US20170001790A1

US20170001790A1 - Cigarette packaging

Info

Publication number: US20170001790A1
Application number: US15/265,285
Authority: US
Inventors: Maui Kahawaiolaa; Paulette Sandra Soon
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-12-09
Filing date: 2016-09-14
Publication date: 2017-01-05

Abstract

An improved cigarette package is provided. The cigarette package first comprises a container which serves as a housing for a plurality of cigarettes. The housing is a rectangularly-shaped outer container formed from a blank. The package also includes a lid, which is hingedly connected to the container at an upper end. Opening and closing the lid provides selective access and closure to the container. The package further includes an inner layer of foil. The inner foil layer is configured to reside along an inner surface of the container. The package additionally includes a substrate. The substrate resides along an inner surface of the lid, and includes an adhesive material. When the lid is in a closed state, the distal end of the substrate generally mates with upper edges of an upper contour of a front surface of the container, while a tab has a distal end that matches an upper contour of the front surface of the inner lining above the front surface of the container, thereby enabling a one-step closure and seal for the cigarette package and thereby increasing the life of the cigarettes inside the box. A method of sealing a cigarette package is also provided herein.

Description

STATEMENT OF RELATED APPLICATIONS

This application is filed as a Continuation-In-Part of U.S. patent application Ser. No. 14/929,932. The parent application was filed on Nov. 2, 2015 and is entitled “Improved Cigarette Packaging, And Method For Assembling A Cigarette Package.”
The parent application, in turn, claimed the benefit of U.S. Provisional Appl. No. 62/089,331 filed Dec. 9, 2014. Both of these applications are incorporated herein in their entireties by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

BACKGROUND OF THE INVENTION

This section is intended to introduce various aspects of the art, which may be associated with exemplary embodiments of the present disclosure. This discussion is believed to assist in providing a framework to facilitate a better understanding of particular aspects of the present disclosure. Accordingly, it should be understood that this section should be read in this light, and not necessarily as admissions of prior art.

Field of the Invention

This invention relates generally to the field of cigarette boxes, particularly those of the hinged-lid type. More specifically, the invention relates to cigarette boxes having improved structure for preserving freshness of the contents.

General Discussion of Technology

Cigarette packs are marketed in different embodiments. The conventional structure of a cigarette pack includes a small box, which may be either a so-called soft box or a hard box. Such boxes form a housing for a plurality of cigarettes, such as 20 cigarettes, and may be fabricated from either a cellulosic material or a synthetic material such as plastic.
Cigarettes have a shelf life. Unfortunately, many cigarettes are not consumed until after extended periods of storage, transportation and retail presentation. In some cases, particularly where cross-country or international transportation is involved, a package of cigarettes may not be consumed for many weeks or even months after manufacture and packaging.
A box of cigarettes is generally good for a period of about one year from the date of manufacture (unless vacuum sealed in freezer storage, which is uncommon). After that one year, cigarettes will become stale and lose flavor. This is because the individual cigarettes become dry and brittle due to the evaporation of aromatic oils. Some stores and individuals use humidors that control humidity to preserve moisture and freshness of tobacco, but these generally are not used for off-the-shelf cigarettes. Further, humidors do not help tobacco packages while they are in transit.
To help maintain freshness, cigarette boxes are typically enwrapped by an outer wrapping made of a plastic foil. Such an outer wrapping keeps air and moisture out of the interior of the box. Cigarette boxes frequently also include an inner lining, which is fabricated from tin or other metal material. Thus, a multi-layer structure is provided to help maintain freshness of the tobacco products therein. Unfortunately, once the package is opened the seal offered by the outer wrapping is lost and the cluster of cigarettes is exposed to ambient conditions. This accelerates the drying of the cigarettes and the loss of aromatic oils.
Several patents have issued in the field of cigarette packaging. One example is U.S. Pat. No. 4,961,496 issued in 1990. This patent is entitled “Cigarette Pack, Especially Hinge-Lid Box.” This package includes a deformable partition within the box, the partition creating an inner waste compartment for the placement of used or partially-used cigarettes. This reduces the likelihood that smoked cigarettes would be tossed away in public streets. The '496 patent is not directed to preserving freshness of the tobacco contents other than the incidental effect of the partition preventing used cigarettes from contacting unsmoked ones.
Another example is U.S. Pat. No. 4,664,310 entitled “Blank for Parallelepipedal Boxes or Box Elements.” The '310 patent offers a “blank” for forming a parallelepipedal box for holding cigarettes. The box is constructed with a removal strip in such a manner that parallel tear lines extend through three connected wall sections of the blank. The patent is not directed towards increasing shelf life of the tobacco contents.
A need exists for an improved cigarette package that extends the shelf life for cigarettes or other smoke tobacco products. A need further exists for a cigarette package that, in one embodiment, does not rely upon a mechanical connection or a friction fit for securing a hinged lid to the box, but relies solely upon a releasable adhesive connection.

