoration. The indicia may be printed or embossed design elements disposed at, on, in, or with the reclosable flap. The markers may include symbols, logos, letters, numbers, images, and other indicia, if appropriate.

In some embodiments, the marker may be embedded in a reclosable flap. In other embodiments, the markers may be disposed at the inner or outer surface of the reclosable flap.

The marker may be provided by the print medium, by one or more protrusions, by one or more depressions, or by a combination thereof. The print medium may include ink, varnish, lacquer, or a combination thereof.

Where the indicia is provided by a print medium, a protective layer may be disposed to cover the print medium to prevent the compound from bleeding from the print medium into the consumer product within the inner package.

In one arrangement, the print media may be disposed on the reclosable flap in a position offset from the access opening when the hinged flap is in the closed position. For example, a frame may be provided on the reclosable flap where the reclosable flap overlies the access opening when the hinged flap is in the closed position. The frame preferably represents a portion of the reclosable flap that is free of print media and may be about 2mm to 5mm wide. Thus, the frame may create a gap that the print media cannot traverse in order to inhibit the print media from traveling toward the access opening.

The hinged flap may include a first flap panel that is movable relative to a second flap panel during movement of the hinged flap between the open and closed positions. The planar wall of the hinged flap may be provided by the first flap panel. In this manner, the reclosable flap can be positioned against the first flip panel such that the reclosable flap can be provided in a planar configuration during opening and closing. Further, the reclosable flap can be attached to the first flip panel.

The reclosable flap can be disposed against a first flap panel that is a single-walled portion of the container. This may simplify the construction of the hinged flip cover and may reduce the adhesive required to create the double-walled assembly.

The marker may be at least one of: text, symbols (e.g., logos), images, and patterns. By providing the indicia on the planar portion of the reclosable flap, distortion effects are advantageously avoided. The reclosable flap can include a marker on other portions of the reclosable flap, including a freely curved portion of the reclosable flap. These markers may include other types of graphics that are effectively visible even when they are deformed.

In some embodiments, a portion of the reclosable flap can be maintained in a substantially flat, tensioned configuration between the hinge line and the hinged flap when the hinged flap is in the open position. This substantially flat portion may include additional markers. The distortion effect is mitigated by providing additional indicia in the substantially flat portion of the reclosable flap.

The hinged flap may be connected to the reclosable flap such that there is a first opening stage and a second opening stage. In a first opening stage, the hinged flap may be operable to lift a first portion of the reclosable flap away from the inner package to substantially simultaneously separate a two-dimensional area of the reclosable flap from a corresponding two-dimensional area of the inner package. In a second opening stage, the hinged flap may be operable to peel the second portion of the reclosable flap away from the inner package. The two-dimensional area of the reclosable flap can include a marker such that the marker is visible during the first opening stage.

According to a sixth aspect of the present invention there is provided a reclosable flap for use in a container for consumer goods, the reclosable flap comprising a marker disposed at an end portion. The marker may be provided by a print medium. The reclosable flap may include a protective layer arranged to cover the print medium to prevent compound from bleeding from the print medium.

According to a seventh aspect of the present invention there is provided a method of forming a container for consumer goods, the method comprising the steps of: providing a consumer goods inner package comprising an access opening through which consumer goods can be removed; providing a reclosable flap to cover the access opening of the inner package, wherein the reclosable flap comprises a marker; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap; and attaching the reclosable flap to the hinged flap such that at least a portion of the reclosable flap is substantially coplanar with the planar wall of the hinged flap as the hinged flap moves between the open and closed positions.

In some embodiments, the step of attaching the reclosable flap to the hinged flap comprises attaching the reclosable flap to a first flap panel, and the step of forming the outer shell from the blank comprises the step of forming the hinged flap in a manner that enables the first flap panel to move relative to a second flap panel when the container is in use.

According to an eighth aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing including a hinged flap rotatable between an open position and a closed position; an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed; a reclosable flap arranged to cover the access opening and attached to the hinged flap, whereby the reclosable flap moves relative to the access opening during movement of the hinged flap; wherein the reclosable flap carries the indicia in a manner such that the indicia is not visible when the flap is in the closed position and such that the indicia becomes visible in an intermediate position where the reclosable flap covers the perimeter of the access opening during movement of the hinged flap from the closed position toward the open position.

This provides increased space for communication with the consumer, which becomes visible when the consumer opens the container but before the contents are exposed to atmospheric conditions.

The reclosable flap can be attached to the hinged flap such that a portion of the reclosable flap is substantially coplanar with the planar wall of the hinged flap as the hinged flap moves between the open and closed positions. Preferably, the coplanar portions of the reclosable flap comprise at least a portion of the indicia.

According to a ninth aspect of the present invention there is provided a method of forming a container for consumer goods, the method comprising the steps of: providing a consumer goods inner package comprising an access opening through which consumer goods can be removed; providing a reclosable flap having a logo and arranged to cover the access opening of the inner package; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap; and attaching the reclosable flap to the hinged flap such that the indicia is not visible when the flap is in the closed position and such that the indicia becomes visible in an intermediate position where the reclosable flap covers the entire perimeter of the access opening during movement of the hinged flap from the closed position toward the open position.

The method can include the additional step of positioning the reclosable flap on the inner package relative to the access opening such that at least a portion of the indicia is outside a perimeter of the access opening.

A tenth aspect of the invention relates to a container for consumer goods, such as smoking articles, having an outer shell with a hinged flap, the outer shell housing an inner package of consumer goods. The inner package has an access opening through which the consumer goods can be removed, and the access opening is covered by a reclosable flap. A reclosable flap is attached to the first flip panel, which is movable relative to the second flip panel throughout rotation of the flip between the flip open position and the flip closed position. By providing a first flap panel that is movable relative to a second flap panel during rotation of the flap between a flap open position and a flap closed position, and attaching a reclosable flap to the first movable panel, the reliability of closing the access opening with the reclosable flap is enhanced over the life of the container.

The reclosable flap and the first flip panel may be arranged to generate a biasing force on the hinged flip. A biasing force may be generated to facilitate or resist movement of the flip between the open and closed positions in one or both senses. A biasing force may be generated to initially resist and subsequently facilitate the movement of the flip.

The reclosable flap and the movable panel may be arranged to generate a biasing force towards the open position when the flip is moved from the closed position towards the open position. Opening the flip cover is facilitated by arranging the reclosable flap and the movable panel to generate such a biasing force during opening of the flip cover.

The reclosable flap and the movable panel may be arranged to generate a biasing force towards the closed position when the flip is moved from the closed position towards the open position. By arranging the reclosable flap and the movable panel to generate such a biasing force during opening of the flap, inadvertent opening of the flap is prevented, particularly when the container is contained in a bag or pocket.

The reclosable flap and the movable panel may be arranged to generate a biasing force towards the closed position when the flip is moved from the open position towards the closed position. Closing the flip cover is facilitated by arranging the reclosable flap and the movable panel to generate a biasing force toward the closed position during closing of the flip cover.

The reclosable flap and the movable panel may be arranged to generate a biasing force towards the open position when the flip is moved from the open position towards the closed position. By arranging the re-closable flap and the movable panel to create this biasing force, the user must apply additional force to close the flip. As a result, the user is assured that the flip has been securely closed.

In some embodiments, the first flip panel may be rotatable about the second flip panel about a rotational axis, in which case the biasing force may be generated by a lever effect. The biasing force may assist in opening the flip cover and/or closing the flip cover. Alternatively or additionally, the biasing force may prevent inadvertent opening and/or closing of the flip.

For example, the first flip panel can be hingedly connected (e.g., via a crease line) to the second flip panel. In a particularly preferred example, an edge of the rotatable panel (which may be opposite the axis of rotation of the first flip panel) is in pivotal contact with the inner package during a portion of the rotation of the flip between the open and closed positions. The pivotal contact occurs between the closed position of the flip and an intermediate position after which the pivotal contact is stopped. Preferably, in the intermediate position, the access opening is covered by a reclosable flap.

In this configuration, the rotatable panel and the reclosable flap resist opening the flap over the first few degrees of opening, thereby preventing inadvertent opening of the flap, particularly when the container is contained in a bag or pocket. Further rotation of the flip toward the open position causes the rotatable panel to come into pivotal contact with the inner package and pivot about the pivot edge. As a result, the rotatable panel partially pulls the reclosable flap away from the inner package, thereby thus reducing the necessary force required to pull the reclosable flap away from the inner package.

The rotatable panel extends the extent of the reclosable flap in the open position and tensions the reclosable flap during closing of the flip, thereby ensuring accurate repositioning of the reclosable flap against the inner package. During closing of the flip, the pivoting edge of the rotatable panel comes into contact with the inner package in the stop motion position. By applying additional force, the rotatable panel overcomes the stop motion position and pivots about the pivot edge to the flip closed position without requiring additional force. Thus, the user is assured that the container is properly closed by this tactile feedback and the clicking effect.

The length of the first flip panel, measured from its axis of rotation to the opposite edge, may be at least 6mm, for example at least 7 mm. This helps attach the reclosable flap to the first flip panel, especially when a permanent adhesive is used for this purpose.

The length of the first flip panel, measured from its axis of rotation to the opposite edge, may be no greater than 12mm, such as no greater than 10mm, such as about 9 mm. By limiting the length of the first flip panel, the risk of damage to the panel during opening and closing of the flip (e.g., by bending) is reduced, thereby widening the material selection options. By adding certain features from other aspects of the invention, the length of the first flip panel can be increased without increasing the risk of damaging the first flip panel during flip opening.

In some embodiments, the relative movement of the movable panel is rotation. In a preferred embodiment, the first flip panel rotates about an axis parallel to the axis of rotation of the flip. In other embodiments, however, the relative movement of the movable panels is a translation, for example in a direction substantially perpendicular to the inner package. In yet a further embodiment, the relative movement of the movable panels is a combination of rotation and translation.

In some embodiments, the first flip panel may be initially fixed relative to the second flip panel. By providing an initial relative fixation of the first and second flap panels, the first flap panel is immovable relative to the second flap panel during manufacture and becomes movable only after the breaking of one or more breakable connections, which occurs upon first opening of the container due to the attachment of the reclosable flap to the first flap panel. This makes it easy to attach the reclosable flap to the first flip panel during manufacture and prevents possible jamming.

