GB2533593A

GB2533593A - Package

Info

Publication number: GB2533593A
Application number: GB1422989.2A
Authority: GB
Inventors: Hill Mark; Shaw Mark
Original assignee: Parkside Flexibles Europe Ltd
Current assignee: Parkside Flexibles Europe Ltd
Priority date: 2014-12-22
Filing date: 2014-12-22
Publication date: 2016-06-29

Abstract

A package 10 comprises a first flexible sheet part 1 and a second flexible sheet part 2, each flexible sheet part comprising a pair of longitudinal edges 4, 5 and a pair of side edges 8, 9. The package 10 has a first longitudinal seal 21 between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges 4, 5. The package 10 has a first edge seal 22 between the first flexible sheet part and the second flexible sheet part along, or adjacent to, one side edge of the sheet parts 8. The package 10 has a second edge seal 23 between the first flexible sheet part and the second flexible sheet part along, or adjacent to, the other side edge 9 of the sheet parts. The package 10 has at least one intermediate seal 24, 25 between the first flexible sheet part and the second flexible sheet part. The intermediate seal(s) 24, 25 form at least two separate compartments 11, 12,13. Each of the compartments 11, 12, 13 is openable independently of the other compartment(s). The package is foldable between an open configuration in which the compartments are in a side-by-side relationship and a folded configuration in which the compartments are stacked against one another.

Description

PACKAGE

Background

It is desirable that a packaged product remains fresh for as long as possible. One type of packaged product is a tobacco industry product, such as cigarettes.

A popular type of cigarette packaging comprises a container with a box and a hinged lid. A plastic film wrapper is initially provided around the container. After initial opening of the package, the plastic film is discarded. A disadvantage of this packaging is that the container offers little protection once the package has been opened for the first time. After opening the package, tobacco loses moisture and dries out, so affecting the smoking experience. The cigarettes can degrade before a user has had the opportunity to consume all of the cigarettes.

There is a requirement for alternative packaging. Summary This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

An aspect of the invention provides a package comprising: a first flexible sheet part; a second flexible sheet part, each flexible sheet part comprising a pair of longitudinal edges and a pair of side edges; a first longitudinal seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges; a first edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, one side edge of the sheet parts; a second edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, the other side edge of the sheet parts; and at least one intermediate seal between the first flexible sheet part and the second flexible sheet part, the at least one intermediate seal extending parallel to the first edge seal and the second edge seal to form at least two separate compartments; wherein each of the compartments is openable independently of the other compartment(s), and wherein the package is foldable between an open configuration in which the compartments are in a side-by-side relationship and a folded configuration in which the compartments are stacked against one another.

The first flexible sheet part and the second flexible sheet part may be parts of a continuous flexible sheet, with the second flexible sheet part folded against the first flexible sheet part along the second of the longitudinal edges.

The first flexible sheet part and the second flexible sheet part may be separate pieces of flexible sheet and the package may further comprise a fourth seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, the second of the longitudinal edges.

The package may further comprise a cut line along each of the at least one intermediate seals defining a line of weakness.

Each of the compartments may comprise an openable portion.

The openable portion may be resealable to provide a resealable opening in the compartment.

The flexible sheet may be a multi-layer laminate and the openable portion may be formed by cut lines in the layers of the first flexible sheet part, the cut lines being offset from one another to form the resealable opening.

The openable portion may be defined by: a first cut line in at least a first of the layers of the laminate defining a first flap portion; a second cut line in at least a second layer of the laminate defining a second flap portion, wherein the at least a first of the layers is different from the at least a second of the layers; wherein the second cut line is located within the first cut line, the arrangement of the first and second cut lines allowing the first flap portion and the second flap portion to be lifted together to create an opening in the laminate, the first flap portion separating from the second layer in a peripheral region of the first flap portion between the first and second cut lines, and wherein a resealable adhesive seal is provided between the peripheral region and the second layer of the laminate.

A perimeter of the openable portion may be defined by one of a cut line in at least one layer of the first flexible sheet part and a tear strip.

The openable portion may be a flap which is unitary with one of the flexible sheet parts The package may further comprise a support element within at least one of the compartments.

The package may further comprise a support element within each of the compartments.

The support element may be a tray.

The support element may be located on a side of the compartment adjacent the first flexible sheet part and the support element may have a cut out region which is at least partially aligned with an openable portion of the first flexible sheet part.

The compartments may include at least one compartment which is of a different width compared to other compartments.

The compartments may contain the same product, or at least one of the compartments may contain a product which is different from a product, or products, in other compartments.

The compartments may contain smoking articles.

The package may comprise three compartments in total, with two of the compartments containing seven smoking articles and one of the compartments containing six smoking articles.

The package may further comprise a retaining element to retain the package in a folded configuration in which the compartments are folded alongside one another.