SUMMARY OF THE INVENTION

An improved cigarette package is first provided. In one embodiment, the cigarette package first comprises a container. The container serves as a housing for a plurality of cigarettes. In one aspect, the housing is fabricated from a compliant synthetic material such as a plastic material. In another aspect, the housing is fabricated from a somewhat rigid cellulosic material such as a light weight cardboard. In either aspect, the housing is a rectangularly-shaped outer container formed from a blank, and is configured to closely hold a plurality of cigarettes.
The package also includes a lid. The lid is pivotally connected to the container proximate an upper end. Opening and closing the lid provides selective access and closure to the container.
The package further includes an inner layer of foil. The inner foil layer is configured to reside along an inner surface of the container. The inner layer of foil is fabricated from a metallic material that maintains a generally air-tight and moisture-proof environment for the container, thereby holding in aromatic oils and moisture. In one embodiment, the layer of foil comprises aluminum, tin, nickel, or combinations thereof.
The package additionally includes a tab. The tab extends up from a back side of the container and resides along an inner surface of the lid. The tab is also fabricated from a moisture-proof material to increase the life of the cigarettes when the cigarettes are placed inside the box and the lid is in its closed position.
The package additionally includes a substrate. The substrate resides at least along an inner surface of the lid, and is also preferably fabricated from a moisture-proof material. The substrate includes an adhesive material applied along a distal end of the substrate as a coating. Preferably, the substrate comprises a cellulosic material or a plastic material, with the adhesive material applied as a thin coating thereon. For this reason, the substrate may be referred to as a “sticker.” Closing the lid causes the sticker to attach to a portion of the inner layer of foil (that is, an outer surface of the inner layer of foil) along a front of the package.
In one embodiment, a body of the substrate resides between the tab and the lid. The distal end of the substrate extends beyond the tab but along the inner surface of the lid. In one aspect, the sticker arrangement extends the life of the cigarettes by up to 20% or, more preferably, up to 30% or, more preferably still, greater than 40%.
In one aspect, the cigarette package further comprises an exterior layer of water-resistant foil. The exterior layer resides around the container. The exterior foil layer is preferably fabricated from a transparent, flexible polycarbonate material.
In any arrangement, the substrate comprises a distal end having a contour that matches an upper contour of a front surface of the container. In addition, the tab comprises a distal end having a contour that matches an upper contour of the front surface of the inner lining. This enables a one-step closure and seal for the cigarette package. In this respect, when the lid is pivoted from its open position to its closed position, the distal end of the substrate will mate with (or follow) the upper contour of the front surface of the container, while the distal end of the tab will mate with (or follow) the upper contour of the front surface of the inner lining. State another way, the lid is configured so that sealing and closing the lid is done in one step, and reciprocally opening and unsealing the lid is done in a single step.
A method of sealing a cigarette package is also provided herein. The method first includes providing a package of cigarettes. The package is designed in accordance with the packaging described above, in its various embodiments.
The method also includes:
opening the lid;
removing a cigarette from the container; and
moving the lid from an open position to a closed position to both close and seal the cigarette package in one step.
A method for assembling a cigarette package is also provided herein. The method first includes providing a blank of material to serve as an inner layer of foil. Preferably, the blank of material that serves as the inner layer of foil is fabricated from a moisture and aroma proof material, such as aluminum, tin, nickel or combinations thereof.
The method also includes providing a blank of material to serve as a container. The blank includes a lid portion. The container serves as a housing for a plurality of cigarettes. In one aspect, the housing is fabricated from a compliant synthetic material such as a plastic material. In another aspect, the housing is fabricated from a rigid cellulosic material. In either aspect, the housing is a rectangularly-shaped outer container formed from a blank, and is configured to closely hold a plurality of cigarettes upon assembly.
The method additionally includes providing a blank of material to serve as a tab. The tab is also fabricated from a moisture-proof material.
The method further includes providing a blank of material to serve as a substrate. Preferably, the substrate comprises a distal end having an adhesive material placed thereon.
The method also comprises adhering the blank of material that serves as the inner layer of foil to an inner surface of the container. The method then includes folding the blank of material that serves as the container, along with the adhered inner layer of foil, to form a three-dimensional rectangular housing. The method still further includes folding the blank of material that serves as the container to create a hinged lid for an end of the housing.
The method additionally comprises adhering the substrate to an inner surface of the lid. In one aspect, a body of the substrate resides between the tab and the lid, and the distal end of the substrate extends beyond the tab and along the inner surface of the lid. In this way, a one-step closure and seal system for the cigarette package, with the system being designed to increase the shelf life of the cigarettes when the cigarettes are placed inside the box, when the lid is closed at the top end. In one aspect, the system with the one-step adhesive substrate extends the life of the cigarettes, calculated from when the consumer first opens the package, by up to 20% or even up to 40%.
The method also includes placing a plurality of cigarettes into the housing, and releasably sealing the hinged lid to an outer front surface of the container.
Optionally, the method further comprises providing a water-resistant foil material, and wrapping the container with the water-resistant foil material to provide a moisture barrier. The exterior foil layer is preferably fabricated from a transparent, flexible polycarbonate material.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the present inventions can be better understood, certain drawings, charts, graphs and/or flow charts are appended hereto. It is to be noted, however, that the drawings illustrate only selected embodiments of the inventions and are therefore not to be considered limiting of scope, for the inventions may admit to other equally effective embodiments and applications.