For example, the first flip panel may be movable relative to the second flip panel after the breakable connection has been broken. In a particularly preferred example, the first flip panel is connected to the third flip panel by one or more breakable connections.

One or more breakable or rupturable connections may be formed in different ways. For example, the first and third flip panels may be connected by a weakened line, which may be continuous or discontinuous. In some examples, the first flip panel and the third flip panel are connected by a row of perforations. In other examples, the first flip panel and the third flip panel are connected by a score line having a suitable depth. For example, the depth of the score line may be about 80% of the thickness of the first and third flap panels, for example about 90% of the thickness of the first and third flap panels. In yet another example, the first flap panel is partially die cut from the third flap panel leaving one or more attachment notches.

In a preferred embodiment, in the closed position, the reclosable flap and the inner package are disposed adjacent to each other about the perimeter of the access opening in a coupling region having resealable adhesive to releasably affix the inner package and the reclosable flap.

An eleventh aspect of the invention relates to a blank for forming an outer shell of the container of the invention. The blank has a box portion and a flip portion having a first panel, a second panel, and a third panel. The first panel is hingedly connected to the second panel and is also connected to the third panel by one or more breakable connections. By providing a hinged connection between the first panel and the second panel and one or more breakable connections between the first panel and the third panel, the first panel can be made movable by breaking the one or more connections to the third panel and can be made rotatable to the second panel. This makes it easy to attach the reclosable flap to the first flip panel during manufacture and prevents possible jamming.

A twelfth aspect of the invention relates to a blank for forming an outer shell of the container of the invention. The blank has a box portion and a flip portion having a first panel, a second panel, and a third panel. The second panel is connected to the first panel and the third panel, and the first panel is surrounded by the second panel and the third panel.

According to a thirteenth aspect, the present invention also provides a method of forming a container for consumer goods. The method comprises the following steps: providing a consumer product inner package, the inner package comprising an access opening through which consumer products can be removed, the access opening being covered by a reclosable flap; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap; and attaching a reclosable flap to the first flip panel of the hinged flip. The step of forming the housing from the blank includes the step of forming the hinged flap in a manner such that the first flap panel can move relative to the second flap panel when the container is in use.

In some embodiments, the step of forming the hinged flap comprises applying no permanent adhesive to secure the first flap panel to any other flap panel. The first flip panel is made movable relative to the second flip panel by securing the first flip panel to any other flip panel without providing a permanent adhesive.

In some embodiments, the step of forming the hinged flap comprises folding the first flap panel against the second flap panel, rather than permanently bonding the first flap panel and the second flap panel. In other words, the first flip panel can be folded against the second flip panel without providing a permanent adhesive between the first flip panel and the second flip panel.

According to a fourteenth aspect of the present invention, there is provided a container for consumer goods, the container comprising: a housing including a hinged flap rotatable between an open position and a closed position; an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap; wherein the hinged flap is connected to the reclosable flap such that there is a first opening stage and a second opening stage, and wherein, in the first opening stage, the hinged flap is operable to lift a first portion of the reclosable flap away from the inner package to substantially simultaneously separate a two-dimensional area of the reclosable flap from a corresponding two-dimensional area of the inner package, and wherein, in the second opening stage, the hinged flap is operable to peel a second portion of the reclosable flap away from the inner package.

Preferably, the hinged flap comprises a first flap panel and a second flap panel, the first flap panel being movable relative to the second flap panel. The reclosable flap can be attached to the first flip panel.

In the first opening stage, the reclosable flap may be arranged to pivot away from the inner package with the first flip panel, thereby substantially simultaneously separating the two-dimensional area of the reclosable flap from a corresponding two-dimensional area of the inner package.

In the second opening stage, the hinged flap may be arranged to apply a tensioning force to the reclosable flap to peel the second portion of the reclosable flap from the inner package. However, substantially no tension may be applied to the reclosable flap during the first opening stage.

According to a fifteenth aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing including a hinged flap rotatable between an open position and a closed position; an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap; wherein the hinged flap is connected to the reclosable flap such that there is a first closing stage and a second closing stage, and wherein, in the first closing stage, the hinged flap is operable to roll a second portion of the reclosable flap onto the inner package, and wherein, in the second closing stage, the hinged flap is operable to lower a first portion of the reclosable flap onto the inner package so as to substantially simultaneously bring a two-dimensional area of the reclosable flap into contact with a corresponding two-dimensional area of the inner package.

In the second closing phase, the reclosable flap may be arranged to pivot towards the inner package with the first flip panel so as to substantially simultaneously bring the two-dimensional area of the reclosable flap into contact with a corresponding two-dimensional area of the inner package.

In the first closing stage, the hinged flap may be arranged to apply tension to the reclosable flap to cause the second portion of the reclosable flap to roll over the inner package. However, in the second closing phase, substantially no tension may be applied to the reclosable flap.

According to a sixteenth aspect of the present invention, there is provided a method for opening a container for consumer goods, wherein the container comprises: a housing including a hinged flap rotatable between an open position and a closed position; and an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap, the reclosable flap being connected to the hinged flap, wherein the method comprises: a first opening stage in which the hinged flap lifts a first portion of the reclosable flap away from the inner package, thereby substantially simultaneously separating a two-dimensional area of the reclosable flap from a corresponding two-dimensional area of the inner package; and a second opening stage in which the hinged flap peels a second portion of the reclosable flap from the inner package.

According to a seventeenth aspect of the present invention, there is provided a method for closing a container for consumer goods, wherein the container comprises: a housing including a hinged flap rotatable between an open position and a closed position; and an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap, the reclosable flap being connected to the hinged flap, wherein the method comprises: a first closing stage in which the hinged flap rolls a second portion of the reclosable flap onto the inner package; and a second closing stage in which the hinged flap lowers the first portion of the reclosable flap onto the inner package substantially simultaneously bringing the two-dimensional area of the reclosable flap into contact with the corresponding two-dimensional area of the inner package.

According to an eighteenth aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing comprising a box and a hinged flap rotatable between an open position and a closed position, wherein the hinged flap comprises a first flap panel and a second flap panel, wherein the first flap panel is movable relative to the second flap panel during movement of the hinged flap between the open position and the closed position; an inner package of consumer goods within the box, the inner package comprising an access opening through which consumer goods can be removed, and the access opening being provided at least at a portion of the top and the front wall of the inner package; and a reclosable flap is arranged to cover the access opening and attached to the first flip panel; wherein the ratio of the length of the first flip panel to the distance between the top front edge of the inner package and the top front edge of the box is at least 0.3.

In this manner, the first flip panel can brush against the top surface as the hinged flip is closed. This can control the movement of the first flip panel to ensure that the first flip panel is in the correct position for attachment to the reclosable flap and mitigate the risk of jamming during formation of the housing. In particular, when a fluid adhesive is used, contact between the first flip panel and the top surface can prevent the first flip panel from wiping the fluid adhesive from the glue area.

During a closing operation, the first flip panel can brush against the top surface of the reclosable flap and then the front surface of the inner package. This may represent two discrete contacts separated in time. Alternatively, there may be continuous contact between the first flip panel and the reclosable flap, including a brushing contact on the top surface and a brushing contact on the front surface.

Preferably, the first flip panel is configured to come into contact with the top front edge of the reclosable flap as the hinged flip is moved from the open position toward the closed position.

In some embodiments, the first flip panel is further configured to come into contact with the top surface of the inner package before the reclosable flap is attached to the first flip panel as the hinged flip moves from the open position toward the closed position. Preferably, the first flip panel is configured to come into contact with the top front edge of the inner package as the hinged flip is moved from the open position toward the closed position.

As used herein, the top front edge is generally considered to be a portion of the top surface.

Preferably, the first flip panel rotates about an axis of rotation relative to the second flip panel during movement of the flip between the open position and the closed position. In a preferred embodiment, the first flip panel is hingedly connected to the second flip panel.

Contact between the first flip panel and the top surface preferably causes the first flip panel to rotate toward the second flip panel. This may reduce the risk of the first flip panel rotating away from the second flip panel into an undesired configuration during manufacturing.

In some embodiments, in the closed position, the reclosable flap and the inner package are disposed adjacent to each other about a perimeter of the access opening at a coupling region having resealable adhesive to releasably affix the inner package and the reclosable flap. This helps mitigate the undesirable "clamshell grin" effect of the hinged flap opening slightly in the closed position.

The first flip panel can include an edge configured to be in pivotal contact with the inner package after the reclosable flap is attached to the first flip panel during movement of the flip between the open and closed positions.

By providing a ratio of the length of the first flip panel to the distance between the top front edge of the inner package and the top front edge of the box of no more than 0.5, any undesirable flip grinning can be mitigated. This ratio may be no greater than 0.45, such as no greater than 0.40, to further mitigate any possible lid grin.

By the ratio of the length of the first flip panel to the distance between the top front edge of the inner package and the top front edge of the box being at least 0.3, for example at least 0.35, the movement of the first flip panel during manufacture is further controlled and the risk of jamming is further reduced.

An adhesive may be provided to attach the reclosable flap to the first flip panel. The adhesive may be initially in liquid form, and the adhesive may be provided on a reclosable flap. The present arrangement advantageously reduces the likelihood of the first flip panel moving into an undesirable configuration to sweep the liquid adhesive from the reclosable flap. This would be undesirable, firstly because it reduces the likelihood that an effective bond can be created between the reclosable flap and the first flap panel, and secondly because it directs the liquid adhesive onto other surfaces of the container.

According to a nineteenth aspect of the present invention, there is provided a blank for forming an outer shell of a container of the present invention. The blank comprises a box portion and a flap portion comprising a first panel hingedly connected to a second panel, wherein the ratio between the width of the first panel and the width of the second panel is comprised between 0.5 and 1.0. It has been found that such a ratio helps to achieve a consistent brushing of the top surface of the reclosable flap and also results in improved attachment of the reclosable flap.

Preferably, the ratio is at least 0.6, such as at least 0.7, such as at least 0.8. These values further contribute to the previous effect.

The ratio between the length of the first panel and the length of the second panel may be no greater than 0.5, such as no greater than 0.45, such as no greater than 0.40. This mitigates any possible lid grining.

