TW201332858A - Container for consumer goods formed of a single laminar blank - Google Patents

Abstract

The present invention relates to a container for consumer goods. The container comprises an outer housing comprising a lid pivotable, about a hinge line extending across a back wall of the container, between a closed position and an open position, the lid having a first flap depending from a free edge of the lid and folded towards the interior of the container. The container also comprises an inner housing, having an opening, comprising a second flap depending from a free edge of the inner housing and folded towards the exterior of the container. The first and second flaps interact as the lid is moved between the open position and the closed position. The inner and outer housing are mounted such that the lid coincides with the opening of the inner housing. The outer housing and the inner housing are integrally formed from a single laminar blank.

Description

Container for consumer goods formed from a single sheet stock

The present invention relates to a novel container for consumer products. The invention also relates to a single sheet stock used to make a container for consumer products. This container also has a special use as a container for long strips of tobacco such as cigarettes.

It is conventional to package long strips of tobacco or other consumables in a container formed from a folded sheet stock. The container typically includes a housing and a cover. For example, long-length smoking articles (such as cigarettes and cigars) are usually stored in a covered package, and the package has a box for storing the contents of the package; and a cover The body is attached to the casing along a hinge line extending across the rear wall of the container. This cover is typically placed at the top of the housing and hinged along the rear wall of the container. Such packages are typically constructed from a one-piece sheet cardboard blank. In use, the cover is pivoted about the hinge line so that the package can be opened and thus the smoking article held in the case can be removed. The container may have an audible "click" function to allow the container to produce an audible sound when the package is opened or closed. Conventional containers of this type are sometimes subject to problems such as the cover and the housing being incorrectly aligned due to deformation of the cover and a gap being visible between the cover and the body portion on the front of the container. . This is sometimes referred to as the "smile" effect.

It is preferred to provide a novel and improved container. In particular, the container can preferably be assembled and efficiently filled using conventional methods and equipment. Installed. It is also preferred that the container has a rigid cover and a secure closure.

According to an aspect of the present invention, a container for a consumer product is provided. The container includes an outer casing, wherein the outer casing has a cover. The cover is pivotable between a closed position and an open position about a rear wall extending across one of the containers. The cover includes at least one first gusset that depends from a free edge of the cover and is folded toward the inside of the container. The container also includes an inner casing having an opening and including at least one second gusset depending from a free edge of one of the inner casings and being folded toward the outside of the container such that when the cover is moved The at least one first haptic and the at least one second cymbal will interact when between the open position and the closed position. The inner casing is mounted within the outer casing such that the cover can coincide with the opening of the inner casing, thereby allowing access to the opening of the inner casing when the cover is in the open position. According to the invention, the outer casing and the inner casing are integrally formed from a single sheet stock.

The term "interaction" is used throughout the application to indicate that the cover flap and the flap of the housing engage each other when the cover is in the closed position. The jaws thus operate to hold the cover more securely in the closed position. In addition, the cymbals can interact to produce an audible sound when the cover is opened or closed.

The word "coincidence" is used throughout the application to indicate that it has roughly the same space.

By providing a container formed from a single sheet stock, the container can be made using conventional machines. In addition, the provision of a cover flap improves the strength and rigidity of the cover and thus reduces the "smile" effect. Similarly, by providing a flap on the housing, a container with a more secure closure and an audible "squeak" during opening or closing can be provided.

The outer and inner casings may each include a front wall, a rear wall, a bottom wall, a top wall, a first side wall, and a second side wall. Preferably, at least one of the outer casing and the inner casing includes a top portion and a bottom wall.

The terms "before", "after", "upper", "lower", "side", "top", "bottom", "left", "right" and the like are used to describe a container implemented in accordance with the present invention. The nomenclature of the relative positions of the components refers to the container in an upright state having an opening for allowing the consumer product to be removed from the top end and a hinge at the rear. The wall behind the container includes the wall of the hinge line.

The term "longitudinal" refers to a direction from top to bottom or vice versa. The term "horizontal" refers to a direction perpendicular to the longitudinal direction.

The container is preferably a rectangular parallelepiped comprising two wider walls separated by two narrower walls.

"Hinged line" means a line that allows the cover to pivot about opening the container. A hinge line can be, for example, a fold line or score line that is positioned in the sheet forming the wall behind the container.

