Abstract:
A pack for consumer goods includes an outer packaging container and an inner packaging container. The outer packaging container includes a lower box portion with an upper lid portion hingedly connected thereto. The inner packaging container includes a dispensing opening with a resealable closure, a front panel, a back panel, a top panel, a bottom panel, and opposing side panels; each side panel having an inner panel and an outer panel, the inner panel having a first width defining a width of the inner packaging container, and the outer panel including at least a portion having a second width defining flanges having a width greater than the first width. The inner packaging container is insertable within the outer packaging container, the flanges on the back panel of the inner packaging container exert biasing forces on the hinged lid of the outer packaging container to assure lid closure is maintained.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/422,975 filed Dec. 14, 2010. 
    
    
     FIELD OF THE DISCLOSURE 
     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”). 
     WORKING ENVIRONMENT 
     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. 
     SUMMARY 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  shows a perspective view of the pack in a fully folded closed state. 
         FIG. 2  shows a planar view of the outer packaging container blank in an unfolded state. 
         FIG. 3  shows a perspective view of the inner packaging container in a fully closed state. 
         FIG. 4  shows a planar view of the inner packaging container blank in an unfolded state. 
         FIG. 5  shows a perspective view of the pack in an open state during loading of the inner packaging container within the outer packaging container. 
         FIG. 6  shows a perspective view of the pack in a closed state with the inner packaging container fully loaded within the outer packaging container. 
         FIGS. 7A-7E  show the pack during erecting, folding, gluing and loading of the inner packaging container within the outer container packing. 
         FIG. 8  is a detail view of one of the side panels of the inner box of a preferred embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1 and 3 , a pack  300  is described herein, the pack  300  comprising an outer packaging container (outer box)  100  having an inner packaging container (inner box)  200  therewithin. When the pack  300  is 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 pack  300  is 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 container  100  is preferably a hinged lid type of container formed from a paper or paperboard blank. As best shown in  FIG. 2 , the blank for outer packaging container  100  comprises a front panel  10 ; a back panel  20 ; a left side panel  30  connected between a side edge of the back panel  20  along a longitudinal fold line  23  and a side edge of the front panel  10  along a longitudinal fold line  25 ; a right side panel  40  connected to an opposite side edge of the front panel  10  along another longitudinal fold line  24 ; and a glue flap  45  connected to an opposite side edge of the back panel  20  along longitudinal fold line  22 . When folded, as described in greater detail below, glue flap  45  is glued to an inner surface of side panel  40  to 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 container  100  further includes an inner top closure panel  60  connected to the back panel  20  along a transverse fold line  26 ; an outer top closure panel  50  connected to the front panel  10  along a transverse fold line  27 ; an inner bottom closure panel  70  connected to the back panel  20  along a transverse fold line  28 ; and an outer bottom closure panel  80  connected to the front panel  10  along a transverse fold line  29 . When folded, inner top closure panel  60  is adhered to an inner surface of outer top panel closure panel  50  and inner bottom closure panel  70  is adhered to an inner surface of outer bottom closure panel  80 . 
     Outer packaging container  100  also comprises upper and lower dust flaps  12 ,  16  connected to left side panel  30  along upper and lower transverse fold lines  31 ,  32 , respectively, and upper and lower dust flaps  14 ,  18  connected to right side panel  40  along upper and lower transverse fold lines  33 ,  34 , respectively. 