The ratio between the length of the first panel and the length of the second panel may be at least 0.3, such as at least 0.35. This helps control the movement of the first flip panel during manufacture and reduces the risk of jamming.

In some embodiments, the flip portion further comprises a third panel hingedly connected to the box portion. The ratio between the length of the first panel and the length of the third panel may be no greater than 2, such as no greater than 1.75, such as no greater than 1.5. These values help mitigate any possible lid grinning.

The ratio between the length of the first panel and the length of the third panel may be at least 1.2, such as at least 1.25, such as at least 1.3. This helps control the movement of the first flip panel during manufacture and reduces the risk of jamming.

According to a twentieth aspect of the present invention there is provided a method of forming a container for consumer goods, the method comprising the steps of: providing a consumer product inner package, the inner package comprising an access opening through which consumer products can be removed, the access opening being covered by a reclosable flap; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap and forming the hinged flap in a manner such that the first flap panel can be moved relative to the second flap panel when the container is in use; for example, during or after the step of folding the blank, moving the second flap panel toward the reclosable flap such that the first flap panel comes into contact with the top surface of the reclosable flap; and attaching a reclosable flap to the first flip panel.

According to a twenty-first aspect of the present invention there is provided a container for consumer goods, the container comprising: a housing comprising a hinged flap rotatable between an open position and a closed position, wherein the hinged flap comprises a first flap panel and a second flap panel, the first flap panel being movable relative to the second flap panel during movement of the flap between the open position and the closed position; an inner package of consumer goods within the outer shell, the inner package comprising an access opening through which consumer goods can be removed; and a reclosable flap arranged to cover the access opening, wherein, in the closed position, an inner surface of the reclosable flap forms an overlapping region with an outer surface of the inner package extending around a periphery of the access opening, the overlapping region comprising a non-adhesive region; wherein an outer surface of the reclosable flap is attached to the first flip panel at an attachment region disposed opposite the non-adhesive region; wherein the non-adhesive region has a surface that is at least the same size as a surface of the attachment region.

By attaching the outer surface of the reclosable flap to the first flip panel opposite the non-adhesive area and providing a surface of the non-adhesive area that is at least the same size as the surface of the attachment area, movement of the first flip panel relative to the second flip panel during movement of the flip is facilitated. This results in an easier opening and closing of the flip-top lid during the entire life of the container, which is particularly evident when the container is opened for the first time.

The non-adhesive area in the overlap area advantageously has a surface or size that is substantially the same as the surface or size of the attachment area, but preferably the surface or size of the non-adhesive area is larger than the surface or size of the attachment area. By providing a non-adhesive area that is larger than the attachment area, manufacturing is simplified because manufacturing tolerances associated with the attachment of the reclosable flap to the first flip panel are less critical to the proper functioning of the container.

In embodiments where the surface or size of the non-adhesive area is larger than the surface or size of the attachment area, in the closed position the non-adhesive area may extend away from the attachment area, e.g. at least 1mm, e.g. at least 3mm, and preferably towards the access opening. By providing a non-adhesive area extending away from the attachment area towards the access opening in the closed position, movement of the first flip panel relative to the second flip panel during movement of the flip is even further facilitated.

In a preferred embodiment, the attachment area is provided at the free end of the reclosable flap. By providing an attachment area at the free end of the reclosable flap, the construction of the package is simplified and the length of the reclosable flap is optimized.

For some embodiments, when the hinged flap is moved from the closed position to the open position, pivotal movement about the first flap panel may be provided, whereby the first flap panel pivots along a pivot line against the inner package. The non-adhesive area preferably comprises a pivot line. The absence of any adhesive effect in this region may promote ease of pivotal movement that can occur as this enables the reclosable flap to slide against the inner package. This reduces the stress exerted on the inner package and as a result the length of the first flap panel can be selected to ease the attachment of the reclosable flap to the first flap panel and to adjust the force with which the package is closed.

In practice, the position of the pivot line may be movable, as the reclosable flap may slide against the inner package. Preferably, a non-adhesive area is provided for all positions of the pivot line.

The length of the first flip panel, measured from its axis of rotation to the opposite edge, may be at least 6mm, such as at least 7mm, such as at least 8 mm. This helps to attach the reclosable flap to the first flip panel, especially when a permanent adhesive applied in a fluid state is used for this purpose.

The length of the first flip panel, measured from its axis of rotation to the opposite edge, may be no greater than 15mm, such as no greater than 13mm, such as about 10mm or 11 mm. By limiting the length of the first flip panel, the risk of damage to the panel during opening and closing of the flip (e.g., by bending) is reduced, thereby widening the material selection options.

The overlapping region may further comprise an adhesive region to releasably attach the outer surface of the inner package to the inner surface of the reclosable flap. In the closed position, the adhesive region includes at least a portion of a perimeter of the access opening.

In some embodiments, in the closed position, the non-adhesive region does not extend as far as the access opening, and the adhesive region extends around the entire perimeter of the access opening. This provides a reclosable seal for the consumer product, which can improve the preservation of the tobacco product under certain atmospheric conditions by limiting the exposure of the tobacco product to atmospheric conditions.

In other embodiments, in the closed position, the non-adhesive region may comprise a portion of the perimeter of the access opening. This provides a breathable seal for the consumer product, as oxygen exchange is allowed between the external environment and the interior of the inner package, even when the reclosable flap is in the closed position. This is possible because the non-adhesive area, including a portion of the perimeter of the access opening, is non-adhesive. Thus, in the non-adhesive region, the reclosable flap will not typically be attached to the inner package. The reclosable flap may be in contact or intimate contact with the inner package and there may be a slight gap between the two that may allow fluid communication between the interior and exterior of the inner package. This may actually improve the preservation of the tobacco product under certain atmospheric conditions.

The non-adhesive region may preferably extend from the access opening edge to the outer edge of the overlap region, such that fluid communication is provided thereby.

In one arrangement, the adhesive region may comprise at least a portion of the top wall of the inner package. It has been found that this improves the positioning of the reclosable flap against the inner package. The adhesive region may additionally or alternatively comprise a portion of the front wall of the inner package. Thus, the reclosable flap can be wrapped around the front top shoulder of the inner package (including the front top edge of the inner package) and adhered to the inner package. It has been found that this can improve the positioning of the reclosable flap during closure of the flip.

Preferably, the adhesive region comprises a portion of the front wall extending away from the front top edge of the inner package. For example, the first adhesive region may extend away from the front top edge of the inner package by at least 5mm in a direction substantially perpendicular to the front top edge of the inner package.

In some embodiments, the overlap region may include a second non-bonded region, wherein the bonded region is located between the first non-bonded region and the second non-bonded region.

The reclosable flap may be connected to the inner package so as to be movable relative to the inner package about a hinge line, and the second non-adhesive region may be disposed adjacent to the hinge line of the reclosable flap. It has been found that tobacco debris preferentially accumulates at the pinch point (ping point) created by the hinge line between the reclosable flap and the inner package. In some arrangements, the tobacco scraps may be directed toward the hinge line by movement of the reclosable flap. By providing an adhesive free region adjacent the hinge line, the amount of tobacco scraps adhering to the reclosable flap can be reduced. This may provide additional advantages by allowing the reclosable flap to open more fully to improve access to the smoking articles within the inner package.

In some configurations, the second non-adhesive region has a dimension of at least about 4mm, such as at least about 6mm, such as at least about 8mm, extending along the reclosable flap and away from the hinge line. It has been observed that a majority of the tobacco scraps sticking to the prior art container have an average size of less than about 3 mm. These containers sometimes present some tobacco fines having an average size between about 3mm and 5 mm. Isolated larger tobacco pieces up to about 1mm in average size are rarely seen because opening and closing the reclosable flap can grind away the larger tobacco pieces or break them into smaller particles. Thus, by providing a second non-bonded area of at least about 4mm in size, tobacco fines accumulating at the second overlapping area over the life of the container is reduced, as tobacco fines are less likely to stick at the second overlapping area, and a portion of the tobacco fines that do stick to are broken up into smaller particles throughout use of the container and transported towards the second non-bonded area where they eventually fall off. Enlarging the second non-bonded area further reduces the accumulation of tobacco fines.

The dimension may be substantially perpendicular to the hinge line along the reclosable flap. The dimension may be curved in some embodiments. This may occur when the hinge line is located on the rear wall of the inner package and the second non-adhesive region extends partially along the rear wall and partially along the top wall.

The non-adhesive area may be provided as a strip substantially parallel to the hinge line. In another arrangement, a portion of the overlapping region may be provided with reduced tackiness and positioned on the opposite side of the access opening from the hinge line of the reclosable flap. For example, the overlapping region may comprise a first non-adhesive region at the free end of the reclosable flap, a second non-adhesive region adjacent the hinge line of the reclosable flap, a first adhesive region adjacent the second non-adhesive region, and a region of reduced tack between the first adhesive region and the first non-adhesive region.

The hinge line may be provided at the top wall of the inner package. In other arrangements, the hinge line may be provided at the rear wall of the inner package adjacent the hinged flap. The reclosable flap may be connected to the inner package at the top wall and/or the rear wall.

The inner package may have a top wall and a front wall, and the adhesive region may be disposed at least partially at the top wall and at least partially at the front wall. It has been found that providing a resealable adhesive on the top and front walls is advantageous as it can help locate the reclosable flap in the desired position when it is closed. In the closing operation, the adhesion may first occur on the top wall, which may help the reclosable flap to wrap around the upper front edge and adhere against the front wall.

The adhesive region may have a length extending along the inner package and along the top wall away from the front wall of at least about 4mm, such as at least about 6mm, such as at least about 8 mm. In some embodiments, the first adhesive region has a length of at least about 12 mm.

The bonded region may have a length at the top wall that is at least about 25% of the depth of the top wall of the inner package. In another arrangement, the adhesive region may have a length at the top wall that is at least about 25% of the distance between the upper front edge and the hinge line of the reclosable flap.

The overlapping regions may include a plurality of bonded regions and a plurality of unbonded regions, wherein the bonded regions are interposed between the unbonded regions. Preferably, the bonded and unbonded areas are provided as strips, which are preferably substantially parallel to the hinge line.

