Patent Publication Number: US-8118165-B2

Title: Latching blank, sleeve and package

Description:
BACKGROUND 
     Tobacco products, such as chewing tobacco, snus or moist snuff, are provided in different forms of packaging. 
     SUMMARY 
     Provided in an embodiment is a blank of foldable material for forming a sleeve, comprising: pull tab, catch, back cover, front, binding, slot and middle panels for forming respective grip and catch portions of a latch, back cover, front, top, slotted back and dividing walls of the sleeve, wherein the pull tab, the back cover, front, binding, slot and middle panels comprise two substantially parallel sides and two substantially parallel ends which are substantially perpendicular to the sides, the pull tab panel connected to the catch panel by a first fold line, the catch panel comprises ends each having a first part which tapers outward from the first fold line to a locking point and a second part which tapers inward to a corner stop where the catch panel joins the back cover panel, the back cover panel is connected to the front panel by a second fold line, the front panel is connected to the binding panel by a third fold line, the binding panel is connected to the slot panel by a fourth fold line, the slot panel is connected to the middle panel by a fifth fold line, a slot in the slot panel parallel to the sides of the slot panel, the slot comprising a cut-out defined by spaced apart parallel short and long sides wherein the short side is closer to the catch panel, the blank being foldable to form the sleeve defining a recess open at ends thereof with the middle panel dividing the recess, the back cover panel covering a portion of the slot panel and the catch panel can be latched in the slot such that the locking points releaseably engage ends of the slot with the pull tab panel overlying the catch panel and protruding outwardly from the slot. 
     An embodiment of a method of folding the sleeve from the blank comprises folding back the pull tab panel along the first fold line, folding forward the back cover, front, binding, slot and middle panels of the blank along the second, third, fourth and fifth fold lines, overlying the catch panel with the folded back pull tab panel, inserting the catch panel and a portion of the overlying pull tab panel through the slot such that the locking points releaseably engage ends of the slot to create a latching sleeve. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an inner plan view of a first embodiment of a blank for forming a first embodiment of a latching sleeve. 
         FIG. 1B  is an outer plan view of the blank shown in  FIG. 1A . 
         FIGS. 2A and 2B  show an embodiment of an article and the article attached to an inner surface of the blank shown in  FIG. 1A . 
         FIG. 3  illustrates folding a pull tab panel and a back cover panel of the blank shown in  FIG. 1A . 
         FIG. 4  illustrates folding a middle panel of the blank shown in  FIG. 1A . 
         FIG. 5  shows a slot panel of the blank of  FIG. 1A  folded to form an upper back portion of the latching sleeve. 
         FIG. 6  shows tucking the pull tab panel and a catch panel into a slot in the slot panel of the blank of  FIG. 1A  to form the latching sleeve. 
         FIG. 7  shows a side view of an embodiment of a package formed of the blank of  FIG. 1A  folded to form the latching sleeve having articles contained within the sleeve. 
         FIG. 8A  shows a perspective back view of the embodiment shown in  FIG. 7  of the package formed of the blank of  FIG. 1A  folded to form the latching sleeve having articles contained within the sleeve. 
         FIG. 8B  is a front view of the package shown in  FIG. 8A . 
         FIG. 9  shows an embodiment of a tear off middle panel of the blank shown in  FIG. 1A . 
         FIG. 10  shows a perspective view of another embodiment of a latching sleeve formed of another embodiment of a blank. 
     
    
    