The retaining element may be one of: an adhesive tab, a sleeve. The sheet may be a multi-layer laminate The laminate may comprise a foil or metallised layer.

Another aspect of the invention provides a method of forming a package comprising: providing a first flexible sheet part and a second flexible sheet part, each flexible sheet part comprising a pair of longitudinal edges and a pair of side edges; forming a first edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, one side edge of the sheet parts; forming a second edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, the other side edge of the sheet parts; forming at least one intermediate seal extending between the first seal and the second longitudinal edge to form at least two separate compartments, wherein each of the compartments is openable independently of the other compartment(s); filling the compartments with products; forming a first longitudinal seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges to seal the compartments; and wherein the package is foldable about the at least one intermediate seal.

Another aspect of the invention provides a method of forming a package comprising: providing a first flexible sheet part and a second flexible sheet part, each flexible sheet part comprising a pair of longitudinal edges and a pair of side edges; providing products at spaced apart positions on the first flexible sheet part; forming a first edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, one side edge of the sheet parts; forming a second edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, the other side edge of the sheet pads; forming at least one intermediate seal extending between the first seal and the second longitudinal edge to form at least two separate compartments, wherein each of the compartments is openable independently of the other compartment(s); forming a first longitudinal seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges to seal the compartments; and wherein the package is foldable about the at least one intermediate seal.

An advantage of at least one example package is that contents of the package remain fresher, as a smaller quantity of products are exposed to the surrounding environment once the pack is first opened. A compartment remains fresh until it is opened.

In an example where the package is used to contain smoking articles, the package has an advantage that a user only has access to a limited quantity of smoking articles at a 20 time.

In this specification, the term "resealable adhesive" means an adhesive which allows two surfaces to adhere to one another and which also allows the surfaces to be separated non-destructively from one another and to re-adhere to one another. An example of a resealable adhesive is a Pressure Sensitive Adhesive (PSA), such as a peelable PSA, where an adhesive bond is achieved by applying pressure to the adhesive.

In this specification, the term "resealed" means that two surfaces can be refastened to one another. A degree of sealing may be achieved between the two surfaces when they are refastened to one another. However, the term "resealed" does not require the two surfaces to form a fully airtight seal during the subsequent fastening of the surfaces.

The preferred features may be combined as appropriate, as would be apparent to a skilled person, and may be combined with any of the aspects of the invention.

Brief Description of the Drawings

Embodiments of the invention will be described, by way of example, with reference to the following drawings, in which: Figure 1 shows an example package with three compartments; Figure 2 shows location of seals in the package of Figure 1; Figure 3 shows a web of sheet material which can be used to form a package; Figures 4A-4C show examples of lines of weakness which can be defined in the flexible sheet; Figure 5 shows a sealed package; Figure 6 shows an example of a folded package; Figure 7 shows another example of a folded package; Figures 8 and 9 show examples of folded packages with a securing element; Figure 10 shows a tray for fitting inside a compartment; Figure 11 shows a partially-formed package with open compartments; Figure 12 shows the package of Figure 11 after product has been loaded into the compartments; Figure 13A shows an example of a three-layer laminate wrapper; Figures 13B-13D show a flap formed in the layers of the laminate wrapper of Figure 13A; Figure 14A shows an example of a two-layer laminate wrapper; Figures 14B and 14C show a flap formed in the layers of the laminate wrapper of Figure 14A; Figure 15 shows an example method of forming a package; Figure 16 shows another example method of forming a package.

Common reference numerals are used throughout the figures to indicate similar features.

Detailed Description

Embodiments of the present invention are described below by way of example only.

These examples represent the best ways of putting the invention into practice that are currently known to the Applicant although they are not the only ways in which this could be achieved. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.

Figures 1 and 2 show an example package 10 having three separate compartments 11, 12, 13. While a package having three compartments is described as an example, the package can have a minimum of two compartments, or a larger number of compartments. Each compartment 11, 12, 13 is openable independently of the other compartments. In Figures 1 and 2 each compartment has an openable portion 17. Initially, the three compartments 11, 12, 13 are joined together as one package.

In one example the package is formed from a single continuous sheet of material which is folded in two to form first and second flexible sheet parts. In another example, the package is formed from two separate pieces of sheet material, with one of the pieces being laid upon, and sealed to, the other piece. In each of these examples there is a first flexible sheet part 1 and a second flexible sheet part 2. The example using one continuous sheet will now be described in more detail although it will be understood that most features can also be applied to the example with two separate pieces of sheet material.