According to a twenty-second aspect of the present invention there is provided a method of forming a container for consumer goods, the method comprising the steps of: providing a consumer goods inner package comprising an access opening through which consumer goods can be removed; providing a reclosable flap to cover the access opening of the inner package, wherein in the closed position an inner surface of the reclosable flap forms an overlapping region with an outer surface of the inner package, wherein the overlapping region comprises a non-adhesive region; providing a blank and folding the blank about the inner package for forming an outer shell having a hinged flap; attaching an outer surface of the reclosable flap to a first flap panel of the hinged flap such that the reclosable flap overlaps the first flap panel in the non-adhesive area; wherein the step of forming the housing from the blank comprises the step of forming the hinged flap in a manner such that the first flap panel is movable relative to the second flap panel when the container is in use.

The method can involve positioning the reclosable flap on the inner package relative to the access opening such that the non-adhesive region comprises a predefined portion of a perimeter of the access opening. This may be achieved by setting the position of the non-adhesive area of the overlapping area with respect to the access opening. This may ensure that the reclosable flap is correctly positioned so that the reclosable flap can effectively seal the contents of the inner package.

Many modifications and variations of the described container fall within the scope of the invention. In particular, features of any aspect of the invention may equally be applied to any other aspect of the invention.

The container according to any aspect of the invention may further comprise an inner frame, for example a U-shaped inner frame having a front wall and a pair of opposing side walls. In some embodiments, an internal frame may be disposed within the inner package, surrounding a portion of the consumer product. In other embodiments, the inner frame is disposed between the outer shell and the inner package. By providing an internal frame, the rigidity of the container is increased, which further contributes to an improved reliability of closing the access opening.

The inner package according to any aspect of the present invention may be formed of a metal foil, a metalized paper, or a plastic film. The inner wrapper may be formed as a laminate of a metallised plastic film (e.g. a metallised polyethylene film or a metallised polypropylene) and a liner material. Furthermore, the inner wrapper may be provided with a print-receptive top coating.

In some embodiments, the non-adhesive region may be substantially free of adhesive to ensure that the inner package and reclosable flap do not adhere. For example, the overlapping region may be provided with resealable adhesive in the bonded region, while the non-bonded region may be substantially free of adhesive. In a preferred embodiment, the reclosable flap may be provided with resealable adhesive in the adhesive region and may be substantially free of adhesive in the non-adhesive region(s), while the surface of the inner package is substantially free of adhesive in both the adhesive region and the non-adhesive region.

In other embodiments, the non-adhesive region(s) may be deactivated to ensure that the non-adhesive region does not cause the inner package to adhere to the reclosable flap. For example, the overlap region may initially be provided with resealable adhesive in both the adhesive region and the non-adhesive region, but the resealable adhesive in the non-adhesive region(s) may then be deactivated in order to remove the tack of the adhesive. In a preferred embodiment, the reclosable flap is initially provided with resealable adhesive in both the adhesive and non-adhesive areas, and the resealable adhesive in the non-adhesive area(s) is then deactivated. In a preferred embodiment, the surface of the inner package is substantially free of adhesive.

In another example, one surface of the overlap region may be provided with resealable adhesive in both the adhesive region and the non-adhesive region, and the other surface of the second overlap region may be provided with debonding agent in the non-adhesive region(s) such that the resealable adhesive does not bond in the non-adhesive region(s). In a preferred embodiment, the reclosable flap is provided with resealable adhesive in both the adhesive and non-adhesive regions, and the surface of the inner package is provided with a debonding agent in the non-adhesive region. The debonder may be a silicon-based debonder. Preferably, the debonder is in the form of a printable composition (e.g., ink).

A reclosable flap according to any aspect of the invention may be connected to the inner package so as to be movable relative to the inner package about a hinge line. In some embodiments, the reclosable flap can be attached to an outer surface of the inner package such that the reclosable flap covers the access opening in the inner package. In this case, the reclosable flap preferably extends beyond the perimeter of the access opening.

In other embodiments, the reclosable flap is defined by a cut line or line of weakness in the outer surface of the inner package covering the access opening. In this case, the adhesive label may be adhered to the inner surface of the inner package in the portion of the reclosable flap overlying the adhesive label, and the access opening may be provided in the adhesive label, for example, by a cut or weakened line, or cut line, defining the flap covering the access opening.

Reclosable flaps of any aspect of the inventionMay be made of, for example, High Density Polyethylene (HDPE), Low Density Polyethylene (LDPE), biaxially oriented polypropylene (BOPP), nylon, polystyrene, cellulose films (e.g., polyethylene terephthalate, and the like

And cellulose acetate), polyvinyl chloride (PVC), paper, polyethylene terephthalate (PET), and mixtures of the foregoing.

Preferably, the consumer product is a smoking article. However, the container may be suitable for use with a variety of consumer products, such as candy, dry food, and the like.

The container is preferably a cuboid comprising two wider walls separated by two narrower walls, the cuboid having right-angled longitudinal edges and right-angled transverse edges. Alternatively, the container may include one or more rounded longitudinal edges, rounded transverse edges, chamfered longitudinal edges, or chamfered transverse edges, or a combination thereof.

The container may be formed from any suitable material, including but not limited to cardboard, paperboard, plastic, metal, or combinations thereof. Preferably, the outer case is formed from one or more folded laminated cardboard blanks, and preferably the cardboard has a weight of between about 230g/m2 and about 350g/m 2. In some examples, the cardboard has a weight of at least 250g/m2, such as about 270g/m 2.

When the container has dimensions similar to those of a conventional smoking article container, the flap is preferably hinged at a distance of 12mm or less, for example 10mm or less, for example about 8mm, from the top rear edge of the container.

Containers according to the present invention may be shrink wrapped or otherwise over wrapped with a transparent polymeric film (e.g., high or low density polyethylene, polypropylene, oriented polypropylene, polyvinylidene chloride, cellulose film, or combinations thereof in conventional manners). In case the container according to the invention is overwrapped, the overwrap may comprise one or more tear tapes. Further, the cover wrap may be printed with images, consumer information, or other data.

As used herein, the terms "front", "rear", "upper", "lower", "top", "bottom", and "side" refer to the relative positions of portions of the container and its components according to the present invention when the container is in an upright position, the flip cover of the housing is in a closed position, and the hinge line is at the rear of the container.

The term "longitudinal" refers to a direction from the bottom to the top, or vice versa. The term "transverse" refers to a direction perpendicular to the longitudinal direction. The term "length" is used throughout the specification to refer to the longitudinal extension of a panel of a blank or the longitudinal extension of a wall of a container. The term "width" is used throughout the specification to refer to the lateral extension of a panel of a blank or the lateral extension of a wall of a container.

The term "inner surface" is used throughout the specification to refer to the surface of the components of the assembled container that faces the interior of the container (e.g., toward consumer goods) when the container is in the closed position. The term "outer surface" is used throughout the specification to refer to the surface of a component of the container that faces the exterior of the container.

The term "permanent adhesive" is used throughout the specification to refer to a generally high tack adhesive that is capable of forming a reliable and secure connection between two substrates such that the two substrates do not become substantially separated during normal and intended use of the container. Indeed, separating two substrates attached to each other by means of a permanent adhesive will typically cause some undesired damage (e.g. tearing) or leave an undesired residue to the substrate or substrates involved.

The term "resealable adhesive" is used throughout the specification to describe a generally low tack, removable adhesive that is capable of forming a connection between two substrates such that the two substrates may be repeatedly separated from and reattached to one another.

The term "activatable" is used herein to describe an adhesive element that is provided to a consumer in a non-tacky state (such that it cannot be adhered to another component of the container). The activatable adhesive element requires some form of activation by the consumer to bring the activatable adhesive element into a tacky state for application to another component.

Drawings

The invention(s) will be further described, by way of example only, with reference to the accompanying drawings, in which:

fig. 1 shows a perspective view of a container in a first embodiment of the invention in a flip open position;

FIG. 2 shows a detail of the container of FIG. 1;

fig. 3A and 3B show the container of fig. 1 with the flip cover in an intermediate position, wherein fig. 3A is a perspective view and fig. 3B is a front view;

fig. 4 shows a perspective view of a container in a second embodiment of the invention in a flip open position;

FIG. 5 shows a plan view of a reclosable flap of a container in a second embodiment of the invention;

fig. 6 is a side view of a container in a second embodiment of the invention with the hinged flap in a first open position;

FIG. 7 is a top view of the container shown in FIG. 6;

FIG. 8 is a front view of the container shown in FIG. 6;

fig. 9 is a side view of the container shown in fig. 6 with the hinged flip-top lid in a second open position;

fig. 10 shows a perspective view of a container in a flip open position in a third embodiment of the invention;

FIG. 11 shows a plan view of a reclosable flap of a container in a third embodiment of the present invention;

FIG. 12 is a front view of the inner package of the container in a third embodiment of the present invention;

FIG. 13 shows a plan view of an alternative reclosable flap of the container in a third embodiment;

FIG. 14 is a front view of an alternative inner package of a container in a third embodiment of the invention;

figures 15 to 18 show four different embodiments of a blank for forming the outer shell of the present invention;

FIGS. 19A and 19B illustrate two different embodiments of blanks for forming the inner package of the present invention;

FIG. 20 illustrates an embodiment of a blank for forming the internal frame of the present invention; and is

Figure 21 shows a system for forming the inner package of the present invention.

Detailed Description

The hinged lidded container 1 shown in figure 1 comprises a box 2 and a flip-top 3 hinged to the box 2 along a hinge line. Fig. 1 shows the container 1, the flip 3 in the open position. In the box 2 of the container 1 a packet of cigarettes wrapped in an inner wrapper 5 is housed.

The box body 2 has a box body front wall, a box body left side wall, a box body right side wall, a box body rear wall and a box body bottom wall. The upper side of the box 2 is open to provide an upper opening through which cigarettes can be removed.

The flip 3 has a flip front wall, a flip left side wall, a flip right side wall, a flip rear wall, and a flip top wall. The free edge of the wall of the flap 3 abuts the free edge of the wall of the box 2 along the abutment line when the container 1 is closed. In the closed position, the walls of the flap 3 thus form an extension of the corresponding walls of the box 2 to define the walls of the housing 1.

