Hinged Lid Packaging

This application is a continuation patent application of U.S. patent application Ser. No. 17/901,091, filed Sep. 1, 2022, which is a continuation patent application of U.S. patent application Ser. No. 16/218,918, filed Dec. 13, 2018, which is a divisional patent application of U.S. patent application Ser. No. 15/235,492, filed Aug. 12, 2016, which is a continuation patent application of U.S. patent application Ser. No. 15/172,898, filed Jun. 3, 2016, which issued as U.S. Pat. No. 10,059,506 on Aug. 28, 2018, which is a divisional patent application of U.S. patent application Ser. No. 13/325,803, filed Dec. 14, 2011, which issued as U.S. Pat. No. 9,382,062 on Jul. 5, 2016, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 61/422,975 filed Dec. 14, 2010, the entire contents of each of which is incorporated by reference herein.

The disclosure relates to a packaging container having an inner packaging container adapted to hold a number of consumer items, and in particular to a hinged lid packaging container having an inner resealable packaging container, preferably for accommodating smokeless tobacco pouches or pre-portioned smokeless tobacco (all referenced as “portions of smokeless tobacco”).

Smokeless tobacco products are sold in round metal, plastic or paperboard cans which have removable metal or plastic lids. However, different forms of packaging may appeal and provide conveniences to consumers such as smokers more familiar with hinged-lid packaging.

Disclosed herein is a combination of a resealable inner box and outer box packaging arrangement, particularly suited for smokeless tobacco products.

According to one embodiment, a pack for consumer goods comprises an outer packaging container and an inner packaging container. The outer packaging container includes a generally rectangular lower box portion with an upper lid portion hingedly connected thereto for movement between opened and closed positions, said box defining an inner box width; wherein said upper lid portion includes a lid back panel, a lid front panel, and a lid top panel. The inner packaging container includes a generally rectangular box having a dispensing opening with a resealable closure; wherein the rectangular box includes a front panel, a back panel, a top panel, a bottom panel, and opposing side panels; wherein each said side panel includes an inner panel and an outer panel, said inner panel having a first width defining a width of the inner packaging container, and said outer panel including at least a portion having a second width defining a width greater than the first width. The second width is greater than the inner box width in one embodiment. The inner packaging container is insertable within said outer packaging container.

According to another embodiment, a blank for forming an inner packaging container for insertion into a hinged lid box comprises a front panel defined by a first pair of parallel first and second score lines and a second pair of parallel third and forth score lines; a bottom panel connected to the front panel along the first score line and further including first top and first bottom flaps connected at top and bottom score lines; an outer left side panel connected to the front panel along the third score line; an outer right side panel connected to the front panel along the fourth score line; a top panel connected to the front panel along the second score line and further including second top and second bottom flaps connected at top and bottom score lines and a fifth score line parallel to the second score line; a back panel connected to the top panel along the fifth score line and further including a sixth score line parallel to the fifth score line thereby forming a third pair of parallel score lines, and a fourth pair of parallel seventh and eighth score lines; an inner left side panel connected to the back panel along the seventh score line; an inner right side panel connected to the back panel along the eighth score line; and a glue flap connected to the back panel along the sixth score line. The inner left and right side panels have a first width defining a width of the inner packaging container and at least a portion of said outer left and right side panels have a second width greater than the first width.

Referring to, a packis described herein, the packcomprising an outer packaging container (outer box)having an inner packaging container (inner box)therewithin. When the packis adapted for containing discrete portions of smokeless tobacco, the outer box is configured preferably smaller than a traditional cigarette hinged lid box and can have a height of about 3 inches, a width of about 2 inches and a depth of about ¾ inch. The inner box is sized to fit snugly in the outer box as described below. As used herein in connection with dimensions, “about” means ±10%.

The packis adaptable for containing other articles, such as smoking articles, in which case the overall dimensions may mimic customary dimensions of existing hinge lid boxes.

Outer packaging containeris preferably a hinged lid type of container formed from a paper or paperboard blank. As best shown in, the blank for outer packaging containercomprises a front panel; a back panel; a left side panelconnected between a side edge of the back panelalong a longitudinal fold lineand a side edge of the front panelalong a longitudinal fold line; a right side panelconnected to an opposite side edge of the front panelalong another longitudinal fold line; and a glue flapconnected to an opposite side edge of the back panelalong longitudinal fold line. When folded, as described in greater detail below, glue flapis glued to an inner surface of side panelto form a rectangular shape. As used herein, the term “glued” should be understood to include any type of gluing, securing, thermal sealing or otherwise adhering one surface to an opposing surface.