Preferably, the at least one first cymbal and the at least one second cymbal are folded such that the first and second cymbals are engageable when the cover is in a closed position. The first flap is preferably folded toward the inside of the container and can be attached to the inner wall of one of the covers. The strength of the cover can be increased by attaching the cymbal or each cymbal to the inner wall of the cover. Advantageously, providing such a flap or flaps will increase the strength of the front wall of the lid. Increasing the strength of the front wall of the cover will reduce the so-called "smile" effect influences. In addition to this, advantageously, providing such a flap or flaps will improve the visual aesthetic of the container by forming a so-called "blunt edge" or "printed edge". As used herein, the terms "blunt edge" and "printed edge" refer to an edge formed by folding rather than cutting.

The second flap is preferably folded toward the outside of the container and is preferably not tied to the outside of the container. More preferably, the free edge of one of the at least one first gusset is substantially aligned with the free edge of one of the at least one second gusset to engage the gussets when the cover is in the closed position. The first crotch panel and the second crotch panel are configured such that when the cover system is in the closed position, a gap in a range between about 0.1 mm to about 1 mm is provided at the edge of the first crotch panel Between the edge of the second cymbal. Preferably, the range is between about 0.25 mm and about 0.75 mm. More preferably, the range is between about 0.4 mm and about 0.6 mm.

Preferably, the first flap and the second flap are folded such that an audible sound is produced when the cover is moved from an open position to a closed position or from a closed position to an open position.

Preferably, when the lid system is in the closed position, the second flap is biased to the inside of the lid. When the lid system is in the closed position, the interaction between the first and second jaws can be improved by biasing the second flap against the inside of the lid. In addition, the audible sound produced when the lid of the container is opened or closed can also be improved.

Preferably, the at least one second flap is folded over an angle greater than 90 degrees, more preferably folded at an angle greater than 135 degrees, and more preferably folded at an angle of substantially 180 degrees.

The first crotch panel and the second crotch panel are preferably formed such that each crotch panel has at least three free edges. In other words, the jaws are only tied to the container along a single edge and are not tied to either side edge.

The container includes a plurality of first haptics adapted to interact with a plurality of second cymbals. Alternatively, the container includes a first cymbal and a plurality of second cymbals, or a plurality of first cymbals and a second cymbal. By providing this combination of the first and second cymbals, a very large number of cymbal combination configurations can be provided.

The container can include two first cymbals and two second cymbals. In this case, the tabs are configured such that a triangular recess can be centrally formed in the front wall of the cover when the tabs are folded toward the inside of the container. A pair of equal but opposite triangles are formed on the front wall of the container, and a plurality of corresponding second flaps can be provided on the free edge of the front wall.

Alternatively, a trapezoidal recess can be provided to provide a triangular shape that is offset from the center point and, in addition to other configurations, a straight edge that is not perpendicular to the side wall of the cover.

Preferably, at least one wall of the cover is integrally formed with the inner casing and the outer casing. More preferably, the wall behind the cover is integrally formed with the inner casing and the outer casing. Therefore, the hinge line of the container is formed in the rear wall of the outer casing and the rear wall of the inner casing, and thus the strength of the hinge can be advantageously improved.

The container may be constructed of any suitable material including, but not limited to, cardboard, cardboard, plastic, metal, or combinations thereof. Preferably, the first housing and the second housing are each composed of one or more folded sheet cardboard blanks, and the cardboard preferably has a thickness of between about 100 g/m ² and 350 g/m ² . The weight between the two.

As described above, the container constructed in accordance with the present invention may have a rectangular parallelepiped shape having a plurality of right angle longitudinal and right angle lateral edges. Alternatively, the container may include one or more circular longitudinal edges, circular lateral edges, beveled longitudinal edges, beveled lateral edges, or combinations thereof. For example, a container implemented in accordance with the present invention may include, without limitation:

- one or two longitudinal circular or beveled edges on the front wall and/or one or two longitudinal circular or beveled edges on the rear wall.

- one or two transverse circular or beveled edges on the front wall and/or one or two transverse circular or beveled edges on the rear wall.

- a longitudinal circular edge and a longitudinal beveled edge on the front wall and/or a transverse circular edge and a transverse beveled edge on the rear wall.

- one or two transverse circular or beveled edges on the front wall and one or two longitudinal circular or beveled edges on the front wall.

- two longitudinal circular or beveled edges on the first side wall or two transverse circular or beveled edges on the second side wall.

In the case where the container comprises one or more rounded edges and is made of a sheet stock, the blank preferably comprises three, four, five, six or seven score lines or fold lines so that it can be assembled Each of the rounded edges is formed in the container. The score lines or fold lines can be located on the inside of the container or on the outside of the container. Preferably, the score lines or fold lines are spaced apart from one another by a distance of between about 0.3 mm and 4 mm.

