Box in a box re-sealable cigarette pack

An exemplary container for consumer goods includes a rigid outer box and a rigid inner box. The outer box has a hinged top configured to provide access to an inner volume of the outer box. The inner box is a laminate of paperboard and an inner liner and pre-cut opening configured to provide access to an inner volume of the inner box. A pull tab covers the opening. The pull tab includes a first adhesive that releasably adheres an edge portion of the pull tab to the inner box and a second adhesive that permanently adheres the pull tab to the inner box and the outer box.

FIELD

The present disclosure relates to a package for consumer goods and particularly to a re-sealable cigarette pack.

BACKGROUND

Numerous approaches have been made for packaging consumer goods. In the case of cigarettes, for example, packages are designed to preserve the flavor and freshness of the consumer goods and also protect the goods from contamination. Known packages employ outer containers having a hinged lid providing access to an inner container with an opening for accessing the consumer goods. The outer containers are generally formed of a rigid paperboard, cardboard, or other suitable material. The inner container is generally formed of a material or combination of materials having substantially less rigidity than the outer container. For example, the inner container is known to be formed of paperboard, packing material, paper, and/or aluminium. In known designs, a label with a tacky substance for sealing and re-sealing can be used to cover the opening of the inner container.

SUMMARY

An exemplary container for consumer goods is disclosed. The container comprises a rigid outer box having a hinged top configured to provide access to an inner volume of the outer box; a rigid inner box having an opening configured to provide access to an inner volume of the inner box; and a pull tab covering the opening, the pull-tab having a first adhesive that releasably adheres an edge portion of the pull tab to the inner box, a second adhesive that permanently adheres the pull tab to the inner box and the outer box, and an inner liner.

A container for consumer goods is disclosed. The container comprises an outer box blank configured to be assembled into a rigid outer box having a hinged top that allows access to an inner volume of the outer box; and an inner box blank configured to be assembled into a rigid inner box having a pre-cut opening configured to provide access to an inner volume of the inner box, wherein each of the outer box blank and the inner box blank includes a plurality of panels and one or more pre-cut flaps that are folded about fold lines during assembly, and wherein one surface of the inner box blank includes a material that establishes an inner liner of the container.

A method of assembling a container for consumer goods is disclosed. The method comprises folding a plurality of panels and associated flaps of an inner box blank to form an assembled inner box, wherein during an intermediate step of assembly of the inner box the consumer goods are deposited in a partially folded inner box blank; folding a plurality of panels and associated flaps of an outer box blank to form and assembled outer box, wherein during an intermediate step of assembly of the outer box the assembled inner box is deposited in a partially folded outer box blank; and covering a pre-cut opening of the assembled inner box with a pull-tab, wherein edge portions of the pull tab are releasably adhered around the pre-cut opening, and opposite ends of the pull tab are permanently adhered to a back panel of the inner box and an inner surface of the outer box.

DETAILED DESCRIPTION

Reference will now be made in detail to the various embodiments, one or more examples of which are illustrated in each figure. Each example is provided by way of explanation and is not meant as a limitation. For example, features and/or method steps illustrated or described as part of one embodiment and/or method can be used on or in conjunction with other exemplary embodiments and/or method steps to yield yet further exemplary embodiments or methods. It is intended that the present disclosure includes such modifications and variations.