FIGS. 1A and 1B are perspective views showing a known cigarette package design. This represents a hard box.

FIGS. 2A through 2H present a series of views of a cigarette package in accordance with the present invention, in one embodiment. The package is intended to illustrate a hard box as the container.

FIG. 2A is a perspective view of the cigarette package. The lid is shown in a closed position.

FIGS. 2B and 2C are front and back plan views of the cigarette package of FIG. 2A, respectively.

FIGS. 2D and 2E are left and right side plan views of the cigarette package of FIG. 2A, respectively.

FIGS. 2F and 2G are additional perspective views of the cigarette package of FIG. 2A. In FIG. 2F, the hinged lid is being moved from its closed position to an open position, revealing cigarettes within the container. In FIG. 2G, the hinged lid is in its fully open position. The cigarettes have been removed for illustration.

FIG. 2H is still another perspective view of the cigarette package of FIG. 2A. Here, certain internal components of the package are shown in exploded-apart relation.

FIGS. 3A through 3D present engineering views of “blank” materials used in forming the cigarette package of FIGS. 2A through 2H.

FIG. 3A is a plan view of a blank of material used to create a container for the package of FIG. 2A, in one embodiment

FIG. 3B is a plan view of a blank of material used to create a front portion of the container of FIG. 3A.

FIG. 3C is a plan view of a blank of material used to create the inner lining, or inner foil layer, for the package of FIG. 2A, in one embodiment. A sealing tab is shown there along.

FIG. 3D is a plan view of a blank of material used to create a substrate. The substrate receives an adhesive material at a distal end.

FIGS. 4A through 4H present a series of views of a cigarette package in accordance with the present invention, in an alternate embodiment. The package is intended to illustrate a soft box as the container.

FIG. 4A is a perspective view of the cigarette package. The lid is shown in a closed position.

FIGS. 4B and 4C are front and back plan views of the cigarette package of FIG. 4A, respectively.

FIGS. 4D and 4E are left and right side plan views of the cigarette package of FIG. 4A, respectively.

FIGS. 4F and 4G are additional perspective views of the cigarette package of FIG. 4A. In FIG. 4F, the hinged lid is being moved from its closed position to an open position, revealing cigarettes within the container. In FIG. 4G, the hinged lid is in its fully open position. The cigarettes have been removed.

FIG. 4H is still another perspective view of the cigarette package of FIG. 4A. Here, certain internal components of the package are shown in exploded-apart relation.

FIGS. 5A through 5C present engineering views of “blank” materials used in forming the cigarette package of FIGS. 4A through 4H.

FIG. 5A is a plan view of a blank of material used to create the soft outer container, in one embodiment.

FIG. 5B is a plan view of a blank of material used to create the inner lining, or foil, for the package of FIG. 4A, in one embodiment. A sealing tab is shown therein.

FIG. 5C is a plan view of a blank of material used to create the substrate. The substrate receives an adhesive material at a distal end.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

Definitions

As used herein, the term “blank” refers to a substrate that is folded along designated lines to form a three-dimensional object.