Preferably, the spacing of the score lines or fold lines is a function of the thickness of the sheet stock. Preferably, the spacing between the score lines or fold lines is about 0.5 to 4 times greater than the thickness of the sheet stock.

Where the container comprises one or more beveled edges, the beveled edges preferably have a width of between about 1 mm and about 10 mm, preferably between about 2 mm and about 6 mm. Alternatively, the container may comprise a double bevel formed by three parallel fold lines or score lines that are separated so that two different bevels can be formed on the edge of the container.

In the case where the container comprises a beveled edge and is formed from a sheet stock, the bevel may be formed by two parallel crease lines or score lines located in the sheet stock. The crease lines or score lines may be symmetrically disposed between the first wall and the second wall relative to the edge. Alternatively, the crease lines or score lines may be asymmetrically disposed between the first wall and the second wall relative to the edge such that the slope extends into the first wall more than to Inside the second wall.

Alternatively, the container has a non-rectangular cross section such as a triangular or hexagonal polygon, a semi-ellipse or a semi-circular shape.

The container practiced in accordance with the present invention has particular utility as a package for elongated tobacco articles such as cigarettes or cigars. It will be appreciated that the container of the present invention can be designed for many different sized smoking articles of conventional size, oversize, oversized, fine, ultra-fine, etc., by appropriately selecting their dimensions. Alternatively, other consumer products may be stored inside the container.

By appropriately selecting the size thereof, the container of the present invention can be designed to hold a different total number of smoking articles or smoking articles of different arrangements. For example, the container of the present invention can be designed to hold a total of between 10 and 30 cigarettes by appropriately selecting its size.

Cigarettes can be configured in different arrangements, depending on the total amount of smoking number. For example, the smoking article can be configured as a single column of six, seven, eight, nine or ten. Alternatively, the smoking article can be configured in two or more columns. The two or more columns may include the same amount of smoking. For example, the smoking articles can be configured to have two columns of five, six, seven, eight, nine or ten; three columns of five or seven; or four columns of four, five or six. Alternatively, the two or more columns may include at least two columns comprising different amounts of smoking articles from each other. For example, the smoking articles can be configured as: a row of five branches and a column of six branches (5-6); a column of six branches and a column of seven branches (6-7); a column of seven branches and a column of eight branches (7-8); In the middle column, five branches and two outer columns are six branches (6-5-6); one middle column is five branches and two outer columns are seven branches (7-5-7); one middle column is six branches and two outer columns are five branches (5 -6-5); one middle column of six branches and two outer columns of seven branches (7-6-7); one middle column of seven branches and two outer columns of six branches (6-7-6); one middle column of nine branches and The two outer columns are eight branches (8-9-8); or one middle column is six branches and one outer column is five branches and the other outer column is seven branches (5-6-7).

The container of the present invention can hold the same type or brand of cigarettes, or different types or brands of cigarettes. In addition, filterless smoking articles and smoking articles having a variety of different filters may be included, as well as having different lengths (eg, between about 40 mm and about 180 mm) and diameters (eg, between about 4 mm and about Smoke between 9 mm). In addition, the tobacco products may differ in taste strength, suction resistance, and total particulate matter transfer. Preferably, the size of the container conforms to the length of the smoking article and the arrangement of the smoking article. Typically, the outer dimensions of the container are greater than between about 0.5 mm and about 5 mm in size of the bundle or bundle of articles stored within the interior of the container.

The length, width and depth of the container of the present invention can be such that the final formed total size of the container can be approximated to a typical disposable hinge when the cover is closed. The size of the chain cover twenty cigarette packs.

Preferably, the container of the present invention has a height of between about 60 mm and about 150 mm, more preferably between about 70 mm and about 125 mm, wherein the height is measured from the bottom wall of the container. To its top wall.

Preferably, the container of the present invention has a width of between about 12 mm and about 150 mm, more preferably between about 70 mm and about 125 mm, wherein the width is measured from one of the side walls of the container. To the other side wall.

Preferably, the container of the present invention has a depth of between about 6 mm and about 150 mm, more preferably between about 12 mm and about 25 mm, wherein the depth is measured from the front wall of the container to At the rear wall (including the hinge between the box and the cover).

Preferably, the ratio of the height of the container to the depth of the container is between about 0.3:1 and about 10:1, more preferably between about 2:1 and about 8:1, optimally Between about 3:1 and about 5:1.