Exemplary embodiments of the present disclosure are directed to a container for consumer goods having rigid inner and outer boxes. The outer box has a hinged lid that opens and closes to allow access the inner box. The inner box has an opening for accessing the consumer goods. The opening is covered by a re-sealable pull-tab. An inner surface of the hinged lid being arranged to rotate about a fold line based on a tension force applied to the inner surface via the pull tab when the hinged lid is opened and closed. The inner box also has an inner liner including at least a layer of paper or other suitable material as desired. According to an exemplary embodiment the re-sealable pull-tab has one or more layers where an innermost layer is composed of foil, paper, bundle wrap, or any combination thereof as desired. According to another exemplary embodiment the re-sealable pull-tab includes at least one vent that allows air trapped under the releasable pull-tab to escape when the inner box is sealed or re-sealed. The pull-tab can be permanently connected to the inner box and the inner surface of the hinged lid. The exemplary container described herein provides several advantages such as an improved barrier and a simplified opening process designed to eliminate waste and one or more package opening steps. The arrangement of the re-sealable pull-tab prevents spillage of the product when the package is accessed the first time. The container of the present disclosure also provides a more durable package by protecting the product from physical damage while the product is in use and a less expensive packaging solution as fewer pieces of equipment are needed to make the package. Moreover, the package assembly can be performed faster and with fewer material components over known re-sealable packaging designs.

FIG. 1illustrates a layout of a container for consumer goods in accordance with an exemplary embodiment of the present disclosure. As shown inFIG. 1, the container100includes a rigid outer box102having a hinged top104configured to provide access to a rigid inner box106and having a body105within which the inner box106is deposited. The inner box106has an opening110configured to provide access to consumer goods112stored or contained within an inner volume109. The inner box106is of sufficient size to slidably and snugly fit within an inner volume108of the outer box102. The inner box106can be securely held within the outer box102via contact friction between the surfaces of the inner box106and outer box102. A pull tab114is arranged to cover the opening110.

FIG. 2aillustrates a first perspective view of a layer structure of the container in accordance with an exemplary embodiment of the present disclosure. As shown inFIG. 2a, the outer box102includes one or more layers. A first layer115can be formed of a rigid material including cardboard, paperboard, or any other suitable material as desired. According to an exemplary embodiment, the first layer115can be formed of Promina SBS C1S Paperboard. According to another exemplary embodiment, the first layer115can be embossed with a design, lettering, pattern, and/or symbol as desired. A second layer117can include an ink, varnish, metallization, or other suitable material for product identification. When the container100is fully assembled, the outer box102can be wrapped with a third layer118, such as a polypropylene film. The third layer118can include a tear tape120that allows for tearing open the polypropylene film118.

The inner box106can include a plurality of layers. A first layer122can be formed of a rigid material such as cardboard, paperboard, or any other suitable material as desired. For example, according to an exemplary embodiment the first layer122can be formed of Promina SBS Board stock. A second layer124of the inner box106can include one or more layers formed as a bundle wrap. For example, the second layer124can include a foil layer126and a paper layer128as an inner liner bound by an adhesive130. The paper layer128is the layer closest to or in contact with the consumer goods112stored in the inner box106. According to an exemplary embodiment, the adhesive130used to bind the layers of the bundle wrap can include at least sodium silicate or any other suitable material as desired. The first layer122and the second layer124of the inner box106can also be bound to each other via an adhesive131, such as a polyvinyl alcohol (PVA) based adhesive.

In accordance with another exemplary embodiment, the inner box106can also include a third layer132formed on a surface of the first layer122. For example, the third layer132can include a polypropylene film or a metallized polyester (MET) material such that the layer structure of the inner box106includes bundle wrap/board/film or bundle wrap/board/MET, and more particularly the layer structure includes paper/foil/board/film or paper/foil/board/MET.

The pull tab114includes an adhesive layer131for adhering the pull tab114to the inner box106and a permanent adhesive layer154, shown inFIG. 2b, that attaches the pull tab114to an inner surface of the hinged lid104of the outer box102. The pull tab114can also include a plurality of layers comprising a polymer material136, a paper layer138, and an adhesive layer140disposed between the polymer material136and the paper layer138.

FIG. 2billustrates a second perspective view of the layer structure of the container in accordance with an exemplary embodiment of the present disclosure. As shown inFIG. 2b, the adhesive layer131of the pull tab114includes a permanent adhesive area133and a non-permanent (e.g., re-sealable) adhesive area135. The permanent adhesive area133can be arranged to extend from a top surface144of the inner box106to a rear surface146of the inner box106. The non-permanent adhesive area135surrounds an adhesive-free region (not shown) of the adhesive layer131, and is arranged to contact portions of the top surface144and a front surface148of the inner box106that border the opening110.