     As mentioned above, outer packaging container  100  is preferably a hinged lid type of container in that a pivotable hinged lid portion  90  is 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  90 . As best illustrated in  FIG. 2 , hinged lid portion  90  is preferably formed by cut line  91  along glue flap  45 , cut line  92  along side panel  30 , cut line  93  across the front panel  10  which defines the hinged lid front panel  96  thereabove, and cut line  94  along side panel  40 . Cut lines  91 ,  92 ,  93  and  94  that define the hinge lid include “nicks” or “breaks”  802  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  300 . In addition, a score line  95  is provided along back panel  20  to define the hinge between the upper lid back panel  97  and the lower portion of the back panel  20  such that the hinged lid portion  90  is pivotal about score line  95 . The outer box is not limited to the exact shape and angles illustrated for hinged lid portion  90 , as one skilled in the art will appreciate that other configurations of the same are possible. For example, the cut extending across front panel  10  and defining the front panel of hinged lid portion may optionally include a semi-circular cut-away portion  98  below cut line  93  so as to form a thumb notch (cutaway) region allowing easy opening of hinged lid portion  90 ; the cut line  93  preferably extends straight across the front panel. Any other configuration may be used. 
     The outer blank  100  is a blank configuration which is laterally folded and “glued” to form the intended box structure. 
     As best shown in  FIG. 4 , a paper or paperboard blank for inner packaging container  200  comprises a front panel  110 ; a back panel  120 ; a top panel  130  connected between a top edge of the back panel  120  along a longitudinal fold line  125  and a top edge of the front panel  110  along a longitudinal fold line  123 ; a bottom panel  140  connected to a bottom edge of the back panel  120  along another longitudinal fold line  122 ; and a glue flap  145  connected to a bottom edge of the front panel  110  along longitudinal fold line  124 . When folded, as described in greater detail below, glue flap  145  is adhered to an inner surface of the bottom panel  140  to form a rectangular shape. 
     The inner packaging container blank  200  further includes an inner side closure left panel  160  connected to the back panel  120  along a longitudinal fold line  126 ; an outer side closure left panel  150  connected to the front panel  110  along a longitudinal fold line  127 ; an inner side closure right panel  170  connected to the back panel  120  along a longitudinal fold line  128 ; and an outer side closure right panel  180  connected to the front panel  110  along a longitudinal fold line  129 . When folded, inner side closure left panel  160  is adhered to an inner surface of outer side closure left panel closure panel  150  and inner side closure right panel  170  is adhered to an inner surface of outer side closure right panel  180 . 
     Inner packaging container blank  200  also comprises left and right side dust flaps  112 ,  116  connected to bottom panel  140  along left and right longitudinal fold lines  131 ,  132 , respectively, and left and right dust flaps  114 ,  118  connected to top panel  130  along left and right longitudinal fold lines  133 ,  134 , respectively. 
     Inner packaging container blank  200  further comprises a dispensing door  192  which is provided to allow access and removal of the contents within inner packaging container  200 . Door  192  is formed by establishing the perimeter thereof preferably with a score line  195  located partially across a central portion of the upper back panel  120  and with a perforated cut line  193  into central portions of the front and top panels  110  and  130  of the inner packaging container blank  200 , as shown best in  FIGS. 3 and 4 . As illustrated therein, fold lines  123 ,  125  extend across door  192  and the score line  195  is provided along a rear edge of door  192 , thus allowing door  192  to be opened and reclosed in a foldable manner. In one embodiment, the dispensing door  192  is also covered by a resealable label  198 , thereby permitting inner packaging container  200  to be resealed after the initial opening by the consumer. Resealable label  198  may 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  192 , or any other suitable reclosing mechanism. Preferably, a permanent bonding adhesive may cover the undersurface of label  198  which superposes the door  192 , and, preferably, edge portions of the label  198  beyond the edges of dispensing door  192  are provided with a peel-and-reseal adhesive sufficient to maintain a sealed closure. 
     Alternatively, the door  192  may be an opening of the same or comparable perimeter of lines  195  and  193 , covered only by a label  198 . 