Preferably, the ratio of the width of the container to the depth of the container is between about 0.3:1 and about 10:1, more preferably between about 2:1 and about 8:1, optimally Between about 2:1 and about 3:1.

Preferably, the height of the rear wall of the cover is a ratio of the height of the rear wall of the outer casing to about 0:1 (the cover system is located at the top edge of the container) and about 1:1, more preferably Between about 1:5 and about 1:10, optimally between about 1:6 and about 1:8.

Preferably, the height of the front wall of the cover of the outer kit is a ratio of the height of the front wall of the outer casing to about 1:0 (the cover covers the entire front wall) and Between about 1:10, more preferably between about 1:1 and about 1:5, optimally between about 1:2 and about 1:3.

In the case where the container of the present invention contains a plurality of smoking articles, the container may additionally include a waste chamber, such as for soot or cigarette but also for other consumer products such as matches, lighters, extinguishing devices, breath fresheners or electronic devices. Such other consumer products may be attached to the outside of the container, may be contained within the container along with the smoking article, may be located in a separate compartment of the container, or may be a combination of these.

The outer surface of the container of the present invention may be printed, embossed, indented, or otherwise decorated with manufacturer's or brand identity, trademarks, slogans and other consumer information, indicators, and optional components such as Fresnel lenses ( Fresnel lens).

In the case where the container of the present invention comprises a bundle of cigarettes or other elongated smoking articles, the smoking articles are preferably wrapped in a liner such as a metal foil or metallized paper.

Once filled, the container of the present invention can be heat shrunk or otherwise covered in a conventional manner to a transparent polymeric film, such as high or low density polyethylene, polypropylene, oriented polypropylene, polychlorinated A combination of ethylene, a cellulose film, or the like. Where the container of the present invention is covered by the entire cover, the entire cover wrap may include one or more tear strips. In addition, the entire overlay package can be printed with images, consumer information, or other materials.

The present invention also provides a single sheet stock for forming a container as embodied in accordance with the present invention as described above. The sheet stock includes a first portion for forming an outer casing. This first part contains one or more cuts The cutting portion and a hinge line extending across the wall panel behind the cover portion to define the cover and the at least one first flap. The blank also includes a second portion for forming the inner casing. The second portion includes one or more cutouts for forming an opening in the inner housing and the second flap.

Preferably, the second portion is joined to the first portion along an edge of one of the side wall panels of the first portion.

The container of the present invention is adapted to be assembled from a single foil blank using conventional assembly methods and equipment, as described in detail below. For example, the container may be automatic assembly machine on Bergami ^® type smoking article package used for the group In one stand.

According to the present invention, there is also provided a method for assembling a container constructed in accordance with the present invention from a single sheet stock.

The sheet stock is first partially assembled by folding it along a longitudinal fold line and bonding the outer shell portions, the inner shell portion and the respective side walls of the inner frame to form an open end sleeve such that the inner shell The system is located inside the outer casing. This resulting open end kit can advantageously be flattened at this stage to facilitate efficient storage and transport.

In the same or a separate process from the portion, the consumer product will then be inserted into the inner casing via one of the open ends. Preferably, the consumer product is inserted into the bottom of the container. When the package that has been filled advances through an automated packaging machine, the substrates are preferably folded inwardly toward the consumer product by about 90 degrees. The glue is applied to the outer surface of the inner bottom plate.

After the application of the adhesive, the outer bottom plate is folded inwardly toward the inner bottom plate so that the outer bottom plate is adhered to the inner bottom plate.

During assembly of the container, the sheets from which the blank is formed to form the cover are also folded and bonded.

The invention will be further illustrated by way of example and with the accompanying drawings.

The container 100 shown in Fig. 1(a) is a rectangular parallelepiped and includes an outer casing 102 and an inner casing 104 mounted in the outer casing 102. The container also includes a cover 106 that is shown in the drawings in a closed position. The cover is fastened to one of the outer casings 102 at the hinge line on the rear wall of the container. A bundle of smoking articles (not shown) is stored in the inner casing of the container 100. The free edge of the cover is formed by folding a flap to the rear wall of the container and thereby creating a visually pleasing and reinforced blunt edge. In addition, the cover flap is configured to interact with a corresponding flap on a free edge of the outer casing (not shown). The interaction of the cover flap with the outer crotch panel produces an audible click when the cover is moved from the closed position to the open position and from the open position to the closed position. In addition, the jaws interact to provide a more secure closure of the cover.