The outer box102includes a front flap152that is adhered to the pull-tab114via a permanent adhesive154. The front flap152can be folded about a fold line FL so that it forms the inner surface of the hinged lid104to which the pull tab114is attached. It should be understood that the material properties of the outer box102provide that once folded the front flap152can be spaced from the surface of the outer box at an angle α, where 0<α<90°. The opposite side of front flap152is not adhered to the hinged lid104, which allows the front flap152to freely move (e.g., rotate) about the fold line FL when a tension force between the front flap and the pull tab114is generated during opening and closing of the hinged lid104. For example, the tension force applied to the front flap152during opening of the hinged lid104causes the front flap152to move about the fold line FL, which results in the pull-tab114gradually peeling away from the top and front surfaces144,148of the inner box106along a length of the non-permanent adhesive area135to fully uncover a lower portion150of the opening110. As the hinged lid104is closed, the tension force applied to the front flap152results in the pull-tab114gradually rolling onto the top and front surfaces144,148of the inner box106to re-establish the seal and fully cover the opening110. According to an exemplary embodiment, the front flap can move (e.g., rotate) about the fold line FL within an angle ϕ, where 0<ϕ<180°.

According to another exemplary embodiment, the front flap152can be adhered to a back surface147of the hinged lid104. In this arrangement the pull tab114follows the contour of the hinged lid104such that when the hinged lid104is opened, a substantial portion (e.g., greater than half the length) of the pull-tab114is instantly pulled away from the top and front surfaces144,148of the inner box106. In addition, when the hinged lid104is closed, a substantial portion (e.g., greater than half the length) of the pull-tab114is instantly pressed onto the top and front surfaces144,148of the inner box106.

FIGS. 3a-3cillustrate a first pull tab of the container in accordance with an exemplary embodiment of the present disclosure. As shown inFIG. 3, the pull tab300can include an adhesive-free area301which overlies opening110and can form a window if the pull tab is made of a transparent polymer material, a first adhesive area302, and a second adhesive area304. The first adhesive area302and the second adhesive area304can be formed on a lower surface or inner box-side surface of the pull-tab300. The pull-tab can be formed in any desired shape or size sufficient to fully cover and seal the opening110of the inner box106when the outer box102is closed. The pull-tab300can be formed from a single layer of polymer material such as PET or other suitable material such as a multi-layer laminate as desired. According to an exemplary embodiment, the pull-tab300can be formed of a 2 mils thick piece of PET. The adhesive-free area301is arranged approximately in a central region of the pull-tab300and aligned to fully cover the opening110when the pull tab300is adhered to the inner box106. For example, left and right edge regions306located on opposites sides of the adhesive-free area301are of approximately the same width W1. A width W2of a bottom edge region308located below the adhesive-free area301can be larger than a width W3of a top edge region310above the adhesive-free area301. The first adhesive area302includes a re-sealable adhesive film formed on the bottom edge region308, the left and right edge regions306, and the top edge region310of the pull tab300, which surround the adhesive-free area301. The re-sealable adhesive can include an ultra violet (UV) cured material, rubber based material, or a solvent based material. The second adhesive area304includes the top edge region310of the pull tab300. The second adhesive portion304includes a permanent adhesive, which can be formed from UV-cured, rubber-based, or solvent-based materials.

The pull-tab300includes a vent312that extends longitudinally from at least one of the left or right edge regions306of the adhesive-free area301. The vent312is formed by an adhesive-free gap configured to allow the release of air located under the pull-tab300when the pull-tab300seals or re-seals the opening110as the hinged top104of the outer box102is closed. The pull-tab300also includes a lip314on a bottom edge of the bottom edge region308. The lip314can have permanent adhesive324on an outer surface to adhere to the front flap152of the hinged top104of the outer box102.