The outer packaging containerfurther includes an inner top closure panelconnected to the back panelalong a transverse fold line; an outer top closure panelconnected to the front panelalong a transverse fold line; an inner bottom closure panelconnected to the back panelalong a transverse fold line; and an outer bottom closure panelconnected to the front panelalong a transverse fold line. When folded, inner top closure panelis adhered to an inner surface of outer top panel closure paneland inner bottom closure panelis adhered to an inner surface of outer bottom closure panel.

Outer packaging containeralso comprises upper and lower dust flaps,connected to left side panelalong upper and lower transverse fold lines,, respectively, and upper and lower dust flaps,connected to right side panelalong upper and lower transverse fold lines,, respectively.

As mentioned above, outer packaging containeris preferably a hinged lid type of container in that a pivotable hinged lid portionis provided in order to gain access to the contents therein. In order to obtain this functionality from a one-piece blank, the blank is pre-cut to define the perimeter of hinged lid portion. As best illustrated in, hinged lid portionis preferably formed by cut linealong glue flap, cut linealong side panel, cut lineacross the front panelwhich defines the hinged lid front panelthereabove, and cut linealong side panel. Cut lines,,andthat define the hinge lid include “nicks” or “breaks”at spaced locations such that correlated adjoining panels remain connected through folding, gluing, erecting and loading, until the consumer chooses to break open the lid of a completed pack. In addition, a score lineis provided along back panelto define the hinge between the upper lid back paneland the lower portion of the back panelsuch that the hinged lid portionis pivotal about score line. The outer box is not limited to the exact shape and angles illustrated for hinged lid portion, as one skilled in the art will appreciate that other configurations of the same are possible. For example, the cut extending across front paneland defining the front panel of hinged lid portion may optionally include a semi-circular cut-away portionbelow cut lineso as to form a thumb notch (cutaway) region allowing easy opening of hinged lid portion; the cut linepreferably extends straight across the front panel. Any other configuration may be used.

The outer blankis a blank configuration which is laterally folded and “glued” to form the intended box structure.

As best shown in, a paper or paperboard blank for inner packaging containercomprises a front panel; a back panel; a top panelconnected between a top edge of the back panelalong a longitudinal fold lineand a top edge of the front panelalong a longitudinal fold line; a bottom panelconnected to a bottom edge of the back panelalong another longitudinal fold line; and a glue flapconnected to a bottom edge of the front panelalong longitudinal fold line. When folded, as described in greater detail below, glue flapis adhered to an inner surface of the bottom panelto form a rectangular shape.

The inner packaging container blankfurther includes an inner side closure left panelconnected to the back panelalong a longitudinal fold line; an outer side closure left panelconnected to the front panelalong a longitudinal fold line; an inner side closure right panelconnected to the back panelalong a longitudinal fold line; and an outer side closure right panelconnected to the front panelalong a longitudinal fold line. When folded, inner side closure left panelis adhered to an inner surface of outer side closure left panel closure paneland inner side closure right panelis adhered to an inner surface of outer side closure right panel.

Inner packaging container blankalso comprises left and right side dust flaps,connected to bottom panelalong left and right longitudinal fold lines,, respectively, and left and right dust flaps,connected to top panelalong left and right longitudinal fold lines,, respectively.

Inner packaging container blankfurther comprises a dispensing doorwhich is provided to allow access and removal of the contents within inner packaging container. Dooris formed by establishing the perimeter thereof preferably with a score linelocated partially across a central portion of the upper back paneland with a perforated cut lineinto central portions of the front and top panelsandof the inner packaging container blank, as shown best in. As illustrated therein, fold lines,extend across doorand the score lineis provided along a rear edge of door, thus allowing doorto be opened and reclosed in a foldable manner. In one embodiment, the dispensing dooris also covered by a resealable label, thereby permitting inner packaging containerto be resealed after the initial opening by the consumer. Resealable labelmay comprise a single layer of polymer material and include a permanently tacky material on one side thereof, permanent bonding adhesive, or the like, permitting repeated opening and closing of dispensing door, or any other suitable reclosing mechanism. Preferably, a permanent bonding adhesive may cover the undersurface of labelwhich superposes the door, and, preferably, edge portions of the labelbeyond the edges of dispensing doorare provided with a peel-and-reseal adhesive sufficient to maintain a sealed closure.