     The left and right outer side closure panels  150 ,  180  of the inner packaging container  200  have an upper side width “W 1 ” that is slightly greater than the lower side width “W 2 ” thereof. The upper side width W 1  of the left and right side closure panels  150 ,  180  is also slightly greater than the side width “W 3 ” of the left and right inner side closure panels  160 ,  170 , the width W 3  thereof preferably being substantially equal to width W 2 . Moreover, the upper side width W 1  of the left and right side closure panels  150 ,  180  is also slightly greater than the inner width defined within outer packaging container  100 . As a result of the slightly greater width W 1  of the upper portion of the left and right outer side closure panels  150 ,  180 , when inner packaging container  200  is folded, glued and sealed, the inner packaging container  200  comprises rearwardly projecting flanges  190 , as best shown in  FIGS. 3 and 5 . The projecting flanges  190  cooperate with other features of the box  100  to assure and retain a complete closure of the lid  90  of the outer packaging container  100 . 
     More particularly, in one preferred embodiment, flanges  190  have a gradually increasing width from W 2  to W 1  which feature facilitates insertion of an erected inner box into an erected outer box. Referring now to  FIG. 8 , preferably, each outer side panel  150 ,  180  includes from top to bottom: an operative flange portion  400  of a width W 1 ; a transition portion  402  and a lower portion  404  of a width W 2 . Preferably, the operative flange portion includes straight, rear flange edge  408  which extends from a rounded, upper rear corner portion  406  of the side panels  150 ,  180  to the inclined edge  410  of the transition portion  402 . The length of the straight flange edge  408  (or the flange portion  400 ) 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  300 . Generally, a longer flange edge  408  will 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  400 , the transition portion  402  and the lower portion  404  are of essentially equal length (from a direction of top to bottom of the pack  300 ). 
     The flange portion  400  and its biasing action also serve in essence to “lock” the inner box  200  within the outer box  100  with a friction fit such that the inner box  200  remains 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 box  200  and the interior surface of the bottom of the outer box  100  to further assure the desired positioning of the inner box  200  within the outer box  100 . 
     Preferably, both the outer box  100  and the inner box  200  are constructed of 12 or 14 point paper board, preferably 12 point board is used for the inner box  200  and 14 point board is used for the outer box  100 . Most preferably, a laminated or metalized board is used in the construction of the inner box  200 , 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 lid  90  can 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 box  200  preferably holds about fifteen portions of smokeless tobacco. The door  192  can have a width of about 1¼ inches at hinge line  195  and length of about 1½ inches from the hinge line  195  to 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 flanges  190  preferably 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 box  200  is approximately of a same height as that of the outer box  100  (with accommodation for the layers of board at the upper and lower panels of the outer box  100 ). It is envisioned that with the inclusion of flanges  190  (or comparable arrangement to bias an upper edge portion of the inner box  200 ), the inner box  200  may be of a height less than that comparable to the outer box  100 . 
     Referring to  FIG. 5 , when inner packaging container  200  is loaded into outer packaging container  100  during 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 flanges  190  engage the back panel  20  near the side panels of the outer packaging container  100  close to fold lines  22  and  23 . The engagement of the rear flanges  190  with the back panel of the outer packaging container  100  causes the upper portion of inner packaging container  200  to be biased forward toward the front panel  10  of the outer packaging container  100 . As a result, when the hinged-top portion  90  of the outer packaging container  100  is reclosed, the inside face of the front lid panel  96  slidingly engages upper front face portion  97  of the inner box  200  such that position of the inner packaging container  200  assists in securing and maintaining the hinged-top portion  90  in a closed position, as shown in  FIG. 6 . The width W 1  can be selected as desired to define a width greater than width W 2  and the inner width within outer packaging container  100 , so long as inner packaging container  200  can still be inserted within outer container  100  and the hinged lid top portion  90  maintains the desired closed position. 
     A method of making the pack  300  according to one embodiment is described below. 