As shown inFIG. 3c, the pull tab300can include a plurality of layers. A first layer318can be formed of polyethylene terephthalate (PET). A second layer320can be formed on the first layer318and includes adhesives applied to form the first and second adhesive portions302,304already discussed. As discussed inFIG. 3a, the second layer320can be applied such that an adhesive-free region301is established. A third layer322can be formed on an opposite side of the first layer318, and include an ink or other suitable print material as desired.

FIGS. 4a-4cillustrate a second pull tab of the container in accordance with an exemplary embodiment of the present disclosure. An exemplary pull tab400can have substantially the same planar dimensions as the first pull tab300ofFIG. 3. The pull tab400can include a plurality of layers defined by the first, second, and third layers402,404,406, which correspond to layers318,320, and322, respectively, ofFIG. 3. As shown inFIGS. 4band 4c, the pull-tab400can further include a fourth layer408. The fourth layer408can be formed of a piece of bundle wrap414sized to fully cover and extend slightly past edges of opening410in the inner box106. Instead of an adhesive-free area301as inFIG. 3c, the adhesive covers substantially the entire inner surface412or product side of the pull tab400. The fourth layer408can be adhered to the pull tab400via a suitable permanent adhesive416; examples of which are discussed herein.

FIG. 5illustrates a planar view of an outer box blank of the container in accordance with an exemplary embodiment of the present disclosure. As shown inFIG. 5, the blank500for forming outer box102includes a top panel502, a bottom panel504, a top front panel506, a bottom front panel508, a bottom back panel510, and a top back panel512. The top panel502includes a front flap513. The top panel502and the bottom panel504include left and right dust flaps. The top panel502includes a left dust flap514and a right dust flap516, and the bottom panel504includes a left dust flap518and a right dust flap520. An upper section562of the outer box blank500includes the top panel502, the top back panel512, and the top front panel506and their associated side and dust flaps are configured to form the hinged top104of the assembled outer box102when folded. A lower section564of the outer box blank500includes the bottom panel504, the bottom front panel508, the bottom back panel510and their associated side and dust flaps discussed below are configured to form the body105of the assembled outer box102when folded.

The top back panel512, the bottom front panel508, and the bottom back panel510include left and right flaps. For example, the top front panel506includes a left side flap522and a right side flap524; the top back panel512includes a left side flap526and a right side flap528; the bottom front panel508includes a left side flap530and a right side flap532; and the bottom back panel510includes a left side flap534and a right side flap536.

Each panel of the outer box102and the associated left and right flaps are separated from an adjacent panel and its associated left and right flaps by a transverse fold line. The front flap513and the top front panel506are separated by transverse fold line539. The top front panel506, the left side flap522, and the right side flap524are separated from the top panel502, the left dust flap514, and the right dust flap516, respectively, by transverse fold line538. The top panel502, the left dust flap514, and the right dust flap516are separated from the top back panel512, the left side flap526, and the right side flap528, respectively, by transverse fold line540. The top back panel512, the left side flap526, and the right side flap528are separated from the bottom back panel510, the left side flap534, and the right side flap536, respectively, by transverse fold line542. The bottom back panel510, the left side flap534, and the right side flap536are separated from the bottom panel504, the left dust flap518and the right dust flap520, respectively, by transverse fold line544. The bottom panel504, the left dust flap518, and the right dust flap520are separated from the bottom front panel508, the left side flap530, and the right side flap532, respectively, by transverse fold line546.