Figure 2 shows the location of seals in the package of Figure 1. The package is formed from a single continuous sheet of material 7 which is folded in two to form the package shown in Figures 1 and 2. Figure 3 shows a web 6 of flexible sheet material which can be divided along lines 4, 5 to provide a sheet 7 for forming a single package. The sheet 7 has two longitudinal edges 4, Sand two side edges 8, 9. The sheet 7 is folded along line 3 to provide a first flexible sheet part 1 and a second flexible sheet part 2. The first flexible sheet part 1 will be called the front face and the second flexible sheet part 2 will be called the back face in the following description. The flexible sheet material can have a single layer or multiple layers bonded together. A multiple layer material is called a laminate. The laminate can include a foil layer or a metallised layer which can serve as a moisture barrier.

A longitudinal seal 21 is formed between the front face 1 and the back face 2 along, or adjacent to, longitudinal edges 4, 5. A first edge seal 22 is formed between the front face 1 and the back face 2 along, or adjacent to, a first side edge 8. A second edge seal 23 is formed between the front face 1 and the back face 2 along, or adjacent to, the opposing side edge 9. An intermediate seal 24 is formed between the front face 1 and the back face 2 along a line extending between the folded edge 3 and the non-folded longitudinal edges 4, 5. An intermediate seal 25 is formed between the front face 1 and the back face 2 along a line extending between the folded edge 3 and the non-folded edges 4, 5. The intermediate seals 24, 25 are parallel to the edge seals 22, 23.

A first compartment 11 is defined by a fold along line 3, seal 21, seal 22 and seal 24. A second compartment 12 is defined by a fold along line 3, seal 21, seal 24 and seal 25. A third compartment 13 is defined by a fold along line 3, seal 21, seal 23 and seal 25. The perimeter of each compartment 11, 12, 13 is bounded by seals. Advantageously this provides a hermetically sealed environment for the packaged commodity, although a fully hermetically sealed environment is not essential. It will be understood that the total number of compartments in the package can be varied from three by varying the number of intermediate seals 24, 25. For example, three intermediate seals provides a total of four compartments. Each of the compartments 11, 12, 13 is openable independently of the other compartments.

Advantageously, an openable portion 17 is provided for each compartment. This allows an opening to be formed in a defined position in each compartment.

The seals 21, 22, 23, 24, 25 can be permanent seals. A permanent seal is a seal which provides structural integrity to a seam of the package and cannot easily be opened by a user. For example, it can be a strong adhesive bond, or a heat weld. An example of a permanent seal is where heat is applied to the sheet 7, causing the polymers of the sheet to melt and weld together giving a permanent seal.

Figure 2 shows seals along the edges 4, 5, 8 and 9, with the front face 1 and back face 2 pressed together in a face-to-face relationship and sealed together. It is also possible to form one or more of the seals 21, 22, 23 by folding one of the faces over the other face and forming the seal between the faces. For example, the sheet of material of the front face can be folded over the back face and a seal formed on the back face. In this case, the seal will be formed adjacent to the longitudinal edge or side edge. This can provide a more concealed seal and can help to reduce the size of the package as the seal regions shown around the periphery of the package of Figure 2 are avoided.

A cut line can be provided between the compartments to define a line of weakness 14, 15 in the sheet material. The cut line can be formed by a laser. The lines of weakness can be located on the seals 24, 25. A first line of weakness 14 is provided between compartments 11 and 12. A second line of weakness 15 is provided between compartments 12 and 13. Examples of a cut line defining a line of weakness are a perforated line, a score line, a scribe line and a crenellated line. The lines of weakness have two functions. Firstly, the lines of weakness can be useful for folding the package. A line of weakness can define a line along which the package is folded. The package will more readily fold about a line of weakness in the flexible sheet. Secondly, the lines of weakness can allow a compartment to be separated from a remainder of the package. In use, a force is applied to one compartment and the compartment will separate from the remaining compartment(s) along the line of weakness. A compartment may be separated before it is first opened, or after the contents have been used. Each seal 24, 25 extends each side of a respective line of weakness 14, 15. This maintains a proper seal of compartments on each side of the line of weakness when a compartment is separated from a remainder of the package along a line of weakness 14, 15.

Where the package is formed of a sheet having multiple layers, the line of weakness may be formed in one or more of the total number of layers. For example, the cut line may cut through one layer while leaving other layers intact. In another example, the cut line may cut perforations through multiple layers while leaving other portions of the layers along the cut line intact.

Figures 4A-4C show examples of cut lines to define lines of weakness. One of these cut lines can be used to define the lines of weakness 14, 15 between compartments. The cut line can, for example, be created by a laser. One or more properties of the cut line can be varied during the cut, such as the depth of cut. Each of the examples Figures 4A-4C shows a cross-section through flexible sheet material and a plan view of the sheet material.