     Referring to  FIG. 7A , a flat blank for the inner packaging container blank  200  is provided and the resealable label  198  is disposed over the dispensing door  192 . As shown in  FIG. 7B , inner packaging container blank  200  is folded by first pre-breaking fold lines  124 ,  125  and then folding the blank 180° along fold lines  123  and  122  so as to form a collapsed, erectable structure  701 . In so doing, the outer surface of glue flap  145  is glued to the inner surface of bottom panel  140 . Inner packaging container blank  200  is then erected from the collapsed, erectable structure  701  by, for example, squeezing the top and bottom surfaces to erect the box  701  into an open, rectangular structure  702 . Alternatively, the open, rectangular structure  702  can be obtained by applying suction to the front and back surfaces of the collapsed, erectable structure  701  alone or in combination with the squeezing. One side of the open, rectangular structure  702  is then also folded and glued to form a partially closed structure  703 . In the illustrated embodiment, dust flaps  116  and  118  are folded along fold lines  132  and  134 , respectively, and then an outer surface of right side inner closure panel  170  is glued to an inner surface of right side outer closure panel  180  so as to seal the right side of the inner packaging container blank  200 . 
     Product is then loaded into the partially closed structure  703  through the remaining open side of the structure  703 , 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  112 ,  114  are folded along fold lines  131 ,  133 , respectively, and then an outer surface of left side inner closure panel  160  is glued to an inner surface of left side outer closure panel  150  so as to completely seal inner packaging container  200  and 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 blank  200  is in a “longitudinal” sense, i.e. the end panels are rotated during erection. 
     Referring to  FIG. 7C , the outer packaging container blank  100  is folded and glued. More particularly, in one embodiment, glue flap  45  is glued to an inner surface of side panel  40  to form a collapsed erectable structure  710 . The outer container is then formed into an open rectangular structure  712  by, for example, squeezing the opposing sides of the erectable structure  710 . Alternatively, the open rectangular structure  712  can be obtained by applying suction to the front and back surfaces of the collapsed erectable structure  710  alone or in combination with the squeezing. Dust flaps  16  and  18  are then folded inwardly along fold lines  32  and  34 , respectively. Inner bottom closure panel  70  is folded inwardly along fold line  28  and an outer surface thereof is glued to an inner surface of outer bottom panel closure  80  which is folded inwardly along fold line  29 , thereby closing one end of the open structure  712  to form a partially closed structure  714 . It is to be noted that the erection of the outer blank  100  is “lateral” or “transverse” in that the side panels are rotated during erection. Thereafter, as schematically shown in  FIG. 7D , sealed inner packaging container  200  is loaded into the one open end of outer packaging container  100 , such as the top end of outer packaging container  100 . The top end of outer packaging container  100  is then closed and glued. More particularly, in one embodiment, dust flaps  12  and  14  are folded inwardly along fold lines  31 ,  33 , respectively. Inner top closure panel  60  is folded inwardly along fold line  26 , outer top closure panel  50  is folded inwardly along fold line  27 , and an outer surface of inner top closure panel  60  is glued to outer top closure panel  50 , thereby forming finished pack  300 . As shown in  FIG. 7E , cut lines  91 - 94  (with nicks) formed in the blank for outer packaging container  100  form hinged lid portion  90  which is openable by the consumer by breaking the nicks to gain access to the inner packaging container  200 . Inner packing container  200  includes, in turn, dispensing door  192  which, in one embodiment, is repeatedly openable and closable by way of resealable label  198 . 
     The box structure of the pack  300  and its manner of erection and loading provides: 
     a resealable feature which prolongs freshness; 
     the resealable flap  198  that may be pressed against opposing portions of the top panel of  130  to assure adhesion and may be reinforced by the board structure of the door  192 ; 
     the inclined edge  410  of the flanges  190  of the inner box  200  facilitates insertion of the inner box  200  into the outer box  100  during packing; 
     having one of the boxes  100 ,  200  erectable in a lateral sense (e.g. box  100 ) and the other being erectable in a longitudinal sense (e.g. box  200 ), assures rectangularity in the pack  300  once the pack  300  has been fully assembled; and 
     the flanges  190  bias an upper front edge portion of the inner box  200  against an inner front surface of the lid during and after reclosure so as to assure a complete reclosure and to maintain it fully closed (the avoidance of a “smile” along the lid line). 
     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.