The inner package 5 comprises an access opening 6 through which the cigarettes can be removed. When inner package 5 of cigarettes is placed inside box 2, access opening 6 is positioned at the open upper end of box 2. The access opening 6 includes a cut line 57 defining a flap 58 covering the access opening 6. The cover sheet 58 is movable to cover and uncover the access opening 6 and thus does not allow or allows access to the cigarettes. A line of weakness may be provided in place of cut line 57 to allow flap 58 to be separated from inner package 5 whenever container 1 is opened for the first time. Alternatively, the access opening 6 is a cut 59 (see fig. 19B).

An inner frame 4 (formed from the blank shown in figure 20) is mounted within the inner package 5 of the container 1. The inner frame 4 comprises an inner frame front wall, an inner frame left side wall, and an inner frame right side wall, which are positioned adjacent to the inner surface of the inner package front wall, the inner surface of the inner package left side wall, and the inner surface of the inner package right side wall, respectively. The inner frame 4 may optionally be connected (e.g. glued) to the inner package 5. To facilitate the removal of the cigarettes from the box 2, the inner frame front wall comprises a rectangular cut-out at the top free edge. The rectangular cut-out corresponds approximately to the front wall portion of the inner package 5 having the access opening 6. The walls of the internal frame extend above the upper edge of the box 2.

A reclosable flap 8 is attached to the outer surface of the inner package 5 such that it covers the access opening 6 in the inner package 5. A reclosable flap 8 is affixed to the inner package 5 at the upper rear edge of the inner package 5, the reclosable flap being provided with a hinge line 7 about which the reclosable flap 8 can be pivoted to open and close the access opening 6. In other words, the reclosable flap 8 is attached to the inner package 5 such that during movement of the flip 3, a portion of the reclosable flap 8 is movable relative to the inner package 5 while another portion of the reclosable flap 8 is not movable during movement of the flip 3. Reclosable flap 8 extends beyond the perimeter 57 of the access opening and is also affixed to inner package flap 58.

The reclosable flap 8 in this embodiment is a self-adhesive label. Label 8 includes a resealable adhesive on its inner surface that substantially compresses a portion of inner package 5 about perimeter 57 of access opening 6. The resealable adhesive affixes the adhesive label 8 to the inner package 5 when the flip cover 3 is in the closed position.

Resealable adhesive may also be used to attach inner package cover sheet 58, although it is preferred to use permanent adhesive to prevent inner package cover sheet 58 from peeling away from label 8 after multiple openings. The resealable adhesive may be a pressure sensitive adhesive. The permanent adhesive may be a UV cured pressure sensitive adhesive.

The permanent adhesive may be disposed within a border of the resealable adhesive within the perimeter 57 of the access opening 6, as shown in fig. 5, wherein the permanent adhesive is disposed in the area 17 within the perimeter 57 of the access opening 6. The bezel may have a minimum separation of about 1mm to 5mm (e.g., about 2mm to 3mm) from the perimeter 57 of the access opening 6. By providing a resealable adhesive border around the permanent adhesive region 17 within the perimeter 57 of the access opening 6, peeling of the inner package cover sheet 58 from the label 8 after multiple openings is reduced while accommodating positioning errors of the label 8 on the inner package cover sheet 58 that may result in the label 8 being permanently adhered to the inner package 5 both inside and outside of the access opening 6, thereby preventing the inner package 5 from being opened without damage thereto. Although shown only in this embodiment, permanent adhesive region 17 may optionally be present in any embodiment having an inner package flap 58.

In an alternative embodiment where access opening 6 is a cut-out 59, label 8 is substantially free of adhesive within perimeter 57 of access opening 6.

As shown in fig. 2, the flip front wall comprises a flip outer front panel 31 and two flip inner

front panels

32, 33 connected to the flip outer front panel 31 by crease lines. The first flip inner front panel 32 is connected to the flip outer front panel 31 only by crease lines, which define a rotation axis 32' about which the first flip inner front panel 32 can rotate relative to the flip outer front panel 31. The first flip inner front panel 32 is thus rotatable relative to the flip outer front panel 31 about the lower front edge of the flip 3. The second flip inner front panel 33 is connected to the flip outer front panel 31 by a crease line and by a permanent adhesive so that the flip outer front panel 31 and the second flip inner front panel 33 do not move relative to each other.

The outer surface of label 8 is permanently affixed at its free end 9 to the first flap inner front panel 32, for example by means of a permanent adhesive (e.g. a hot melt adhesive or a spot of PVA) provided in a fluid state on the label 8 and/or on the inner surface of the flap 3 or a permanent adhesive (e.g. double-sided adhesive tape) provided on a carrier material. As a result, movement of the flip 3 causes movement of the label 8 and movement of the first flip inner front panel 32, which rotates relative to the flip outer front panel 31. The inner surface of free end 9 of label 8 may be substantially free of resealable adhesive to reduce the force required to open flip cover 3. Alternatively, the resealable adhesive applied to the inner surface of the label 8 may extend to its free end 9 to securely close the flip 3.

To access the cigarettes inside the inner package 5, the hinged flap 3 is moved from the closed position to the open position shown in fig. 1. As the flap 3 is moved from the closed position, the edge 32 "of the first flap inner front panel 32 is in pivotal contact with the outer surface of the inner package 5. This causes the first flip inner front panel 32 to pivot about the edge 32 "from an initial position where the first flip inner front panel 32 is substantially parallel to the flip outer front panel 31 to a position where the first flip inner front panel 32 is about perpendicular to the flip outer front panel 31, as can be appreciated in fig. 3A. In other embodiments not shown, the first flip top inner front panel 32 pivots about the edge 32 "from an initial position to a position where the first flip top inner front panel 32 is substantially perpendicular to the inner package 5. Further rotation of the hinged flap 3 peels the label 8 off the inner package 5, thereby uncovering the access opening 6 in the inner package 5 through which one or more cigarettes can be removed.

Thus, the container 1 of the present invention provides a two-stage opening of the flip 3. In a first stage, the free end 9 of the reclosable flap or label 8 is pivoted about the inner package 5. In a second stage, the reclosable flap or label 8 is peeled off the inner package 5, thereby uncovering the access opening 6 in the inner package 5. In the first stage, the reclosable flap or label 8 preferably does not even partially uncover the access opening 6.

To close the container 1, the hinged flap 3 is moved from the open position to the closed position. As flap 3 is moved from the open position, label 8 rolls over inner package 5, thus covering access opening 6 in inner package 5. First flap inner front panel 32 extends the extent of label 8 in the open position and tensions label 8 during closing of the flap, thereby ensuring accurate repositioning of adhesive label 8 against inner package 5. In the stop motion position shown in fig. 3A, the edge 32 "of the first flip inner front panel 32 is in contact with the inner package 5. Further rotation of the hinged flip 3 causes the first flip inner front panel 32 to pivot about the edge 32 "from an initial position where the first flip inner front panel 32 is approximately perpendicular to the flip outer front panel 31 to a position where the first flip inner front panel 32 is approximately parallel to the flip outer front panel 31, thereby closing the container 1 accordingly. In other embodiments, not shown, the first flip top inner front panel 32 pivots about the edge 32 "from an initial position where the first flip top inner front panel 32 is approximately perpendicular to the inner package 5 to a position where the first flip top inner front panel 32 is approximately parallel to the flip top outer front panel 31, thereby closing the container 1 accordingly.

Thus, the container 1 of the present invention provides a two-stage closing of the flip 3. In a first stage, a reclosable flap or label 8 is rolled over the inner package 5, thus covering the access opening 6 in the inner package 5. In a second stage, the free end 9 of the reclosable flap or label 8 is pivoted about the inner package 5.

The flap 3 is thus movable about the box 2 between the open and closed positions through the intermediate stable position shown in fig. 3A. Movement of the flip 3 between the closed position and the intermediate position (or vice versa) requires overcoming a biasing force which, in this embodiment, may be generated by the reclosable flap 8 in cooperation with the movable flip panel (first flip inner front panel 32).

The reclosable flap 8 is provided with a marking 118 on its inner side, which is the side that comes into contact with the inner package 5 when the flap 3 is in the closed position. The flag 118 may be disposed at a variety of locations on the reclosable flap 8. In particular, however, the flag 118 is disposed towards the free end 9 of the reclosable flap where it is attached to the first flap inner front panel 32. The first flip inner front panel 32 is generally flat and planar. The reclosable flap 8 is also flat and coplanar with the first flap inner front panel 32 where the two base materials are adjacent to each other. Thus, the indicia 118 on the reclosable flap 8 can be disposed on the generally planar surface adjacent the first flap inner front panel 32. This has been found to be desirable as it minimizes any possible distortion of the marker 118 that might otherwise be introduced by curved or non-planar surfaces.

In this example, the markers 118 are text. However, any other type of indication or identification or combination thereof may be provided, including numbers, logos, and images. Advantageously, the indicia 118 may be represented on the reclosable flap 8 without causing any distortion near the first flap inner front panel 32.

The marker 118 may also be provided on other portions of the reclosable flap 8 that are free to flex. The markers 118 on the flexible portion of the reclosable flap 8 are chosen so that they can be effectively observed, even when deformed on a flexible substrate. A repeating pattern is an example of a marker 118 that can be effectively disposed on a flexible substrate.

The markers 118 may be provided by one or more of ink, varnish, lacquer, embossing, debossing, and hot foil stamping. Where the markers 118 are provided by ink, they may be spaced from the consumer product in the inner package 5 so as to prevent any potential migration of the compound to the consumer product. This may be accomplished by placing the flag 118 on the reclosable flap 8 in a position that is offset from the access opening 6 when the hinged flip-lid 3 is in the closed position. Alternatively, or in addition, a coating (not shown) may be provided on the reclosable flap 8 adjacent the marker 118 to prevent the compound from seeping out of the marker and into the consumer product. In one arrangement, a frame (not shown) may be provided on the reclosable flap 8 surrounding a portion of the reclosable flap 8 that overlies the access opening 6 when the hinged flip 3 is in the closed position.