Figure 4A shows a cut line which is discontinuous along the surface, as shown in the plan view. This type of cut line is a perforated cut line. The cut line comprises non-perforated portions 110 where the sheet material has not been cut and remains intact, as shown in the cross-section A-B. The cut line also comprises perforated portions 111 where the cut line extends fully through the sheet material, as shown in the cross-section C-D. The sheet material is weakened along the cut line. When a force is applied to the line of weakness, the force will rupture the non-perforated portions 110 and the sheet material will separate along the line of weakness.

Figure 4B shows a cut line which is continuous along the surface, as shown in the plan view. The cut line extends partially fully through the sheet material, as shown in the cross-section A-B. This type of cut line is a score line or scribe line. The layer is weakened along the cut line. When a force is applied to the line of weakness, the force will rupture the sheet material along the line of weakness.

Figure 4C shows a cut line which is continuous along the surface, as shown in the plan view. The cut line extends partially through the sheet material. The depth of the cut varies along the cut line. Two cross-sections are shown. At cross-section A-B the cut extends a first depth into the sheet material. At cross-section C-D the cut extends a second depth into the sheet material. The second depth is greater than the first depth. This type of cut line can be called a crenellated line. The line can alternate between the cut depths shown in the two cross-sections along the length of the line. The first depth may be zero, such that the line has some portions which are not cut at all, and some portions where the cut line extends partially into the sheet material. The sheet material is weakened along the cut line.

When a force is applied to the line of weakness, the sheet material will separate along the line of weakness.

In each of the examples 4A-4C, the cut line may be formed in one or more layers of the sheet material. For example, where the sheet material comprises a multiple layer laminate, the perforations of Figure 4A can be formed through the multiple layers of the sheet material. The score line shown in Figure 4B can be formed in a single layer of a multiple layer laminate, or can extend entirely through one layer of the laminate.

Figures 5 and 6 show an example of how the package can be folded to a folded configuration. Figure 5 shows the package 10 in an open configuration. The compartments 11, 12, 13 are in a side-by-side relationship. The package 10 can be folded into a folded configuration in which the compartments are stacked against one another, as shown in Figure 6. The three compartments 11, 12, 13 of the package 10 are folded together. Firstly, compartment 13 is folded onto compartment 12. Secondly, compartment 11 is folded onto the top of compartment 13. Figure 6 shows the completed package, viewed from the bottom end. This provides a more conveniently shaped package for storage.

Figure 7 shows another possible folded configuration. This is a 2-shaped configuration. Compartment 12 is folded against compartment 11, such that the back face of compartment 11 lies against the back face of compartment 12. Then, compartment 13 is folded against compartment 12 such that the front face of compartment 13 lies against the front face of compartment 12. There are other possibilities for a Z-shaped folded configuration.

Conveniently, the compartments can be of different sizes. In the example of Figure 6, the package holds smoking articles (e.g. cigarettes). Compartments 11 and 12 each hold seven cigarettes. Compartment 13 holds six cigarettes. The total number of cigarettes in the package is 7+7+6 = 20. This allows the package to hold the same number of cigarettes as a conventional cigarette box. The 7-7-6 relationship is similar to the way cigarettes are stored in a cigarette package, with two rows of seven cigarettes and one row of six cigarettes lying between the rows of seven cigarettes. The folded package 10 can have similar dimensions to a conventional cigarette box. Another possible configuration is four compartments each holding five cigarettes with a total capacity of twenty cigarettes.

Providing at least one compartment which is of a different size to the other compartments can help the compartments to fold more compactly. In the example shown in the drawings the smallest compartment, compartment 13, is located on the end of the package and is the compartment folded into the centre of the package. The larger compartments 11, 12 fold around the smaller compartment. The smallest compartment can be located at one end of the unfolded package, as shown in Figures 6 and 7, or the smallest compartment can be located between the largest compartments. One or more features of the package may be adapted to allow a package to fold more easily and/or more compactly. Possible features are: the type of line of weakness 14, 15 (score line, perforated line etc.), the width of the seals 24, 25; the location of the smallest compartment in relation to the larger compartment(s). For the folded configuration shown in Figure 6, it can be helpful to provide a wider seal 24 between compartments 11 and 12 compared to the seal 25 between compartments 12 and 13.

The package shown in Figure 6 or 7 can be provided with one or more elements which retain the package 10 in the folded configuration. Figures 8 and 9 show two possible examples of a final package, viewed from one end. Figure 8 shows a tab 31 secured between an outer face of compartment 11 and an outer face of compartment 12, on one side of the folded package. The tab can be formed of paper, card or a polymer material. The tab 31 can comprise a resealable adhesive seal which allows the tab 31 to be refitted when a user wishes to refold the package 10. Alternatively, the tab 31 may be removed or broken upon first opening of the package. The tab could be provided as a separate element or it could be incorporated into the package. For example, one of the flexible sheet parts 1, 2 can have a tab extending from one, or both, of the side edges 8,9, with re-sealable properties. In another example, a label can be provided as part of the package which can be peeled off (e.g. a lasered square of laminate which can peel off and be used as a sticker/label).