Description of Selected Specific Embodiments

The inventions are described herein in connection with certain specific embodiments. However, to the extent that the following detailed description is specific to a particular embodiment or a particular use, such is intended to be illustrative only and is not to be construed as limiting the scope of the inventions or claims.
FIGS. 1A and 1B are perspective views showing a design for a known cigarette package 100. The cigarette package 100 defines a container 110 for holding a plurality of cigarettes 150. In FIG. 1A, a few of the cigarettes 150 are shown extending from the container 110 for illustrative purposes.
The container 110 has a lower end 112 and an upper end 114. A lid 115 is hingedly connected to the container 110 at the upper end 114. A hinge line is shown at 116. It is understood that the hinge line extends along a back surface (not shown).
The lid 115 is movable from an open position wherein in a cigarette 150 may be accessed, to a closed position wherein the lid 115 seats on a shoulder 118. It is observed that while closing the lid 115 may limit contact of the cigarettes 150 with the air, it does not provide a moisture barrier or an air tight seal.
FIGS. 2A through 2H present a series of views of a cigarette package 200 in accordance with the present invention, in one embodiment. The package 200 is intended to illustrate a hard box as a container 210.
First, FIG. 2A is a perspective view of the cigarette package 200. A container 210 having a rectangular profile is first shown. The container 210 has a lower end 212 and an upper end 214. A lid 215 is disposed at the upper end 214. The lid 215 is pivotally connected to the container 210 through an integral hinge line 216. (The hinge line 216 is best seen in FIG. 2C.) Preferably, the lid 215 is integrally connected to the container 210 as shown in the blank of FIG. 3A.
FIGS. 2B and 2C are front and back plan views of the cigarette package 200 of FIG. 2A, respectively. In FIG. 2B, a front panel 210B of the container 210 is seen; in FIG. 2C, a back portion 210C of the container is shown. The front panel 210B includes a recessed portion (seen at 211 in FIG. 2F) that accommodates the lid 215 when the lid 215 is in its closed position.
It is also noted that a front portion 215B of the lid 215 is seen in FIG. 2B, while a back portion 215C of the lid 215 is visible in FIG. 2C. The hinge line 216 is also shown in FIG. 2C.
FIGS. 2D and 2E are left and right side plan views of the cigarette package 200 of FIG. 2A, respectively. In these views, the lid 215 remains in its closed position.
FIGS. 2F and 2G are additional perspective views of the cigarette package 200 of FIG. 2A. In FIG. 2F, the pivoting lid 215 is being moved from a closed position to an open position, revealing cigarettes 150 within the container 210. Arrow “O” indicates a direction of movement of the lid 215. In FIG. 2G, the pivoting lid 215 is in its fully open position. Here, the cigarettes 150 have been removed for clarity.
Additional details of the package 200 are presented in FIGS. 2F and 2G. First, it is noted that the container 210 includes a shoulder 218. The shoulder 218 defines a crease in the material forming the container 210. Above the shoulder 218 is the recessed portion 211. The recessed portion 211 has a front profile, or contour 213, contour 213 is generally rectangular or trapezoidal in shape. As is seen partially in FIG. 2G, and as will be described further below, the contour 213 matches a contour of a distal end 234 of a substrate 230 mounted to the interior surface of the lid 215. The substrate 230 has an adhesive material coated on the exterior or exposed surface opposite the lid 215. The adhesive material resides at the distal end 234. In this way, the lid 215 may be closed and sealed in one novel step, as described in more detail hereinafter.
Also visible in FIGS. 2F and 2G, wherein the lid 215 is open, is a front portion 225 of an inner lining 220. The front portion 225 includes a front notch, or upper contour 224. Again, the contour 224 is generally rectangular or trapezoidal in shape. The front portion 225 is part of a larger inner lining (seen more fully at 220 in FIG. 3C) that defines a layer of foil material. The inner lining 220 has an exterior surface with a peripheral margin portion 226 which is exposed above the recess portion 211. The inner lining 220 resides along a substantial portion of an inner surface 227 of the container 210. The inner lining 220 is fabricated from a material that is moisture proof. For example, the material may comprise aluminum, tin, nickel or combinations thereof. The lining 220 helps to maintain the aromatic oils and moisture of the cigarettes within the container 210, even after the package 200 has been opened by the consumer.
Also visible (at least partially in FIG. 2G) is a tab 240. The tab 240, in essence, is an extension of the inner lining 220, and extends up into an inner-surface 217 of the lid 215. The tab 240 is also fabricated from a moisture-proof material such as aluminum, tin, nickel or combinations thereof.
FIG. 2H is still another perspective view of the cigarette package 200 of FIG. 2A. Here, certain inner components of the package 200 are shown in exploded-apart relation. Of interest, the tab 240 is seen extending up from a back of the container 210. Behind the tab 240 is the substrate 230. In practice, the substrate 230 resides between the tab 240 and the under surface 217 of the lid 215. As noted above, the substrate 230 has a distal end 234 (seen also in FIG. 3D) that is exposed above the tab 240, and that receives the adhesive material, or then coating.
FIGS. 3A through 3D present engineering views of “blank” materials used in forming the cigarette package 200 of FIGS. 2A through 2H. These views provide fuller presentations of components.
FIG. 3A is a plan view of a blank of material used to create the container 210 for the package 200 of FIG. 2A, in one embodiment. The container 210 includes front 210B and back 210C panels. The container 210 also includes opposing side panels. Dashed lines show where the container 210 is to be creased during manufacture.
FIG. 3B is a plan view of a blank of material used to create the recessed portion 211 of the container 210 of FIG. 3A. Dashed lines again show where the material is to be creased during manufacture. A contour for the recessed portion 211 is shown at 219.
FIG. 3C is a plan view of a blank of material used to create the inner lining 220, or foil, in one embodiment. Dashed lines again show where the lining 220 is to be creased during manufacture. Opposing ends 221, 223 are folded over each other to form a base. The lining 220 also includes opposing side panels.