Advantageously, the marker 118 is always visible when the hinged flip-lid 3 is moved from the closed position to the open position. In the first opening phase, the free end 9 of the reclosable flap 8 pivots about the inner package 5. The marker 118 is visible in fig. 3A and 3B in an intermediate stable position shown when the container is in a plurality of different orientations. In just two examples, the marker 118 is visible in the perspective view shown in fig. 3A and the front view shown in fig. 3B. In a second stage, the reclosable lid flap 8 is peeled off the inner package 5, thereby uncovering the access opening 6 in the inner package 5. The markers 118 adjacent the first flap inner front panel 32 are visible during the first and second opening stages in a configuration that avoids introducing any distortion.

Fig. 4 is a perspective view of another embodiment of the hinge-lid container 1. For the sake of brevity, only the differences between the containers will be explained below, and the same reference numerals as used for the container 1 of the first embodiment will be used to refer to similar elements.

The inner surface of the reclosable flap 8 comprises an overlapping area, wherein the reclosable flap 8 is arranged close to the inner package 5 around the periphery 57 of the access opening 6 when the lid 3 is in the closed position. The inner surface of reclosable flap 8 includes a first portion 14 having resealable adhesive to releasably attach inner package 5 to reclosable flap 8 and a second portion 16 substantially free of adhesive. In the closed position, first portion 14 of reclosable flap 8 is disposed adjacent to sealing portion 15 of inner package 5, thereby causing the corresponding walls to adhere. Of course, in another embodiment, the resealable adhesive may be provided on the sealing portion 15 of the inner wrapper 5, rather than on the reclosable flap 8. In the closed position, second portion 16 of reclosable flap 8 is disposed proximate to a corresponding portion of inner package 5 on perimeter 57 of access opening 6, but no adhesion occurs between these two surfaces. The corresponding surfaces may be very close together, or in direct contact, but the absence of a sealing engagement means that fluid exchange between the interior of the inner package 5 and the external environment is possible. This forms a breathable seal to the access opening 6, which can help preserve the tobacco in the cigarette under certain atmospheric conditions.

In this arrangement, the second portion 16 of the reclosable flap 8, which is substantially free of resealable adhesive, is disposed at the free end 9 of the label 8 and around a portion of the perimeter 57 of the access opening 6. The first portion 14 of the reclosable flap 8 provided with resealable adhesive extends from the second portion 16 to the hinge line 7. As can be appreciated in fig. 4, the resealable adhesive extends in the top wall of the inner wrapper 5 around the left and side edges of the perimeter 57 of the access opening 6, extends in the front wall of the inner wrapper 5 around a portion of the left and side edges of the perimeter 57 of the access opening 6, but does not extend around the lower perimeter 57 of the access opening 6.

A second portion 16 of the reclosable flap 8 that is substantially free of resealable adhesive is disposed on the inner surface of the free end portion 9 of the reclosable flap 8. The area of the second portion 16 of the reclosable flap 8 is greater than the area of the reclosable flap 8 that overlaps the first flap inner front panel 32. In particular, the length of the second portion 16 (measured along the reclosable flap 8 from the free end 9) is at least 1mm greater than the length of the overlapping portion of the reclosable flap 8 and the first flap inner front panel 32 (measured along the reclosable flap 8 from the free end 9). This arrangement means that when the edge 32 "of the first flap inner front panel 32 and the inner package 5 are brought into pivotal contact, the second portion 16 of the reclosable flap 8, which is substantially free of adhesive, is disposed therebetween.

This pivoting contact occurs about a pivot line in the second portion 16 of the reclosable flap 8. In such an arrangement, the absence of any adhesive is considered to be advantageous, as this prevents any interference in the pivoting movement. The reverse process occurs when the flip 3 is moved from the open position towards the closed position, whereby the edge 32 "can pivot along the pivot line in the second portion 16 of the reclosable lid sheet 8.

A low friction interaction between the reclosable flap 8 and the inner package 5 in the areas where there is no adhesive can be provided. This may cause some movement of the pivot line of the edge 32 "during opening and/or closing of the flip 3. Advantageously, the edge 32 "is provided in the second portion of the reclosable flap 8 for all possible positions of the pivot line.

Fig. 5 is a plan view of the inside surface of a reclosable flap 8 used in the receptacle 4 shown in fig. 1. For ease of reference, the perimeter 57 of the access opening 6 has been shown but is not part of the reclosable flap 8. Hinge line 7 is also shown in phantom. Similarly, the dashed transverse lines indicate the relative positions of the upper front edge and the upper rear edge of the inner package 5 when the reclosable flap 8 is in the closed position over the inner package 5.

As can be seen in fig. 5, when the flip 3 is in the closed position, the reclosable flap 8 comprises a rear surface 81, a top surface 82, and a front surface 83. These are the positions of the

relevant surfaces

81, 82, 83 of the reclosable flap 8 on the rectangular cube, i.e. the inner package 5.

It has been found advantageous to provide a resealable adhesive on the first portion 14 of the reclosable flap 8, at least on the top surface 82 and the front surface 83. This may allow the reclosable flap 8 to be wrapped around the top front edge of the inner package 5 in a reliable manner, which may help ensure that the reclosable flap 8 is correctly positioned when the flip 3 is moved from the open position towards the closed position.

The outer surface of the free end 9 of the reclosable flap 8 is provided with a permanent adhesive (not shown) for attachment to the inner surface of the flap 3.

In another embodiment, not shown, inner package 5 may be provided with a debonding agent such that when reclosable flap 8 (essentially comprising a layer of adhesive) is overlaid on inner package 5, reclosable flap 8 will not adhere to inner package 5 in that area.

In this arrangement, the movable portion of the reclosable flap 8 comprises the majority of the front surface 83 and the top surface 82, while the non-movable portion comprises the rear surface 81 and a portion of the top surface 82 near the rear upper edge.

Hinge line 7 is located at a distance of about 7.5mm from the top rear edge of inner package 5. The top wall of the inner package 5 has a length of about 21.5mm and the hinge line 7 is therefore provided at a distance of about 30% of the distance from the top rear edge of the inner package 5 to the top front edge of the inner package 5. In the case of an inner package 5 containing cigarettes, the position of hinge line 7 substantially corresponds to the interface between the cigarettes of the rear row and the cigarettes of the middle row; this is best understood with reference to fig. 7.

Fig. 6 is a side view of the housing 1 formed from the blank 13 shown in fig. 18 together with the reclosable flap 8 shown in fig. 5. Fig. 7 is a top view of the same housing 1, and fig. 8 is a front view. In this configuration, the hinged flip 3 is shown in a first open position. In the first open position, the hinged flip 3 is rotated approximately 180 ° from the closed position so that the flip back wall 36 is approximately parallel and adjacent to the box back wall 24, although the two are not in contact. In this first open position, the flip top wall 37 is disposed approximately perpendicular to the box back wall 24.

Fig. 9 is another side view of the housing formed from blank 13, showing hinged flip 3 in the second open position. In the second open position, the flap rear wall 36 is disposed in contact with the case rear wall 24. Thus, an acute angle is formed between the flip top wall 37 and the box back wall 24. The second open position corresponds to the "fully open" position of the hinged flip 3, which is the extreme end of the normal operational movement of the flip 3.

A ratio between a first distance, measured in a straight line between the lower front edge of the flip front wall (which in this embodiment corresponds to the axis of rotation 32' of the first flip inner front panel 32) and the hinge line 7 when the hinged flip 3 is in the first open position or the second open position, and a second distance, along the reclosable flap 8, between the hinge line 7 and the edge of the reclosable flap 8 at the free end 9 can be defined. The dimensions of the reclosable flap 8 and the blank 13 are chosen such that the ratio between the first distance and the second distance is comprised between 70% and 100%. The second distance is along the partially curved path of the reclosable flap 8. In contrast, the first distance is a straight line between hinge line 7 and the axis of rotation 32' of the first flip inner front panel 32 to which the reclosable flap 8 is attached. The location of hinge line 7 is best seen by reference to figure 7, which also shows flap 58 in inner package 5. This arrangement causes the reclosable flap 8 to be tensioned in both the first and second open positions. In the second open position, the tension in the reclosable flap 8 is high, as can be observed by the relatively flat shape it takes. Providing a tension in the reclosable flap 8 in the first and second open positions is advantageous as it biases the hinged flap 3 away from the first or second open position and towards the closed position. This may improve the positioning of the reclosable flap 8, in particular against the top surface of the inner package 5, during the closing operation.

The reclosable flap 8 comprises a flat portion and a curved or convex portion in both the first and second open positions. In some configurations, it is also possible to provide a concavely curved portion in the reclosable flap 8.

From a comparison between fig. 6 and 9, it will be understood that the angle between the first flip inner front panel 32 and the flip outer front panel 31 changes when the flip 3 is moved from the first open position to the second open position. In the first open position, the angle between the first flip inner front panel 32 and the flip outer front panel 31 is about 90 °. In the second open position, the first flip inner front panel 32 and the flip outer front panel 31 form an acute angle of less than 90 ° therebetween.

In both the first open position and the second open position, a portion of the reclosable flap 8 is maintained in a generally flat, tensioned configuration between the hinge line 7 and the first flap inner front panel 32. In the first open position the flat portion of the reclosable flap 8, which comprises the portion of the reclosable flap 8 attached to the (flat) first flap inner front panel 32, is about 14mm in length. In the second open position, the length of the flat portion of the reclosable flap 8 is about 37mm or 38mm, as measured from the free end 9 of the reclosable flap 8. The flat portion also includes the portion of the reclosable flap 8 attached to the first flap inner front panel 32. Thus, the length of the flat portion of the reclosable flap 8 increases by a factor or proportion of about 2.7 when the flip 3 is moved from the first open position to the second open position.

Fig. 10 is a perspective view of a container 1 in a third embodiment of the invention, and fig. 11 is a plan view of a reclosable flap 8. Fig. 12 is a front view of an inner package 5 for use in the container 1 of the present invention and the reclosable flap 8 of fig. 11. This embodiment differs from the second embodiment in that the second portion 16 of the reclosable flap 8 has about the same size and shape as the first flip interior front panel 32. In this arrangement, when the hinged flip-lid 3 is in the closed position, the second portion 16 of the reclosable flap 8 does not extend as far as to access the opening 6. Thus, in this embodiment, the resealable adhesive extends around the entire perimeter 57 of the access opening 6.