Figure 9 shows another example of retaining the package in a folded configuration. A sleeve 32 is fitted around the folded package. The sleeve 32 can be removed from the folded package at the time of first opening the package. Optionally, the sleeve can be refitted as many times as required, when the package is stowed between uses. Example materials for the sleeve are paper, card or a polymer material. Another possibility (not shown) is to fit the folded package within a container, such as a box or carton.

In the example shown in Figure 6 each compartment 11, 12, 13 contains an additional packaging element in the form of a tray 35. The tray 35 provides structural support to the compartment and to the overall package 10. The tray 35 can also serve as a carrier which retains the packaged product during assembly of the package. The tray 35 can retain the product as the tray is slid into a compartment, or while the flexible sheet is fitted around the tray. The tray 35 can provide a stable surface surrounding the opening in the compartment, which helps to form a more reliable seal. Figure 10 shows an example of a blank which can be used as the tray 35 shown in Figure 6. The tray 35 comprises a sheet of material, such as card, with a central panel 36 and flaps 37 located on each side of the panel 36. The flaps 37 can be folded inwardly to form side walls of the tray on each side of the panel 36. A cut out 38 is provided in the panel 36, near to a top edge of the panel 36. The cut out provides access to the product within the compartment. The region of the panel 36 around the cut out 38 provides a stable surface against which a user can reseal flap 17 of a compartment (Figure 1). In an alternative example, the compartments 11, 12, 13 may only contain products, without any additional packaging element.

The example described in Figures 1-3 shows a package formed of a single flexible sheet part which is folded into two along a longitudinal edge 3. In another example, the package is formed from two separate flexible sheet parts. This requires an additional seal along, or adjacent to, the longitudinal edge 3. The seal can be formed around the outside of the package, similar to seal 21 shown in Figure 2, or it can be formed more discretely by folding the first flexible sheet part 1 around the second flexible sheet part 2 and sealing the two flexible sheet parts together on the back face. The first flexible sheet part may be larger than the second flexible sheet part to provide additional material to form the fold.

Figures 11 and 12 show some stages of an example manufacturing process of the package. The package is partially assembled to form pockets to receive the products (Figure 11) before filling the pockets with products (Figure 12). Figure 10 shows the partially formed package. The sheet 7 shown in Figure 3 has been folded into two along fold line 3 and seals 22, 23, 24, 25 have been formed to define compartments 11, 12, 13. At this stage, the bottom ends of the compartments 11, 12, 13 are left open. Separately, products (e.g. cigarettes) are loaded into trays 35. Trays 35 containing cigarettes are fitted into the open ends of the compartments 11, 12, 13. The trays 35 simplify the loading of the loose products into the compartments. Figure 12 shows the package after the trays 35 have been fitted into the compartments 11, 12, 13. Subsequently, the compartments are sealed by forming the seal 21 (Figure 2) between the front face 1 and back face 2, adjacent edges 4, 5. In this example, the tray 35 is fitted such that the planar panel 36 of the tray lies alongside the front face 1 of the package. Figures 11 and 12 show the package viewed from the back face 2. Referring again to Figure 1, the cut out region 38 of the tray 35 can be seen through the opening 16 of compartment 11. The method shown in Figures 11 and 12 can also be applied to the example of the package with two flexible sheet parts. This will have a seal along edge 3 instead of a fold line.

Another example manufacturing process can form the package around the products. Products are laid in required positions on the first flexible sheet part 1 and then the second flexible sheet part 2 is folded over the products and first flexible sheet part 1. Seals 21-25 are formed. In another example manufacturing process, seals 22 and 23 are formed before loading products, and intermediate seals 24, 25 and seal 21 are formed after loading products.

Each of the compartments 11, 12, 13 has an openable portion 17. A perimeter of the openable portion 17 may be defined in some manner, such as by a cut line in at least one layer of the flexible sheet part 1. The cut line can be a line of weakness. That is, the cut line weakens the flexible sheet part such that, when force is applied to the openable portion 17, the openable portion 17 will open along the line of weakness. The line of weakness can, for example, be a score line, a scribe line or a perforated line. In another example the perimeter of the openable portion 17 may be defined by a tear strip. When force is applied to the tear strip the flexible sheet part 1 will rupture along the path of the tear strip to provide an openable portion 17 of the wrapper.