Along the blank material of FIG. 3C, and forming a top portion during manufacture, is a sealing tab 240, in one embodiment. Dashed lines show where the tab 240 is to be creased during manufacture. The sealing tab 240 includes distal end 244. The majority of the tab 240 resides along the under-surface 217 of the lid 215. However, the distal end 244 is exposed along the under surface 217 of the lid 215.
Finally, FIG. 3D is a plan view of a blank of material used to create the substrate 230. Dashed lines show where the substrate 230 is to be creased during manufacture. As shown in FIG. 3D, the substrate 230 has a proximal end 232 that preferably resides below the back panel 210C of the container 210. The substrate 230 also has a distal end 234. The distal end 234 has a contour that generally matches the contour 219 of the recessed portion 211 of the front cover 210B.
An area 235 near the distal end 234 of the substrate 230 is coated with an adhesive material. Coated area 235 lands on the front portion 225 of the lining 220 (at peripheral margin portion 226) when the lid 215 is moved to its closed position. In this way, the lid 215 may beneficially be closed and sealed in one step, meaning the lid 415 may be manually moved to its closed position wherein the distal end 244 of the tab 240 generally aligns with the contour 224 of the inner lining 220 to create a substantially complete enclosure of moisture proof material. The closure also automatically causes the adhesive material on substrate area 235 to land upon the margin 226 of the inner lining 220 about the contour 224, in the area between “notch” or contour 213 and contour 224, so that it seals the inner lining 220 and maintains the lid 215 in a closed position. At the same time, the contour of the distal end 234 generally follows the contour 213. Thus, the lid 215 is closed and the inner lining 220 is sealed in one movement or step, rather than having to manually seal an inner packaging prior to closing the outer packaging, as with the prior art.
FIGS. 4A through 4H present a series of views of a cigarette package 400 in accordance with the present invention, in an alternate embodiment. The package 400 is intended to illustrate a soft box as the container.
First, FIG. 4A is a perspective view of the cigarette package 400. A container 410 having a rectangular profile is first shown. The container 410 has a lower end 412 and an upper end 414. A lid 415 is disposed at the upper end 414. The lid 415 is pivotally connected to the container 410 through an integral hinge line 416, shown in FIG. 4C.
FIGS. 4B and 4C are front and back plan views of the cigarette package 400 of FIG. 4A, respectively. In FIG. 4B, a front panel 410B of the container 410 is seen; in FIG. 4C, a back portion 410C of the container 410 is shown. The front panel 410B includes an upper contour line (seen at 411 in FIG. 4F) that accommodates the lid 415 when the lid 415 is in its closed position.
It is also noted that a front portion 415B of the lid 415 is seen in FIG. 4B; however, there is no back portion of the lid 415 so no portion of the lid 415 is visible in FIG. 4C. The hinge line 416 is shown at the top of FIG. 4C.
FIGS. 4D and 4E are left and right side plan views of the cigarette package 400 of FIG. 4A, respectively. The lid 415 is shown in its closed position.
FIGS. 4F and 4G are additional perspective views of the cigarette package 400 of FIG. 4A. In FIG. 4F, the pivoting lid 415 is being moved from a closed position to an open position, revealing cigarettes 150 within the container 410. Arrow “O” indicates a direction of movement of the lid 415. In FIG. 4G, the pivoting lid 415 is in its open position. The cigarettes have been removed for clarity.
Additional details of the package 400 are presented in FIGS. 4F and 4G. First, it is again noted that the container 410 includes the upper contour line 411. As is seen partially in FIG. 4G, and as will be described more fully below, the contour line 411 matches a contour of a distal end 434 of a substrate 430 permanently mounted to the interior surface 417 of the lid 415 with an adhesive or the like. The substrate 430 has an adhesive material coated on the exterior or exposed surface opposite the lid 215. In this way, the lid 415 may be closed and sealed in one novel step, as described in more detail hereinafter.
Also visible in FIGS. 4F and 4G, wherein the lid 415 is open, is a front portion 425 of an inner lining 420. The front portion 420 includes a notch or upper contour 424. The front portion 425 is part of a larger inner lining (seen fully at 420 in FIG. 5B) that defines a layer of foil material. The inner lining 420 resides along a substantial portion of an inner surface 417 of the container 410. The inner lining 420 is fabricated from a material that is moisture proof. For example, the material may comprise aluminum, tin, nickel or combinations thereof. The lining 420 helps to maintain the aromatic oils and moisture within the container 410.
Also visible (at least partially in FIG. 4G) is a tab 440. The tab 440, in essence, is an extension of the inner lining 420, and extends up into the under-surface 417 of the lid 415. The tab 440 is also fabricated from a moisture-proof material such as aluminum, tin, nickel or combinations thereof.
FIG. 4H is still another perspective view of the cigarette package 400 of FIG. 4A. Here, certain components of the package 400 are shown in exploded-apart relation. Of interest, the tab 440 is seen extending up from a back of the container 410. Behind the tab 440 is the substrate 430. In practice, the substrate 430 resides between the tab 440 and the under surface 417 of the lid 415. The substrate 430 has a distal end (also shown best at 434 in FIG. 5C) that is exposed above the tab 440, and that receives the adhesive material.
FIGS. 5A through 5C present engineering views of “blank” materials used in forming the cigarette package 400 of FIGS. 4A through 4H. These views provide fuller presentations of components.
FIG. 5A is a plan view of a blank of material used to create the container 410 for the package 400 of FIG. 4A, in one embodiment. The container 410 includes front 410B and back 410C panels. The container 410 also includes opposing side panels. Dashed lines show where the container 410 is to be creased during manufacture.
FIG. 5B is a plan view of a blank of material used to create the inner lining 420, or foil, in one embodiment. Dashed lines show where the lining 420 is to be creased during manufacture. Opposing ends 421, 423 are folded over each other to form a base. The lining 420 also includes opposing side panels.
Along the blank material of FIG. 5B, and forming a top portion during manufacture, is a sealing tab 440, in one embodiment. The sealing tab 440 includes a distal end 444. The majority of the tab 440 resides along the inner surface 417 of the lid 415. Dashed lines show where the tab 440 is to be creased during manufacture.