Fig. 1(b) shows the container 100 of Fig. 1(a) in a state in which the lid 106 is partially opened. The outer casing flap 108 depends from the top edge of the front wall of the inner casing and is folded toward the outer side of the container. As previously described, the cover flap (not shown) is adapted to interact with the outer crotch panel 108. An audible sound is produced when the cover is moved from the closed position to the open position. This audible sound is a click that occurs as the cover flap passes through the outer casing.

As shown in FIG. 1(c), and as described above, the cover 106 is coupled to the hinge line 110 of the housing 102. As can be seen in the figures, the hinge line extends horizontally across the rear wall of the inner casing at a small distance from the top of the inner casing. In addition, the hinge line also extends across the rear wall of the outer casing such that the rear wall of the cover can include a wall extending from both the inner and outer casings.

Figure 1(d) shows a container with a lid in a partially closed position. In this position, during closure of the cover, the cover flap passes through the outer casing and again produces an audible sound. In addition, the tabs begin to merge and thus the cover is held more securely in the closed position.

Figure 1(e) shows a close-up view of the cross section of the front wall of the cover and the front wall of the outer casing when the cover is in the closed position. As can be seen, the inner surface of the cover acts on the outer crotch panel 108 and the crotch panel 108 engages the cover crotch panel 112 to more securely close the cover. The cover flap 112 is attached to the inner surface of the front panel of the cover.

In use, the user removes the smoking article stored in the container 100 by opening the lid 104. When the user opens the cover 106, sufficient force is required to act on the cover to ensure that the cover flap 112 can pass through the housing flap 108. As shown in Fig. 1(f) (not shown), the cover flap engaging the housing flap forces the housing flap to rotate about the housing flap hinge line 114. As a result, the front wall of the housing is turned toward the inside of the container. Once the cover reaches a critical point, approximately when the angle θ between the housing flap 108 and the front wall of the cover exceeds 90 degrees, the elastic front wall of the housing returns to its original position, and the cover Free to continue Open without hindrance.

As shown in FIG. 2, the single sheet stock 200 includes an outer portion 202 and an inner portion 204. The blank 200 is suitable for forming the container 100 as shown in Fig. 1. The outer portion 202 forms the outer casing 102 and includes a front wall panel 206, two side wall panels 208 and 210, and a rear wall panel 212. The front wall panel 206 includes a bottom wall panel 214 depending from the bottom edge of the front panel. The front wall of the cover 216 is formed in the front wall panel 206 by cutting. As can be seen, a cover flap 218 is also formed by the front panel 206 and overhangs from the front panel 216 of the cover. The cover top wall panel 220 depends from the front panel 216 of the cover. The cover side wall panels 222 and 224 are separately formed in the side wall panels 208 and 210 by cutting.

The outer rear wall panel 212 includes a bottom wall panel 224. The bottom panel is provided with an area for receiving adhesive so that the bottom panel 224 can be adhered to the inside of the bottom panel 214 during container manufacture. Thereafter the panel also includes a portion of the cover 106. The cover rear wall panel 226 depends from the top edge of the rear wall panel, and the cover top wall panel 228 depends from the cover rear wall panel 226. The hinge line 110 is shown between the outer rear wall panel 212 and the lid rear wall panel 226.

The inner portion 204 forms the inner casing of the container 100 and includes an inner front wall panel 230, an inner rear wall panel 232, and two inner side wall panels 234 and 236. The cover rear wall panel 238 is formed by a portion of the inner rear wall panel 232. The housing crotch panel 240 depends from the inner front wall panel 230. As can be seen, the housing flap 240 has a plurality of tapered edges. The inner side wall panels 234 and 236 also have a plurality of tapered free edges to ensure that the side wall panels do not interfere with the cover when the cover is opened or closed.

The outer portion 202 is along a side wall panel 210 and the interior The edge defined by the wall 232 is then connected to the interior 204.

Figure 3 shows a plurality of folding steps for making the container 100 from a single sheet stock 200. This single sheet stock 200 is formed into a container 100 by first folding the slabs 218 and 240. As shown in Fig. 3(a), the cover flap 218 is folded approximately 180 degrees toward the inside of the container and then attached to the inner surface of the front panel of the cover. The housing flap 240 is folded approximately 180 degrees toward the outside of the container.