The openable portions 17 of the compartments 11, 12, 13 can be resealable. There are various ways of providing a resealable opening. A perimeter of the openable portion 17 can be defined, for example, by a cut line, a line of weakness or a tear strip. This creates an opening at the time of first opening the compartment. The openable portion 17 can comprise a flap in the flexible sheet part 1. The package can also comprise an adhesive label or similar element to reclose or reseal the openable portion 17 to the remainder of the flexible sheet part after the opening has been created. For example, the label may be larger than the flap 17. In an example where the flexible sheet part is formed of a multiple layer laminate, it is possible to provide a resealable opening within the layers of the laminate material, without the need for an additional label. This reduces the number of elements of the package and reduces the number of steps of the manufacturing process. This type of resealable opening is now described in more detail.

A multiple layer laminate can have two or more layers. An example three layer laminate is shown in Figure 13A, comprising: a first outer layer 200, an inner layer 201 and a second outer layer 202. The first outer layer 200 is bonded to the inner layer 201. The inner (e.g. foil) layer 201 is bonded to the second outer layer 202. The first outer layer 200 can be formed, for example, of a polymer material, such as a 20 micron orientated polypropylene (OPP). The inner layer 201 can be formed, for example, of a foil, such as a 9 micron Aluminium foil. A foil layer is particularly advantageous at providing a moisture barrier to maintain freshness. The second outer layer 202 can be formed of a polymer material, which may be the same as the first outer layer, or a different polymer material. The layers 200, 201, 202 can be laminated together utilising a permanent lamination adhesive. A resealable opening can be created in the laminate package by utilising a Pressure Sensitive Adhesive (PSA) 203 to bond the second outer layer 202 to the inner layer 201. The Pressure Sensitive Adhesive can be used between these layers locally in the region of the opening, or generally between these layers. In the example of Figures 13B, 13C, the second outer layer 202 will form the inside of a package formed of the laminate material. An opening is defined by cuts 205, 206, formed in the first outer layer 200 and the inner layer 201. The cuts are offset from one another, to define a region 210 where the first outer layer 200 can adhere to the inner layer 201. A first cut 206 is formed in the first outer layer 200 and the inner layer 201 but not the second outer layer 202. A second cut 205 is formed through the second outer layer 202 but not the layers 200, 201. Figure 13B shows the laminate, after the cuts 205, 206 are formed, from the second outer side (the inside of a package). Figure 13C shows the laminate, after the cuts 205, 206 are formed, from the first outer side (the outside of a package). The dashed lines indicate the location of cuts 205, 206 where the actual cut is not visible in the particular view as it is in a layer of material which is hidden from view.

The cuts 205, 206 form a flap of laminate material 207 which is unitary with the rest of the sheet 209 along the top edge 208 of the flap. The location of the two cuts 205, 206 defines an overlap region 210 in which layers of the flap extend over layers of the remainder of the package. The central area of the flap 207 is formed of all three layers while the edge of the flap, in the overlap region 210, is formed of inner layer 201 and first outer layer 200. In the overlap region the inner layer 201 of the flap is adhered to the second outer layer 202 which remains part of the rest of the material in that region due to the offset of the two cuts 205, 206.

Figure 13D shows the resealable opening of Figures 12A-12C in a partially opened position. The flap 207 has been pulled open to separate the overlap region 210. Area 300 therefore comprises the second outer layer 202. The PSA 203 remains adhered to the first inner layer 201 in area 302 as it has a greater affinity for that material than the material of the outer layers. As the flap 207 is opened, an opening 301 is created through the laminate material. The opening 301 may be resealed by pressing the edge region of the flap which carries the PSA on to the exposed area 300 of the second outer layer 202, to return the opening to the configuration shown in Figures 13B and 13C. The arrangement of cuts through selected layers and use of a pressure sensitive adhesive between two layers thereby allow the formation of a resealable opening in the laminate material without any additional components.

In an alternative embodiment, the edge region of the flap can be formed of only an outer layer as opposed to an outer and an inner layer as shown in the embodiment of Figures 13B-13D. To form a resealable opening, a first cut is formed in the first outer layer and a second cut is formed through the second outer layer and the inner layer. The central region of the flap comprises all three layers, but the edge of the flap in the overlap region is only formed of the first outer layer. The opening of this embodiment operates on the same principles as that of Figures 13B-130, but the separation in the overlap region is between the inner layer 201 and the first outer layer 200. This arrangement may give a different tactile feel to the opening as the edge of the flap will be thinner.

The pressure sensitive adhesive of any embodiments may be patterned to leave areas without any adhesive to make the flap easier to open. In particular, an area in the overlap region 210 may be left without any adhesive. The PSA 203 between the inner layer 201 and the second outer layer 202 can be patterned such that the region below the pull tab is free from PSA. The pull tab may therefore be easily lifted up and used to pull open the flap.

As will be appreciated the shape and design of the cuts may be varied according to the aesthetic and functional requirements of each design, provided the offset relationship of the first and second cuts is maintained to provide the overlap region 210. For example, different shapes may be utilised according to design, or the curvature and shape of the cuts may be selected to avoid tearing of the materials as the flap is opened. As the cut designs become more complex and/or the dimensions of the cut lines increase the time taken to form the openings may increase.