Finally, FIG. 5C is a plan view of a blank of material used to create the substrate 430. Dashed lines show where the substrate 430 is to be creased during manufacture. As shown in FIG. 5C, the substrate 430 has a proximal end 432 that preferably resides below the back panel 410C of the container 410. As noted, the substrate 430 also has a distal end 434 that extends beyond the tab 440. The distal end 434 has a contour that generally matches the contour 411 of the front cover 410B.
An area 435 of the substrate 430 is thinly coated with an adhesive material. Area 435 lands on the front portion 425 of the lining 420 when the lid 415 is moved to its closed position. In this way, the lid 415 may be closed and sealed in one step, meaning the lid 415 may be manually moved to its closed position wherein the distal end 444 of the tab 440 generally aligns with the “notch” or contour 424 of the inner lining 420 to create a substantially complete enclosure of moisture proof material. The closure also automatically causes the adhesive material on substrate 430 to land upon the peripheral margin or margin portion 426 of the exterior or exposed surface of the inner lining 420 about the notch 424 so that it seals the inner lining 420 and maintains the lid 415 in a closed position. Thus, the lid 415 is closed and the inner lining 420 is sealed in one movement or step, rather than having to manually seal an inner packaging prior to closing the outer packaging, as with the prior art.
For both FIGS. 2H and 4H, the substrates 230, 430 (or stickers) and tabs 240, 440 are designed, fabricated and configured to extend the life of the cigarettes 150 within the package 200, 400. It is believed that the life of the cigarettes 150, calculated from when the consumer first opens the package, may be extended by up to 20%, or even up to 40%. It is also believed that the shelf life of the cigarettes 150 before the package is opened is also extended greatly. In the arrangement of FIGS. 2H and 3D, the distal end 234 of the substrate (or “sticker”) 230 is configured to follow a contour 213 of the recessed portion 211, while the distal end 244 of the tab 240 is configured to follow the upper contour 224 of a front portion of the inner lining 220. Similarly, in the arrangement of FIGS. 4H and 5C, the distal end 444 of the tab 440 is configured to follow the upper contour 424 of a front portion of the inner lining 420. These provisions allow for a greater degree of preservation of the tobacco products provided within the containers 210, 410.
A method of sealing a cigarette package is also provided herein. The method first includes providing a package of cigarettes. The packaging is designed in accordance with the packages 200, 400 described above, in their various embodiments.
The method also includes
opening the lid;
removing a cigarette from the container; and
moving the lid from an open position to a closed position to both close and seal the cigarette package in one step.
A method for assembling a cigarette package is also provided herein. The method first includes providing a blank of material to serve as an inner layer of foil. Preferably, the blank of material that serves as the inner layer of foil is fabricated from a moisture-proof material, such as aluminum, tin, nickel or combinations thereof.
The method also includes providing a blank of material to serve as a container. The blank includes a lid portion. The container serves as a housing for a plurality of cigarettes. In one aspect, the housing is fabricated from a compliant synthetic material such as a plastic material. In another aspect, the housing is fabricated from a rigid cellulosic material. In either aspect, the housing is a rectangularly-shaped outer container formed from folding the blank, and is configured to closely hold the plurality of cigarettes after assembly.
The method further includes providing a blank of material to serve as a substrate, or sticker. Preferably, the sticker comprises a body having a distal end. The sticker further comprises an adhesive material placed along the distal end. Preferably, the sticker is fabricated from a cellulosic material. The distal end of the sticker is preferably configured to closely follow the edges of the inner layer of foil material at the front of the container, so that a greater degree of insulative preservation is provided within the container.
The method also comprises adhering the blank of material that serves as the inner layer of foil to an inner surface of the container. The method then includes folding the blank of material that serves as the container, along with the adhered inner layer of foil, to form a rectangular housing for a plurality of cigarettes. The method still further includes folding the blank of material that serves as the container to create a hinged lid.
The method additionally comprises adhering an inner surface of the sticker to an under-surface of the lid. The material is designed to increase the shelf life of the cigarettes when the cigarettes are placed inside the box, when the lid is closed at the top end. In one embodiment, the sticker comprises aluminum, tin, nickel, or combinations thereof. The sticker enables a one-step closure and seal for the cigarettes.
The method also includes placing a plurality of cigarettes into the housing, and releasably sealing the hinged lid to an outer front surface of the container.
Optionally, the method further comprises providing a water-resistant foil material, and wrapping the container with the water-resistant foil material to provide a moisture barrier.
In the above method, a body of the substrate resides between the tab and the lid, and the distal end of the substrate extends beyond the tab and along the under-surface of the lid. In one aspect, the package further comprises an exterior layer of water-resistant foil residing around the container. The container may be fabricated primarily from a rigid cellulosic material or primarily from a synthetic material.
In one aspect, the lining comprises aluminum, tin, nickel, or combinations thereof. Additionally, the substrate comprises aluminum, tin, nickel, or combinations thereof, with an adhesive material applied along the distal end of the adhesive layer as a thin coating. The substrate may comprise a cellulosic material or a plastic material, with an adhesive material applied along the distal end of the adhesive layer as the coating.
In one embodiment, the front surface of the container comprises a recessed portion forming a shoulder on which the lid lands when the lid is pivoted to its closed position. The contour of the distal end of the substrate generally matches a contour of the exposed recessed portion.
A method for sealing a cigarette package is also provided herein. The method includes:

- providing a package of cigarettes, the package comprising:
  - a container formed from folding a blank, the container holding a plurality of cigarettes;
  - a lid portion pivotally connected to the container proximate an upper end to provide selective access to the cigarettes;
  - a moisture-proof lining residing along at least a portion of an inner surface of the container, the lining being fabricated at least partially from a metallic material, and the lining having a front portion that receives the lid when the lid is in a closed position;
  - a tab extending up from a back of the container and residing along an inner surface of the lid, the tab also being fabricated from a moisture-proof material to increase the shelf life of the cigarettes when the cigarettes are inside the box and the lid is in its closed position; and
  - a substrate residing and being exposed along an under-surface of the lid, wherein an adhesive material on the substrate releasably secures the lid to the front portion of the moisture-proof lining when the lid is in its closed position;
- wherein the substrate comprises a distal end having a contour that matches an upper contour of a front surface of the container, and the tab comprises a distal end having a contour that matches an upper contour of the front surface of the lining above the front surface of the container;

The method further includes:

- opening the lid;
- removing a cigarette from the container; and
- moving the lid from an open position to a closed position to both close and seal the cigarette package in one step.

As can be seen, an improved cigarette package is provided herein. The cigarette package operates to extend the life of a conventional package of cigarettes by at least 20% to 40%. While it will be apparent that the inventions herein described are well calculated to achieve the benefits and advantages set forth above, it will be appreciated that the inventions are susceptible to modification, variation and change without departing from the spirit thereof.