Each side flap and dust flap of the outer box102is separated from the associated and adjacent panel by a longitudinal fold line. The top front panel506is separated from the left and right side flaps522,524by longitudinal fold lines548. The right side flap524has a pre-cut edge525that extends at an angle of approximately −45° from the transverse fold line539. The left side flap522has a pre-cut edge523that extends at an angle of approximately −135° from the transverse fold line539. The top panel502is separated from the left and right dust flaps514,516by longitudinal fold lines550. The top back panel512is separated from the left and right side flaps526,528by longitudinal fold lines552. The left side flap526has a pre-cut edge527that extends at an angle of approximately −50° from the transverse fold line542. The right side flap528of top back panel512has a pre-cut edge529that extends at an angle approximately −140° from the transverse fold line542. The bottom back panel510is separated from the left and right side flaps534,536by longitudinal fold lines554. The left side flap534has a pre-cut edge535that extends at an angle of approximately −45° from the transverse fold line542. The right side flap536of the bottom back panel510has a pre-cut edge537that extends at an angle of approximately −135° from the transverse fold line542. The bottom panel504is separated from the left and right dust flaps518,520by longitudinal fold lines556. The bottom front panel508is separated from the left and right side flaps530,532by longitudinal fold lines558. The left side flap530and the right side flap532extend past an edge560of the bottom front panel508. The left side flap530has a pre-cut edge531that extends at approximately −45°, and in a preferred embodiment −39°, from the bottom edge560of the bottom front panel508. The right side flap532a pre-cut an edge533that extends at approximately −135°, and in a preferred embodiment −129°, from the edge560of the front panel508.

The pre-cut angle of the flaps associated with the bottom front panel508and bottom back panel510are complementary to the pre-cut angle of the flaps associated with the top front panel506and the top back panel512so that a side surface of the hinged top of the outer box mates with a side surface of a body of the outer box when the outer box is in a closed state.

The outer box102has dimensions suitable for providing a snug fit for the inner box106when disposed within the outer box102. The outer box102has a width WOBthat is common to each of the top panel502, bottom panel504, top front panel506, bottom front panel508, bottom back panel510, and top back panel512. The bottom back panel510has a length LOB-BBPthat is substantially longer than the length of the top back panel (LOB-TBP)512. The sum of LOB-BBPand LOB-TBPis approximately equal to the length of a cigarette pack, e.g., the length of the inner box106. The length of the bottom front panel (LOB-BFP)508is substantially longer than the length of the top front panel (LOB-TFP)506. The sum of LOB-BFPand LOB-TFPis substantially equal to the sum of LOB-BBPand LOB-TBP. According to an exemplary embodiment LOB-BBP=75.10 mm, LOB-TBP=11.40 mm, LOB-BFP=55.5 mm, and LOB-TFP=31.0 mm. The depth or thickness of the outer box102is equal to the width (WOB-FLP) of the side and dust flaps and the length (e.g., shortest edge) of the top panel (LOB-TP)502and bottom panel (LOB-BP)504. According to an exemplary embodiment LOB-TP=LOB-BP=WOB-FLP=21.9 mm

FIG. 6illustrates a planar view of a blank for forming an inner box106of the container in accordance with an exemplary embodiment of the present disclosure. As shown inFIG. 6, the blank600for inner box106includes a top panel602, a bottom panel604, a top front panel606, a bottom front panel608, and a back panel610. The opening110of the inner box extends across the top front panel606and the top panel602. A surface611of the inner box blank can be substantially covered with a bundle layer. The surface611establishes the product side surface of the assembled inner box106.

Each panel is separated from an adjacent panel by a transverse fold line. The top front panel606is separated from the top panel602by a transverse fold line612. The top panel602is separated from the back panel610by a transverse fold line614. The back panel610is separated from the bottom panel604by a transverse fold line616. The bottom panel604and the bottom front panel608are separated by transverse fold line618.

Each panel includes associated side flaps. The top front panel606includes a left side flap620and a right side flap622. The left side flap620has a pre-cut edge621that extends at an angle of approximately 45° from the transverse fold line612. The right side flap622has a pre-cut edge623that extends at an angle of approximately 135° from the transverse fold line612. The top panel602includes a left side flap624and a right side flap626. The left side flap624has a pre-cut edge625that extends at an angle of approximately 45° from the transverse fold line614. The right side flap626has a pre-cut edge627that extends at an angle of approximately 135° from the transverse fold line614. The back panel610includes left side flap628and a right side flap630. The front panel608includes a left side flap632and a right side flap634.