In a variation of the opening described above, a two-layer laminate may be utilised. The principles described above apply in the same way to such a laminate. Figures 14A-14C shows a two-layer laminate with a resealable opening. First layer 600 is bonded to second layer 601 with a PSA 602. To form the opening, a first cut 603 is made through first layer 600 but not the second layer 601, and a second cut 604 is made through second layer 601 but not the first layer 600. As explained hereinbefore, dashed lines indicate cuts through a layer which is not visible in a particular view. Second layer 601 will form the outside of a package formed from the laminate material. The resealable opening opens in the same way as the triple-layer laminate opening described above by pulling the flap 605 open to separate the layers around the overlap region 606. The PSA may be patterned as described hereinbefore to provide a pull-tab, and as noted above the shape and design of the cuts may be varied as required.

In any of the embodiments, a region adjacent an edge of the flap may be left free of adhesive to allow a user to more easily grasp the flap, without the need to separate the flap from the underlying layer of the laminate.

The above embodiments have been described in relation to a two-layer and three-layer laminates, but as will be appreciated any number of layers may be utilised. The layers of the laminate material may be selected to provide the desired mechanical and tactile performance. For example, a thicker material may give a better feel to a user opening the flap. Different aspects of the package may require different characteristics, requiring a design compromise to select an appropriate material. For example, the body of the package may preferably have a thicker material to give a more rigid package, whereas the flap may preferably use a thinner material to make opening the closure more tactile. The relative thicknesses of the materials may also affect the performance of the product. For example, thickening a metallic layer will have a different effect to thickening a plastic layer.

The PSA is selected such that a sufficient bond is formed to retain the flap in the closed position, while also allowing the flap to be opened by the application of an appropriate force. A PSA can be used to bond the layers in other regions away from the region that retains the flap. The strength of the PSA bond in regions away from the flap can be modified compared to the strength of the bond used for the flap region. Advantageously, the bond in regions away from the flap can be of higher strength to prevent delaminafion during use. The required bond may be achieved by the selection of an appropriate adhesive and/or by the amount of that adhesive utilised.

The package can be designed for any quantity of products and is not limited to the size and/or shape shown in the illustrated example. The package is not limited to a package for tobacco products and can be applied to a package for other types of products such as, for example, confectionery or foodstuffs.

Figure 15 shows an example method of packaging a product. At block 401 a sheet of flexible material, such as a laminate, is folded into two and sealed to create a partially completed package with open compartments, or pockets (e.g. as shown Figure 11). At block 402, the compartments are filled with product (e.g. as shown in Figure 12). At block 403 the compartments are sealed to provide a sealed package (e.g. as shown in Figures 1, 2, and 5.) At block 404 the package is folded (e.g. as shown in Figure 5). Optionally, at block 405 the folded package is secured by fitting a tab, sleeve or other securing element. The method shown in Figure 15 can also be applied to the example of the package with two flexible sheet parts. Block 401 is modified to form a seal along edge 3 instead of folding the flexible sheet material into two.

Figure 16 shows another example method of packaging a product. At block 501 a first flexible sheet part is provided. At block 502, products are added to the first flexible sheet part at spaced-apart positions. At block 503 a second flexible sheet part is fitted around the products and the first flexible sheet part. Seals are formed along the edges and between products to form compartments. Blocks 504 and 505 are the same as blocks 404 and 405 of Figure 15. In another example manufacturing process, seals 22 and 23 are formed before loading products, and intermediate seals 24, 25 and seal 21 are formed after loading products.

The flexible sheet 7 may be formed into a package at one manufacturing location. However, it is also possible that the flexible sheet 7 can be partially formed into the package during a first manufacturing stage at one location (for example, forming the partially-completed package shown in Figure 11) and then the remaining steps are performed during a further manufacturing stage at a different location.

It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.

Any reference to 'an' item refers to one or more of those items. The term 'comprising' is used herein to mean including the method blocks or elements identified, but that such blocks or elements do not comprise an exclusive list and a method or apparatus may contain additional blocks or elements.

The steps of the methods described herein may be carried out in any suitable order, or simultaneously where appropriate. Additionally, individual blocks may be deleted from any of the methods without departing from the spirit and scope of the subject matter described herein. Aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples without losing the effect sought.

It will be understood that the above description of a preferred embodiment is given by way of example only and that various modifications may be made by those skilled in the art. Although various embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention.