Claims

What is claimed is:

1. A cigarette package, comprising:

an outer container formed from a blank, the container configured to closely hold a plurality of cigarettes;

a lid pivotally connected to the container proximate an upper end to provide selective access to the cigarettes, the lid being movable between open and closed positions;

a moisture-proof lining residing within at least a portion of the outer container, the lining being fabricated from a metallic material, and the lining having a front surface that receives the lid when the lid is in its closed position;

a substrate fixedly coupled to and residing along the under-surface of the lid, wherein an adhesive material on the substrate releasably secures the lid to the front surface of the moisture-proof lining when the lid is in its closed position; and

a tab extending up from a back of the container and fixedly coupled to and residing along the substrate, the tab also being fabricated from a moisture-proof material to increase the shelf life of the cigarettes when the cigarettes are placed inside the box and when the lid is in its closed position; wherein:

the substrate comprises a distal end that received the adhesive material, and that has a contour that generally matches an upper contour of a front surface of the container, and

the tab comprises a distal end having a contour that generally matches an upper contour of the front surface of the lining above the front surface of the container,

thereby enabling a one-step closure and seal for the cigarette package.

2. The cigarette package of claim 1, wherein the container has a rectangular cross-section.

3. The cigarette package of claim 1, wherein:

a body of the substrate resides between the tab and the under-surface of the lid, and

the distal end of the substrate extends beyond the tab but terminates along the under-surface of the lid.

4. The cigarette package of claim 3, further comprising:

an exterior layer of water-resistant foil residing around the container.

5. The cigarette package of claim 3, wherein the outer container is fabricated primarily from a rigid cellulosic material.

6. The cigarette package of claim 3, wherein the outer container is fabricated primarily from a synthetic material.

7. The cigarette package of claim 3, wherein:

the tab extends up from a back of the lining, and is integral to the lining; and

the lining and connected tab are fabricated from a blank of moisture- and aroma oil-insulating material.

8. The cigarette package of claim 7, wherein the lining and connected tab comprise aluminum, tin, nickel, or combinations thereof.

9. The cigarette package of claim 7, wherein the substrate comprises aluminum, tin, nickel, or combinations thereof, with an adhesive material applied along the distal end of the adhesive layer as a coating.

10. The cigarette package of claim 7, wherein the substrate comprises a cellulosic material or a plastic material, with an adhesive material applied along the distal end of the adhesive layer as a coating.

11. The cigarette package of claim 3, wherein:

the front surface of the container comprises a recessed portion forming a shoulder on which the lid lands when the lid is pivoted to its closed position; and

the upper contour of the front surface of the container is an upper contour of the recessed portion such that the contour of the distal end of the substrate generally matches an upper contour of the recessed portion.

12. A cigarette package comprising:

an outer container configured to hold a plurality of cigarettes, the outer container having an exterior surface and a recess portion inwardly indented from the outer container exterior surface, the recess portion having a top edge and a first contour extending downwardly from the top edge on a front surface of the outer container;

a moisture-proof lining positioned within the outer container, said lining having a front surface that extends above the top edge and first contour of the recess portion to expose a peripheral margin portion of an exterior surface of the lining, said lining having a second contour generally spaced from the first contour;

a lid pivotally connected to the outer container at an upper back end of the outer container, the lid having an exterior surface and an interior surface, and the lid being movable between an open position and a closed position;

a tab coupled to the interior surface of the lid, the tab having a distal end being configured to conform with the second contour of the lining; and

an adhesive substrate coupled to the interior surface of the lid, said adhesive substrate residing along the interior surface of the lid and extending beyond the distal end of the tab, the adhesive substrate being configured to contact the lining between the first contour of the outer container and the second contour of the lining to provide a moisture-proof seal when the lid is in its closed position;

wherein the lid is thereby configured so that sealing and closing the lid is done in one step, and reciprocally opening and unsealing the lid is done in one step.

13. The cigarette package of claim 12, wherein the second contour follows a geometry of the first contour.

14. A cigarette package comprising:

an outer container configured to hold a plurality of cigarettes, the outer container having a top edge;

a moisture-proof lining positioned within the outer container, said lining having a front surface extending past the top edge of the outer container to expose a peripheral margin portion of an exterior surface of the lining, said lining having a notch to allow access to cigarettes within the lining;

a lid pivotally connected to the outer container at an upper back end of the outer container, the lid having an exterior surface and an interior surface, the lid being movable between an open position and a closed position;

a tab permanently coupled to the interior surface of the lid, the tab being configured to conform with the notch of the lining; and

an adhesive substrate permanently coupled to the interior surface of the lid, said adhesive substrate extending about at least a peripheral portion of the tab, the adhesive substrate being configured to contact the lining at a location upon the lining between the outer container top edge and the notch of the lining