Fig. 13 shows a plan view of an alternative reclosable flap 8 for use in the container 1 of the present invention, and fig. 14 shows a front view of the inner package 5 with the reclosable flap 8 of fig. 13. The reclosable flap 8 is provided with a first portion 14 having resealable adhesive and a second portion 16 substantially free of resealable adhesive and adjacent the hinge line 7. The reclosable flap 8 also comprises a third portion 18 substantially free of adhesive, which is adjacent to the hinged flap 3, in particular at the connecting portion (free end 9) of the label 8. As can be appreciated in fig. 13, the third portion 18 does not include a portion that touches the perimeter 57 of the opening 6. Thus, the resealable adhesive extends in the front wall of the inner wrapper 5 around the lower edge of the perimeter 57 of the access opening 6, around the left and right edges of the perimeter 57 of the access opening 6, and in the top wall of the inner wrapper 5 around a portion of the left and right edges of the perimeter 57 of the access opening 6.

In this arrangement, the reclosable flap 8 advantageously avoids tobacco debris from adhering to the flap 8 adjacent the hinge line 7, promotes substantial opening of the flap 3, and improves the ease of opening the flap 3. Further, the container 1 facilitates the preservation of the tobacco by enabling oxygen exchange between the interior of the inner wrapper 5 and the external environment.

In this embodiment, first portion 14 of reclosable flap 8 has a length l1 of about 9mm extending along top surface 82 in a direction substantially perpendicular to hinge line 7 toward hinge line 7. In this same embodiment, second portion 16 of reclosable flap 8, which is substantially free of resealable adhesive, has a length l2 of about 9mm extending from hinge line 7 along top surface 82 in a direction substantially perpendicular to hinge line 7.

In another embodiment, not shown, first portion 14 of reclosable flap 8 has a length l1 of about 9mm extending along top surface 82 in a direction substantially perpendicular to hinge line 7 from hinge line 7. In this same embodiment, second portion 16 of reclosable flap 8, which is substantially free of resealable adhesive, has a length l2 of about 9mm extending from hinge line 7 along top surface 82 in a direction substantially perpendicular to hinge line 7.

In an alternative embodiment not shown, the third portion 18 (in an embodiment similar to the second portion 16 of the label 8 represented in fig. 5) comprises a lower portion that accesses the perimeter 57 of the opening 6. As a result, the resealable adhesive extends in the top wall of the inner wrapper 5 around a portion of the left and right edges of the perimeter 57 of the access opening 6, and in the front wall of the inner wrapper 5 around a portion of the left and side edges of the perimeter 57 of the access opening 6. The resealable adhesive does not extend around the lower perimeter 57 of the access opening 6.

The second portion 16 of the reclosable flap 8 has been described as being substantially free of resealable adhesive. However, at least some of the advantageous effects described herein may be achieved by providing the second portion 16 with a reduced tackiness compared to the first portion 14.

Fig. 15 shows a blank 10 for forming the outer shell 1 represented in fig. 1 to 4, and 10. The blank 10 is divided into two blank sections, namely a box portion 20 and a flip portion 30. Each blank section comprises a plurality of panels, wherein each individual panel is connected to at least one other panel, for example by crease or fold lines.

The box portion 20 includes a box front panel 21, a box outer left side panel 22 'and a box inner left side panel 22 ", a box outer right side panel 23' and a box inner right side panel 23", a box back panel 24, a box bottom panel 25, and two box glue flaps 26. Although in fig. 15 the connections of the box front panel 21 and the box back panel 24 to the box outer left side panel 23 ', the box inner left side panel 23 ", the box outer right side panel 24', and the box inner right side panel 24" are shown as a plurality of parallel longitudinal crease lines, these connections may equally be achieved by a single longitudinal crease line. The remaining panel connections are a single transverse crease line.

To assemble the box 2 of the housing 1, a box glue flap 26 is glued to the box bottom panel 25 to form the box bottom wall. To form the case left side wall, the case interior left side panel 22 "is glued to the case exterior left side panel 22'. The box inner right side panel 23 "is glued to the box outer right side panel 23' to form the box right wall.

The flip portion 30 includes a flip outer front panel 31, two flip inner

front panels

32, 33, a flip outer left side panel 34 'and a flip inner left side panel 34 ", a flip outer right side panel 35' and a flip inner right side panel 35", a flip back panel 36, a flip top panel 37, and two flip adhesive cover sheets 38. The flip back panel 36 is hingedly connected (e.g., by a crease line) to the box back panel 24.

Although in fig. 15 the connections of the flap outer front panel 31 and the flap rear panel 36 to the flap outer left side panel 34 ', the flap inner left side panel 34 ", the flap outer right side panel 35', and the flap inner right side panel 35" are shown as a plurality of parallel longitudinal crease lines, these connections may equally be made by a single longitudinal crease line. The remaining panel connections are a single transverse crease line.

In this embodiment, the first flip inner front panel 32 and the second flip inner front panel 33 are both connected to the flip outer front panel 31 because the second flip inner front panel 33 surrounds the first flip inner front panel 32. Although not shown in fig. 4, the first flip inner front panel 32 and the second flip inner front panel 33 may be connected by one or more breakable connections. The one or more breakable connections may be provided along at least one of the edges of the first flip inner front panel 32 that is not connected to the flip outer front panel 31, preferably at least along edge 32 ", which is opposite the edge 32' of the first flip inner front panel 32 that is connected to the flip outer front panel 31.

To form the flip 3, both flip inner front panels are folded 180 ° with respect to the flip outer front panel 31 so that they are in contact, but only the flip outer front panel 31 and the second flip inner front panel 33 are glued together. A flip top adhesive cover sheet 38 is glued to the flip top panel 37 to form the flip top wall. The flap left side wall is formed by gluing the flap inner left side panel 34 "to the flap outer side panel 34'. Finally, the flip cover inner right side panel 35 "is glued to the flip cover outer right side panel 35'.

Preferably, an adhesive free area is defined around the perimeter of the first flip inner front panel 32 to prevent adhesive from dripping into the first flip inner front panel 32. The average width of the adhesive free area may be at least 1mm, for example about 2 mm.

Fig. 16 to 18 show

alternative blanks

11, 12, 13 for forming a shell 1 similar to the shells represented in fig. 1 to 4 and 10. For the sake of brevity, only the differences between the blanks will be explained below, and the same reference numerals as used for the blank 10 of the first embodiment will be used to refer to like elements.

The blank 11 of the second embodiment shown in fig. 16 differs from the blank 10 of the first embodiment in that the flip portion 30 has only one flip inner front panel 32. When the flip cover 3 is formed, the flip cover inner front panel 32 is folded 180 ° relative to the flip cover outer front panel 31 so that they are in contact, but not glued to bond the two panels.

The blank 12 of the third embodiment shown in fig. 17 differs from the blank 10 of the first embodiment in that the first flap inner front panel 32 is connected to the flap outer front panel 30 at one edge 32' by a crease or fold line and to the second flap inner front panel 33 at the other, opposite edge 32 "by a line of weakness (e.g., a row of perforations). The lines of weakness 32 "may be formed during the step of forming the outer shell 1 (e.g. by a rotary scoring tool), preferably before any panels of the blank 12 are folded.

When the flip 3 is formed, the first flip inner front panel 32 is folded 180 ° with respect to the flip outer front panel 31. Since the second flip inner front panel 33 is connected to the first flip inner front panel 32, by folding the first flip inner front panel 32 relative to the flip outer front panel 31, the second flip inner front panel 33 is also in contact with the flip outer front panel 31. These latter panels are glued together.

When the reclosable flap 8 is affixed to the first flap inner front panel 32 and the container 1 is opened for the first time, the opening force breaks the weakened line 32 "connecting the first flap inner front panel 32 with the second flap inner front panel 33, thereby making the first flap inner front panel 32 movable, which then becomes rotatable about the crease line 32' connecting it to the flap outer front panel 31. The second flip inner front panel 33 remains attached to the flip outer front panel 31.

The blank 13 of the fourth embodiment shown in fig. 18 differs from the blank 11 shown in fig. 16 in the size and shape of the first flap inner front panel 32.

When the flip 3 is formed, the flip outer front panel 31 is moved toward the reclosable cover sheet 8 so that the first flip inner front panel 32 comes into contact with the outer surface of the reclosable cover sheet 8. Since the first flip inner front panel 32 in the blank 11 is neither glued to the flip outer front panel 31 nor connected to the other flip panel by one or more breakable connections, the first flip inner front panel 32 rotates and there is a risk that it rotates into an undesirable configuration. In particular, there is a risk that the first flip inner front panel 32 has an angle of more than 90 ° with respect to the flip outer front panel 31. This arrangement would be undesirable as it would prevent the first flip inner front panel 32 from effectively engaging the reclosable flap 8. In addition, the first flap inner front panel 32 will likely sweep the liquid permanent adhesive from the free end 9 of the reclosable flap 8. This will reduce the likelihood of effective bonding and cause inadvertent bonding between other surfaces. This may be prevented by sizing the first flip inner front panel 32 such that the first flip inner front panel 32 brushes against the top front edge of the reclosable cover sheet 8 as the hinged flip 3 moves from the open position toward the closed position before any attachment occurs between the first flip inner front panel 32 and the reclosable cover sheet 8.

These undesirable effects are advantageously mitigated by the present arrangement of the blank 13, which is achieved in part by having a first flip-top inner front panel 32 having a length extending in a direction perpendicular to the crease line 32' of about 10.5 mm.

It has been found that the relative dimensions of the first flip inner front panel 32, the flip outer front panel 31, and the flip rear panel 36 help mitigate the undesirable effects described above. The blank 13 is sized and shaped to mitigate these undesirable effects. In particular, the flap outer front panel 31 of the blank 13 has a length of about 30mm and the flap rear panel 36 has a length of about 8 mm. As a result, the ratio between the length of the first flip inner front panel 32 and the length of the flip outer front panel 31 is 0.35, while the ratio between the length of the first flip inner front panel 32 and the length of the flip rear panel 36 is about 1.3. The ratio between the length of the first flap inner front panel 32 and the distance between the top front edge 19 of the inner package 5 and the top front edge 27 of the box 2 is at least 0.3 and preferably no more than 0.5.

Fig. 19A and 19B show two alternative blanks for forming the inner package 5 represented in fig. 1 to 14. The inner package blank 50 is made from a generally rectangular sheet of wrapping material that is folded along the longitudinal and transverse dashed lines indicated in fig. 19A and 19B.