Claims

Claims 1. A package comprising: a first flexible sheet part; a second flexible sheet part, each flexible sheet part comprising a pair of longitudinal edges and a pair of side edges; a first longitudinal seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges; a first edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, one side edge of the sheet parts; a second edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, the other side edge of the sheet parts; and at least one intermediate seal between the first flexible sheet part and the second flexible sheet part, the at least one intermediate seal extending parallel to the first edge seal and the second edge seal to form at least two separate compartments; wherein each of the compartments is openable independently of the other compartment(s), and wherein the package is foldable between an open configuration in which the compartments are in a side-by-side relationship and a folded configuration in which the compartments are stacked against one another.
2. A package according to claim 1 wherein the first flexible sheet part and the second flexible sheet part are pads of a continuous flexible sheet, with the second flexible sheet part folded against the first flexible sheet part along the second of the longitudinal edges.
3. A package according to claim 1 wherein the first flexible sheet part and the second flexible sheet part are separate pieces of flexible sheet and the package further comprises a fourth seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, the second of the longitudinal edges.
4. A package according to any one of the preceding claims further comprising a cut line along each of the at least one intermediate seals defining a line of weakness.
5. A package according to any one of the preceding claims wherein each of the compartments comprises an openable portion.
6. A package according to claim 5 wherein the openable portion is resealable to provide a resealable opening in the compartment.
7. A package according to claim 6 wherein the flexible sheet is a multi-layer laminate and the openable portion is formed by cut lines in the layers of the first flexible sheet part, the cut lines being offset from one another to form the resealable opening.
8. A package according to any one of claims 5 to 7 wherein a perimeter of the openable portion is defined by one of: a cut line in at least one layer of the first flexible sheet part, a tear strip.
9. A package according to any one of claims 5 to 8 wherein the openable portion is a flap which is unitary with one of the flexible sheet parts.
10. A package according to any one of claims 5 to 9 wherein the flexible sheet is a multi-layer laminate and the openable portion is defined by: a first cut line in at least a first of the layers of the laminate defining a first flap portion; a second cut line in at least a second layer of the laminate defining a second flap portion, wherein the at least a first of the layers is different from the at least a second of the layers; wherein the second cut line is located within the first cut line, the arrangement of the first and second cut lines allowing the first flap portion and the second flap portion to be lifted together to create an opening in the laminate, the first flap portion separating from the second layer in a peripheral region of the first flap portion between the first and second cut lines, and wherein a resealable adhesive seal is provided between the peripheral region and the second layer of the laminate.
11. A package according to any one of the preceding claims further comprising a support element within at least one of the compartments.
12. A package according to claim 11 comprising a support element within each of the compartments.
13. A package according to claim 11 or 12 wherein the support element is a tray.
14. A package according to any one of claims 11 to 13 wherein the support element is located on a side of the compartment adjacent the first flexible sheet part and the support element has a cut out region which is at least partially aligned with an openable portion of the first flexible sheet part.
15. A package according to any one of the preceding claims wherein the compartments include at least one compartment which is of a different width compared to other compartments.
16. A package according to any one of the preceding claims wherein the compartments contain the same product.
17. A package according to any one of the preceding claims wherein the compartments contain smoking articles.
18. A package according to claim 17 wherein there are three compartments in total, two of the compartments containing seven smoking articles and one of the compartments containing six smoking articles.
19. A package according to any one of the preceding claims further comprising a retaining element to retain the package in a folded configuration in which the compartments are folded alongside one another.
20. A package according to claim 19 wherein the retaining element is one of: an adhesive tab, a sleeve.
21. A package according to any one of the preceding claims wherein the sheet is a multi-layer laminate.
22. A package according to claim 21 wherein the laminate comprises a foil or metallised layer.
23. A method of forming a package comprising providing a first flexible sheet part and a second flexible sheet part, each flexible sheet part comprising a pair of longitudinal edges and a pair of side edges; forming a first edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, one side edge of the sheet parts; forming a second edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, the other side edge of the sheet parts; forming at least one intermediate seal extending between the first seal and the second longitudinal edge to form at least two separate compartments, wherein each of the compartments is openable independently of the other compartment(s); filling the compartments with products; forming a first longitudinal seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges to seal the compartments; and wherein the package is foldable about the at least one intermediate seal.
24. A method of forming a package comprising: providing a first flexible sheet part and a second flexible sheet part, each flexible sheet part comprising a pair of longitudinal edges and a pair of side edges; providing products at spaced apart positions on the first flexible sheet part; forming a first edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, one side edge of the sheet parts; forming a second edge seal between the first flexible sheet part and the second flexible sheet part along, or adjacent, the other side edge of the sheet pads; forming at least one intermediate seal extending between the first seal and the second longitudinal edge to form at least two separate compartments, wherein each of the compartments is openable independently of the other compartment(s); forming a first longitudinal seal between the first flexible sheet part and the second flexible sheet part along, or adjacent to, a first of the longitudinal edges to seal the compartments; and wherein the package is foldable about the at least one intermediate seal.