As shown in Fig. 3(b), the inner front wall panel 230 is then folded about the fold line A toward the inside of the container. Figure 3(c) shows the side front wall panel 234 being folded about the fold line B towards the inside of the container. Figure 3(d) shows the front wall panel 206 being folded about the fold line C towards the inside of the container. The front wall panel 212 is fastened to the outer surface of the inner front wall panel 230. Finally, Figure 3(e) shows a pre-folded container that is tubular with an open end so that it can accommodate consumer products. A Bergami ^(TM) type machine is used to insert a consumer product into the housing and fold the top and bottom panels toward the inside of the container and tie them together to form a complete container 100.

The order in which the above forming steps are performed may be changed as appropriate.

In all figures, the dotted line represents the "folded" line, while the solid line represents the "cut" line.

100‧‧‧ container

102‧‧‧Outer casing

104‧‧‧ inner casing

106‧‧‧ Cover

108‧‧‧Shell film

110‧‧‧ hinge line

112‧‧‧ Cover film

114‧‧‧ hinge line

200‧‧‧Sheet blank

202‧‧‧External

204‧‧‧Internal

206‧‧‧ front siding

208, 210‧‧‧ side wall panels

212‧‧‧Back wall

214‧‧‧ bottom wall

216‧‧‧ cover

218‧‧‧ cover film

220‧‧‧cover top wall

222, 224‧‧‧ cover body wall panels

226‧‧‧ Cover back panel

228‧‧‧cover top wall

230‧‧‧ inner front panel

232‧‧‧inside siding

234, 236‧‧‧ inner wall panels

238‧‧‧ Cover back panel

240‧‧‧shell film

Figures 1(a) through 1(f) show views of a container implemented in accordance with an embodiment of the present invention.

Figure 2 shows a sheet stock suitable for forming the container shown in Figure 1.

Figures 3(a) through 3(e) show a method for folding a single sheet stock to form the container shown in Figure 1.

100‧‧‧ container

110‧‧‧ hinge line

Claims (15)

A consumer product container comprising: an outer casing comprising a cover pivotable between a closed position and an open position about a hinge line extending across a rear wall of the container, and the cover The body has a first gusset that depends from a free edge of the cover and is folded toward the inside of the container; and an inner casing having an opening and including a draping from the inner casing a second gusset at the edge and folded toward the outside of the container such that when the cover is moved between the open position and the closed position, the first cymbal and the second cymbal will interact. Wherein the inner casing is mounted within the outer casing such that the cover can coincide with the opening of the inner casing, thereby allowing access to the inner casing when the cover is in the open position The opening, and the outer casing and the inner casing are integrally formed from a single sheet blank. The container of claim 1, wherein the first cymbal and the second cymbal are folded such that the first cymbal and the second cymbal can be engaged when the cover is in the closed position. . The container of claim 2, wherein the free edge of one of the first cymbals is substantially aligned with the free edge of one of the second cymbals so as to engage the cover when the cover is in the closed position Wait for the picture. The container of claim 1, 2 or 3, wherein the first cymbal and the second cymbal are folded such that an audible one is emitted when the cover is moved from a closed position to an open position. The sound is loud. A container according to any one of the preceding claims, wherein the first cymbal and the second cymbal are folded such that an audible sound is produced when the cover is moved from an open position to a closed position. . The container of any one of claims 2 to 5 wherein the second flap is springed to the inside of the lid when the lid system is in the closed position. A container according to any one of the preceding claims, wherein the first crotch panel is attached to an inner wall of the cover. A container according to any one of the preceding claims, wherein the second crotch panel is folded at an angle greater than 90 degrees. A container according to any one of the preceding claims, wherein the second crotch panel is folded at an angle greater than 135 degrees. A container according to any of the preceding claims, wherein the second flap is folded at an angle of substantially 180 degrees. A container according to any one of the preceding claims, wherein the first crotch panel and the second crotch panel each have at least three free edges. A container according to any one of the preceding claims, wherein the container comprises a plurality of first crotch sheets adapted to interact with a plurality of second crotch panels. A container according to any of the preceding claims, wherein the inner casing comprises a plurality of smoking articles. A single slab blank for forming a container according to any of the preceding claims, the blank comprising: a first portion for forming the outer casing, wherein the first portion comprises one or more cut portions With an extension spanning the cover portion a hinge line of one of the rear panels to define the cover and the first cymbal; and a second portion for forming the inner casing, wherein the second portion includes one or more cutouts for The opening in the inner casing and the second gusset are formed. A single sheet stock of claim 14 wherein the second portion is joined to the first portion along an edge of one of the side panels of the first portion.