The inner package blank 50 comprises an inner package front panel 51, an inner package outer left side panel 52 'and an inner package inner left side panel 52 ", an inner package outer right side panel 53' and an inner package inner right side panel 53", an inner package rear panel 54, an inner package bottom panel 55, and an inner package top panel 56. Although in fig. 19A and 19B the separation of the inner package front panel 51 and inner package back panel 54 from the inner package outer left side panel 53 ', inner package inner left side panel 53 ", inner package outer right side panel 54', inner package inner right side panel 54" is shown as being two parallel longitudinal fold lines each, this separation may equally be achieved by a single longitudinal fold line.

The inner package blank 50 shown in fig. 19A includes cut lines 57 that define a flap 58. A line of weakness may be provided in place of the cut line to allow the flap 7 to be separated from the inner package 5 as soon as the container 1 is opened for the first time.

To form the inner package 5 from any of the blanks 50 shown in fig. 19A and 19B, the inner package outer left side panel 52' and the inner package inner left side panel 52 "are connected to each other (e.g., by gluing or heat sealing) to form the inner package outer left wall. The inner package right wall is formed by joining the inner package outer right side panel 53' and the inner package inner right side panel 53 ".

In the inner package blank 50 shown in fig. 19B, the cut lines 57 define cutouts 59.

Fig. 20 shows a blank 40 for forming the inner frame to be housed in the inner package 5 of fig. 1 to 14. The inner frame blank 40 includes an inner frame front panel 41, an inner frame left side panel 42, and an inner frame right side panel 43. Although in fig. 20 the connection of the inner frame front panel 41 to the inner frame left side panel 42 and the inner frame right side panel 43 is shown as a plurality of parallel longitudinal crease lines, these connections may equally be realized by a single longitudinal crease line.

The inner frame front panel 41 includes a rectangular cutout 44 at the top free edge to facilitate removal of the cigarettes from the carton 2 when the inner frame is assembled from the blank 40. The rectangular cut-out 44 corresponds approximately to the front wall portion of the access opening 6 in the inner package 5.

To form the inner frame, the inner frame left side panel 42 and the inner frame right side panel 43 are folded by about 90 ° with respect to the inner frame front panel 41. In the assembled state, the inner frame front panel 41 corresponds to the inner frame front wall, and the inner frame left side panel 42 and the inner frame right side panel 43 correspond to the inner frame left side wall and the inner frame right side wall, respectively.

Fig. 21 illustrates a system or apparatus 100 for forming an inner package 5 containing smoking articles (e.g., cigarettes, etc.) according to one embodiment of the invention. The apparatus 100 conveys a series of internal frames 4, each incorporating a respective quantity of cigarettes, along a packing path in the direction of arrow a. The framed quantity of cigarettes G is conveyed under a continuous sheet of wrapping material 500 (e.g. a metallized plastic laminate film) fed from a supply roll (not shown). The wrapping sheet 500 has a preformed reclosable flap 8 for alignment with a corresponding access aperture 44 in the inner frame front panel 41 of each inner frame 4 conveyed beneath the wrapping sheet 500.

The rollers 101 arranged below the inner frame 4 travelling in succession draw the wrapping sheet 500 taut on the front and rear faces of the framed quantity of cigarettes G and against the opposite ends of the framed quantity of cigarettes G, thereby wrapping the framed quantity of cigarettes to form the inner package front, top, rear and bottom walls. The rollers 101 then cooperate with the sealing head 102 to fuse or seal the drawn wrapping sheet 500 to form a transverse seam at the inner package back wall (not shown). Another (or a pair of) elongate sealing heads 103 behind the rollers 101 is then operated to pinch and fuse the lateral seams (e.g. into a "fin seal") in the barrier sheet 500 between each framed quantity of cigarettes G to form the inner package left and right side walls. The trimmer 104 and roller 105 may then trim and flatten the

seams

13, 14 to complete the individual inner package 5.

As explained above, a set of blanks for forming the outer casing 1 according to any of the embodiments represented in fig. 15 to 18 is folded and glued around the inner package 5 to form the box 2 and the flap 3. A permanent adhesive is applied on the outer surface of the reclosable flap 8, particularly at its free edge 9, to attach the reclosable flap 8 to the first flap inner front panel 32. As a result, a container for consumer goods according to the present invention is formed.

To pre-form the reclosable flap 8 in the wrapping sheet 500, the access opening 6 is first cut in the wrapping sheet 500 to define the flap 58 (fig. 19A) or the cut 59 (fig. 19B), and then the reclosable flap 8 is positioned on the wrapping sheet 500 over the access opening 6. A reclosable flap 8 is positioned to cover the access opening 6.

In some embodiments, the application of permanent adhesive on the outer surface of the reclosable flap 8 may be performed during the formation of the outer shell around the inner package 5, preferably during the folding and gluing of the flap portion 30 of the blank.

In other embodiments, the application of the permanent adhesive is completed after the outer shell is completely formed around the inner package 5. In this case, the attachment of the reclosable flap 8 to the first flap inner front panel 32 requires an additional step of creating a space or gap between the flap 3 and the inner package 5 to provide access to the free end 9 of the reclosable flap 8; and the reclosable flap 8 is attached to the first flap inner front panel 32 through or via a space or gap. The attaching step may include bringing the first flip inner front panel 32 and the outer surface of the reclosable flap 8 closer together, desirably in contact with each other, for example by applying pressure to the flip 3.

For example, the hinged flap 3 may be moved from a closed position to an at least partially open position relative to the box 2 so as to create a space or gap between the hinged flap 3 and the inner package 5 through which or via which the reclosable lid sheet 8 and the first flap inner front panel 32 are attached to each other. A liquid permanent adhesive may then be provided at the free end 9 of the reclosable flap 8 through or via the space or gap, and the hinged flap 3 may then be rotated back to the closed position.

Preferably, the hinged flip-lid 3 is rotated relative to the box 2 by an angle of less than about 35 °, such as less than about 30 °, such as less than about 25 °, or such as within a range between about 8 ° and about 20 °. By limiting the extent to which the hinged flip 3 is opened, the detrimental effects of the opening operation can be substantially avoided while providing sufficient space to provide an effective attachment between the reclosable flap 8 and the first flip interior front panel 32.

Claims

1. A container for consumer goods, the container comprising:

a housing comprising a box and a hinged flap rotatable between an open position and a closed position, wherein the hinged flap comprises a first flap panel and a second flap panel, wherein the first flap panel is movable relative to the second flap panel during movement of the hinged flap between the open position and the closed position;

a consumer goods inner package within the box, the consumer goods inner package comprising an access opening through which consumer goods can be removed; and

a reclosable flap movable about a hinge line relative to the consumer goods inner package and arranged to cover the access opening, a portion of the reclosable flap being attached to the first flip panel;

wherein the first flip panel is substantially perpendicular to the flip front wall and the first flip panel is substantially perpendicular to the flip front wall when the hinged flip is in a first open position in which the flip top wall is disposed substantially perpendicular to the box back wall, and

the hinge line is positioned at the top wall of the consumer goods inner package at a distance from the top rear edge of the consumer goods inner package that is about the same as or shorter than the length of the flip attachment portion of the reclosable flap, and the ratio between the length of the flip attachment portion of the reclosable flap and the distance between the hinge line and the top rear edge of the consumer goods inner package is comprised between 1 and 3.

2. The container of claim 1, wherein the hinge line is positioned at the top wall of the consumer goods inner package at a distance of at least 20% of the distance from the top rear edge of the consumer goods inner package to the top front edge of the consumer goods inner package.

3. The container of claim 1, wherein the hinge line is positioned at the top wall of the consumer goods inner package at a distance that is no greater than 40% of the distance from the top rear edge of the consumer goods inner package to the top front edge of the consumer goods inner package.

4. The container of any preceding claim, wherein the reclosable flap is attached to the consumer goods inner package such that during movement of the hinged flap, a portion of the reclosable flap is movable relative to the consumer goods inner package and another portion is immovable during movement of the hinged flap, wherein the hinge line defines movable and non-movable portions of the reclosable flap.

5. A container according to any of claims 2 to 3, wherein the access opening is provided by a cut line or line of weakness defining a flap in the outer surface of the consumer goods inner package, wherein the hinge line of the reclosable flap substantially coincides with the hinge line of the flap in the outer surface of the consumer goods inner package.

6. The container of any of claims 1-3, wherein an angle between the first flap panel and the flap front wall decreases as the hinged flap is rotated from the first open position to a second open position, wherein the first open position is disposed between the closed position and the second open position.

7. The container of claim 1, wherein the hinge line is positioned at the top wall of the consumer goods inner package at a distance from the top rear edge of the consumer goods inner package that is about the same length as or shorter than the length of the first flip top panel.

8. The container of claim 1, wherein a ratio between a length of the flip attachment portion of the reclosable flap and a distance between the hinge line and the top rear edge of the consumer goods inner package can be at least 1.1.

9. The container of claim 1 or claim 8, wherein the ratio between the length of the flip-top attachment portion of the reclosable flap and the distance between the hinge line and the top rear edge of the consumer goods inner package can be no greater than 2.5.

10. A method of forming a container for consumer goods, the method comprising the steps of:

providing a consumer goods inner package comprising an access opening through which consumer goods can be removed, the access opening being covered by a reclosable flap, the reclosable flap being movable relative to the consumer goods inner package about a hinge line;

providing a blank and folding the blank about the consumer goods inner package for forming an outer shell having a hinged flap comprising a first flap panel and a second flap panel in a manner such that the first flap panel is movable relative to the second flap panel when the container is in use;

attaching the free end of the reclosable flap to the first flip panel such that, when the hinged flip is in a first open position in which the flip top wall is disposed generally perpendicular to the box rear wall, the first flip panel is generally perpendicular to the flip front wall,

wherein the hinge line is positioned at the top wall of the consumer goods inner package at a distance from the top rear edge of the consumer goods inner package that is substantially the same as or shorter than the length of the flip attachment portion of the reclosable flap, and the ratio between the length of the flip attachment portion of the reclosable flap and the distance between the hinge line and the top rear edge of the consumer goods inner package is comprised between 1 and 3.