The bottom panel604includes a left dust flap636and a right dust flap638.

The inner box106has dimensions suitable for storing a desired number (e.g., count) of consumer goods, which according to an exemplary embodiment are cigarette articles. The inner box106has a width WIBthat equals the width of each of the top panel602, bottom panel604, top front panel606, bottom front panel608and back panel610. The back panel610has a height or length (LIB-BKP) sufficient for enclosing the consumer goods. The sum of the lengths of the top front panel606(LIB-TFP) and the bottom front panel (LIB-BFP)608is equivalent to LIB-BKP. According to an exemplary embodiment of the present disclosure, LIB-BKP=83.6 mm, LIB-TFP=27.2 mm, and LIB-BFP=43.39 mm. The depth or thickness of the inner box106is established by the width WIB-FLPshared by each of the side and dust flaps and the length (e.g., shortest edge) of the top panel (LIB-TP)602and bottom panel (LIB-BP)604. According to an exemplary embodiment, LIB-TP=LIB-BP=WIB-FLP=20.55 mm.

According to exemplary embodiments of the present disclosure, a sum of lengths of the top back panel512and bottom back panel510of the outer box102is at least equal to a length of the back panel610of the inner box106, where (LOB-TBP+LOB-BBP=LIB-BKP), and in a preferred embodiment the sum of lengths is greater, where (LOB-TBP+LOB-BBP>LIB-BKP), so that the proper fit of the inner box106within the outer box102and closure of the hinged top104can be realized.

Each side and dust flap of the inner box104is separated from the associated and/or adjacent panel by a longitudinal fold line. The top front panel606is separated from the left and right side flaps620,622by longitudinal fold lines640. The top panel602is separated from left and right side flaps624,626by longitudinal fold lines642. The back panel610is separated from left and right side flaps628,630by longitudinal fold lines644. The bottom panel604is separated from left and right dust flaps636,638by longitudinal fold lines646. The bottom front panel608is separated from left and right side flaps632,634by longitudinal fold lines648.

FIGS. 7aand 7bare flow charts of a process for making the container in accordance with an exemplary embodiment of the present disclosure; andFIG. 8illustrates a sequence of assembly states of the container according to the assembly process ofFIGS. 7aand 7b. As shown inFIGS. 7aand 7b, the process includes a first step (S700) in which the inner box102is assembled from the inner box blank600by folding the left and right side flaps628,630about the longitudinal fold lines644so that they are substantially orthogonal to the back panel610. In step S702, the dust flaps636,638of the bottom panel604are folded over the longitudinal fold lines646so that they are substantially planar with the bottom panel604. According to an exemplary embodiment, an adhesive can be applied to the dust flaps636,638so that they adhere to the bottom panel604when folded. As shown in State1ofFIG. 8, a lower section650including the bottom panel604and the bottom front panel608is folded about transverse fold line616so that it is substantially orthogonal to the bottom panel604(S704). The consumer goods or product is then placed into the area bounded by the left and right side flaps628,630and the bottom panel604(S706). An upper section652including the top panel602and the top front panel606is folded about transverse fold line614so that the upper section652is substantially orthogonal to the back panel610(S708, State2). The bottom front panel608is folded over transverse fold line618so that it is parallel with the back panel610(S710, State3). The top front panel606is folded over transverse fold line612so that it is parallel with the back panel610and planar with the bottom front panel608(S712, State4).

An adhesive can be applied to the left and right side flaps624,626of the top panel602. The left and right side flaps624,626of the top panel602are folded over longitudinal fold lines642and adhere to the side flaps628,630of the back panel610(S714, State5). An adhesive can be applied to the side flaps632,634of the bottom front panel608and to the left and right side flaps620,622of the top front panel606. The side flaps632,634of the bottom front panel608are folded about longitudinal fold lines648and adhere to the left and right side flaps628,630, respectively, of the back panel610(S716, State6). The left and right side flaps620,622of the top front panel606are folded about longitudinal fold lines640and adhere to the left and right side flaps628,630, respectively, of the back panel610(S718, State6). It is noted that the left and right side flaps620,622of the top front panel606are planar with and do not overlap the side flaps624,626, respectively of the top panel602because of the pre-cut angles of their respective edges. The pull tab114is placed on the inner box104to cover the opening110(S720, State7). In particular, the second adhesive portion310of the pull tab114adheres to the back panel610of the inner box106. The pull tab114is then folded over the top of the inner box106so that the first adhesive portion302adheres to the left, right, and upper portions of the top panel602and top front panel606that surround the opening110(State7).