Alternatively, the doormay be an opening of the same or comparable perimeter of linesand, covered only by a label.

The left and right outer side closure panels,of the inner packaging containerhave an upper side width “W” that is slightly greater than the lower side width “W” thereof. The upper side width Wof the left and right side closure panels,is also slightly greater than the side width “W” of the left and right inner side closure panels,, the width Wthereof preferably being substantially equal to width W. Moreover, the upper side width Wof the left and right side closure panels,is also slightly greater than the inner width defined within outer packaging container. As a result of the slightly greater width Wof the upper portion of the left and right outer side closure panels,, when inner packaging containeris folded, glued and sealed, the inner packaging containercomprises rearwardly projecting flanges, as best shown in. The projecting flangescooperate with other features of the boxto assure and retain a complete closure of the lidof the outer packaging container.

More particularly, in one preferred embodiment, flangeshave a gradually increasing width from Wto Wwhich feature facilitates insertion of an erected inner box into an erected outer box. Referring now to, preferably, each outer side panel,includes from top to bottom: an operative flange portionof a width W; a transition portionand a lower portionof a width W. Preferably, the operative flange portion includes straight, rear flange edgewhich extends from a rounded, upper rear corner portionof the side panels,to the inclined edgeof the transition portion. The length of the straight flange edge(or the flange portion) may be adjusted both as to relative position and/or length so as to achieve a desired biasing effect regardless of variations in relative dimensions and materials of a particular pack. Generally, a longer flange edgewill increase biasing force against the inner surfaces of the lid during and upon reclosure of the lid. In the preferred embodiment, the operative flange portion, the transition portionand the lower portionare of essentially equal length (from a direction of top to bottom of the pack).

The flange portionand its biasing action also serve in essence to “lock” the inner boxwithin the outer boxwith a friction fit such that the inner boxremains steadfast during handling by the consumer, even when the lid has been opened and product is removed. In addition, a small amount of adhesive (not shown) can be applied between the exterior surface of the bottom of the inner boxand the interior surface of the bottom of the outer boxto further assure the desired positioning of the inner boxwithin the outer box.

Preferably, both the outer boxand the inner boxare constructed of 12 or 14 point paper board, preferably 12 point board is used for the inner boxand 14 point board is used for the outer box. Most preferably, a laminated or metalized board is used in the construction of the inner box, which promotes product stability and shelf life and serves as a barrier against transfer of adhesives, inks or other agents from either of the boxes to the product to be contained therein.

In a preferred embodiment, the outer box has a height of about 3 inches, a width of about 2 inches and a thickness of about ¾ inch, more preferably 2 15/16 inches×2 inches× 11/16 inch. The hinge lidcan have a height of about 1 inch at the front of the outer box and the hinge line at the rear of the box can be located about 1¾ inches from the bottom of the outer box. To snugly fit within the outer box, the inner box preferably has a height of about 2 13/16 inches, a width of about 1⅞ inches and a thickness of about ⅝ inch. The inner boxpreferably holds about fifteen portions of smokeless tobacco. The doorcan have a width of about 1¼ inches at hinge lineand length of about 1½ inches from the hinge lineto a free end of the door. The door is more narrow at the free end with side edges tapering inward 4 to 5° and joining the free end at rounded corners having a radius of about ⅜ inch. The flangespreferably have a length of about 1¼ inches and extend outwardly from the rear of the inner box by about 1/16 to ⅛ inch and ends of the flanges are rounded with a radius of about ⅛ inch.

In a preferred embodiment, the inner boxis approximately of a same height as that of the outer box(with accommodation for the layers of board at the upper and lower panels of the outer box). It is envisioned that with the inclusion of flanges(or comparable arrangement to bias an upper edge portion of the inner box), the inner boxmay be of a height less than that comparable to the outer box.