The outer box102is assembled from the outer box blank500by folding the left and right side flaps534,536of the bottom back panel510about longitudinal fold lines554so that the left and right side flaps534,536are substantially orthogonal to the bottom pack panel510(S720). The left and right dust flaps518,520of bottom panel504are folded over longitudinal fold lines556so that they are substantially planar with each other and parallel with the bottom panel504(S722, State8). According to an exemplary embodiment, adhesive can be applied to the left and right dust flaps518,520so that they adhere to the bottom back panel510when folded. A lower section505of the outer box102including the bottom panel504and the bottom front panel508is folded about transverse fold line544so that the lower section505is substantially orthogonal to the bottom back panel510(S724, State8). The assembled inner box106is placed within the area of the outer box102bounded by the left and right side flaps534,536and the bottom panel504(S726, State9). The bottom front panel508is folded over transverse fold line546so that the panel is substantially parallel with the bottom back panel510(S728, State10). An adhesive can be applied to the left and right side flaps530,532of the bottom front panel508. The side flaps530,532are then folded about longitudinal fold lines558and adhere to the left and right side flaps534,536, respectively, of the bottom back panel510(S730).

An upper section503of the outer box102including the top panel502and the top front panel506is folded about transverse fold line540so that the upper section503is substantially orthogonal to the bottom back panel510(S732, State10). The left and right side flaps526,528of the top back panel512are folded about longitudinal fold lines552so that they are planar with the left and right side flaps534,536, respectively, of the bottom back panel510(S734). It is noted that the angled edges of the left and right side flaps534,536of the bottom back panel510and the angled edges of the left and right side flaps526,528, respectively, of the top back panel512are pre-cut so that they do not overlap and allow for opening of the hinged top104of the outer box102. The top front panel506is folded about transverse fold line538so that the top front panel506is parallel with the bottom back panel510and planar with the bottom front panel508(S736, State11). An adhesive is applied to the left and right side flaps522,524of the top front panel506. The left and right side flaps522,524of the top front panel506are then folded about longitudinal fold lines548and adhere to the folded left and right side flaps526,528, respectively of the top back panel512(S738, State11). Attaching the bottom edge region308of the pull tab114having the permanent adhesive to the front flap513and folding the front flap513about transverse fold line539so that the front flap513establishes the inner surface134of the hinged lid104to which the pull tab114is attached (S740, State11). According to another exemplary embodiment, the front flap513can be adhered to a back surface147of the top front panel506after being folded about the transverse fold line539.

FIGS. 9aand 9billustrate an assembled container in accordance with an exemplary embodiment of the present disclosure. As shown, the assembled container900includes the rigid outer box902and the rigid inner box904. The outer box902includes the hinged lid906for accessing the inner box904and the inner box904includes an opening908for accessing the consumer goods (not shown). The container900also includes a pull-tab910that is affixed to the outer box902and inner box904via areas having areas of permanent and re-sealable adhesives. The pull-tab910is affixed to an inner surface912of the hinged lid906established by the folded front flap513of the outer box blank500via the permanent adhesive. When the hinged lid906is closed, the pull-tab910fully covers the opening908of the inner box904by adhering to a surface of the inner box904surrounding the opening908via the re-sealable adhesive. Alternatively, when the hinged lid906is opened, the pull-tab910fully uncovers the opening908and remains adhered to the hinged lid906of the outer box902and to the inner box904via the areas having the permanent adhesive.