Referring to, when inner packaging containeris loaded into outer packaging containerduring manufacture or after a consumer removes the inner packaging to remove product therein and then places the inner packaging back in the outer packaging, the rearwardly projecting flangesengage the back panelnear the side panels of the outer packaging containerclose to fold linesand. The engagement of the rear flangeswith the back panel of the outer packaging containercauses the upper portion of inner packaging containerto be biased forward toward the front panelof the outer packaging container. As a result, when the hinged-top portionof the outer packaging containeris reclosed, the inside face of the front lid panelslidingly engages upper front face portionof the inner boxsuch that position of the inner packaging containerassists in securing and maintaining the hinged-top portionin a closed position, as shown in. The width Wcan be selected as desired to define a width greater than width Wand the inner width within outer packaging container, so long as inner packaging containercan still be inserted within outer containerand the hinged lid top portionmaintains the desired closed position.

A method of making the packaccording to one embodiment is described below.

Referring to, a flat blank for the inner packaging container blankis provided and the resealable labelis disposed over the dispensing door. As shown in, inner packaging container blankis folded by first pre-breaking fold lines,and then folding the blank 180° along fold linesandso as to form a collapsed, erectable structure. In so doing, the outer surface of glue flapis glued to the inner surface of bottom panel. Inner packaging container blankis then erected from the collapsed, erectable structureby, for example, squeezing the top and bottom surfaces to erect the boxinto an open, rectangular structure. Alternatively, the open, rectangular structurecan be obtained by applying suction to the front and back surfaces of the collapsed, erectable structurealone or in combination with the squeezing. One side of the open, rectangular structureis then also folded and glued to form a partially closed structure. In the illustrated embodiment, dust flapsandare folded along fold linesand, respectively, and then an outer surface of right side inner closure panelis glued to an inner surface of right side outer closure panelso as to seal the right side of the inner packaging container blank.

Product is then loaded into the partially closed structurethrough the remaining open side of the structure, for example, the left side as in the illustrated embodiment. The open side of the container is then sealed in a similar manner by folding the dust flaps and side closure panels. In the illustrated embodiment, for example, dust flaps,are folded along fold lines,, respectively, and then an outer surface of left side inner closure panelis glued to an inner surface of left side outer closure panelso as to completely seal inner packaging containerand the contents therein. Although a preferred practice in an embodiment includes closing one side of the inner box before insertion of product, it is envisioned that product could be inserted before closure of either side.

It is to be noted that the erection of the inner blankis in a “longitudinal” sense, i.e. the end panels are rotated during erection.

Referring to, the outer packaging container blankis folded and glued. More particularly, in one embodiment, glue flapis glued to an inner surface of side panelto form a collapsed erectable structure. The outer container is then formed into an open rectangular structureby, for example, squeezing the opposing sides of the erectable structure. Alternatively, the open rectangular structurecan be obtained by applying suction to the front and back surfaces of the collapsed erectable structurealone or in combination with the squeezing. Dust flapsandare then folded inwardly along fold linesand, respectively. Inner bottom closure panelis folded inwardly along fold lineand an outer surface thereof is glued to an inner surface of outer bottom panel closurewhich is folded inwardly along fold line, thereby closing one end of the open structureto form a partially closed structure. It is to be noted that the erection of the outer blankis “lateral” or “transverse” in that the side panels are rotated during erection. Thereafter, as schematically shown in, sealed inner packaging containeris loaded into the one open end of outer packaging container, such as the top end of outer packaging container. The top end of outer packaging containeris then closed and glued. More particularly, in one embodiment, dust flapsandare folded inwardly along fold lines,, respectively. Inner top closure panelis folded inwardly along fold line, outer top closure panelis folded inwardly along fold line, and an outer surface of inner top closure panelis glued to outer top closure panel, thereby forming finished pack. As shown in FIG.E, cut lines-(with nicks) formed in the blank for outer packaging containerform hinged lid portionwhich is openable by the consumer by breaking the nicks to gain access to the inner packaging container. Inner packing containerincludes, in turn, dispensing doorwhich, in one embodiment, is repeatedly openable and closable by way of resealable label.

The box structure of the packand its manner of erection and loading provides:

While the above pack and the method of packaging have been described in detail with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made, and equivalents employed, without departing from the scope of the appended claims.