     DETAILED DESCRIPTION 
     The following description of the several embodiments is for illustrative purposes and is not intended to limit the disclosed invention to the described embodiments. In the following descriptions of the several embodiments, references to specific orientations in the drawings, for example, up, down, left, right, front, back, is to facilitate the description and is not intended to limit the embodiments to a particular orientation. 
     According to an embodiment, a plurality of articles, for example, snus packets, are releaseably attached to inner surfaces of a sleeve open at left and right ends and having a catch panel latched within a slot on a back of the sleeve to form a package. Preferably, a middle panel of the sleeve separates the interior of the sleeve into two recess portions open at left and right ends each containing articles releaseably attached to an inner surface of a respective panel. A pull tab panel connected to the catch panel preferably provides a gripping surface for a user to easily pull the catch panel out of the slot to open the package. 
     Once opened, the package preferably unfolds to expose articles releaseably attached to inner surfaces of front and back panels. The sleeve opens with the pull tab panel at one side and the middle panel unfolded at the other side, the front and back panels therebetween. In a preferred embodiment, the middle panel can be a tear-off panel and may be a coupon, advertisement, game piece or the like. When the panels are folded, the catch panel can be inserted in the slot in the back panel thus re-closing the package. The ends of the catch panel are preferably caught by ends of the slot to hold the package closed by friction. 
       FIG. 1A  illustrates an embodiment of a blank  100  for forming an openable and closeable latching sleeve adapted to hold articles such as packets of tobacco pouched products (snus packets). In a preferred embodiment the sleeve holds a plurality of such products each of a different attribute, such as by way of example, flavor. The flavors can be peppermint, spearmint, vanilla, citrus, clove, curry, maple, cherry, and the like. The inner surface of the blank panels are shown in  FIG. 1A  and the outer surfaces of the blank panels are shown in  FIG. 1B . The blank  100  can be composed of any suitable material for example plastic, metal, foil, paperboard, cardboard and any combinations thereof. Preferably, the blank  100  is composed of a paper suitable for forming hinged lid cigarette boxes. The blank  100  can include one or more layers of the paper material. The blank  100  preferably has rounded inside and outside corners to be pleasing to the touch by a user and avoid snagging in a user&#39;s pocket. 
     The blank  100  comprises a plurality of substantially rectilinear panels and a catch panel connected along adjacent sides thereof. The rectilinear panels each have two substantially parallel sides and two substantially parallel ends which are substantially perpendicular to the sides. The catch panel has two substantially parallel sides and two faceted ends, each end having first and second parts which extend outward from the sides to meet at an apex. With reference to  FIGS. 1A and 1B  the blank  100  comprises a pull tab panel  104  connected along a first fold line  128  to a catch panel  110 . The pull tab panel  104  has an inner surface  204 , an outside surface  304  and a finger grip portion  106  in a region of a terminal side  208  such that a user can easily operate latching and unlatching the catch panel  110  in the slot  161  as will be described later. A tuck portion  108  of the pull tab panel  104  in a region adjoining the first fold line  128  tucks into the slot  161  when the catch panel  110  is latched in the slot  161  and connects the grip portion  106  to the catch panel  110 . 
     The catch panel  110  has an inner surface  210 , an outer surface  310  and two ends  112 ,  114  and is connected to a back cover panel  230 . Each end  112 ,  114  comprises first and second parts. The first (lower) end  112  has a first part  116  which tapers outward from the first fold line  128  to a locking point  120  and a second part  118  which extends inward to a first corner stop  111  at a first side of the back cover panel  230 . The second (upper) end  114  has a first part  122  which tapers outward from the first fold line  128  to a locking point  126  and a second part  124  which extends inward to a second corner stop  113  at the first side of the back cover panel  230 . Preferably, the first and second parts  116 ,  118  of the first end  112  are symmetrical about the locking point  120  and the second end  114  is a mirror image of the first end  112 . Although the first and second parts of the first and second ends are shown as straight, the first and second parts of the first and second ends can also be curved. 
     Preferably, the sides of the back cover panel  130  are longer end to end than the sides of the pull tab panel  104  and the catch panel  110 . Preferably, the catch panel  110  is centered on the first side of the back cover panel  130 . The back cover panel  130  has an inner surface  230 , an outer surface  330  and is connected to the front panel  140  along a second fold line  138  defining a second side of the back cover panel  130 . 
     The front panel  140  has an inner surface  240 , an outer surface  340  and is connected to a binding panel  150  along a third fold line  148 . The binding panel  150  has an inner surface  250 , an outer surface  350  and is connected to a slot panel  160  along a fourth fold line  158 . 
     The slot panel  160  has an inner surface  260 , an outer surface  360  and is connected to a middle panel  190  along a fifth fold line  178 . The middle panel  190  is at a right side of the blank  100 , but is folded into the middle of the sleeve  480  formed of the folded blank  100  ( FIG. 6 ). The middle panel  190  is preferably shorter end-to-end than the slot panel  160  and is centered along the side of the slot panel  160  at the fifth fold line. Preferably, the middle panel  190  is connected to the side of the slot panel  160  at rounded inside corners  192 ,  194  as shown in  FIGS. 1A and 1B . 
     The slot panel  160  has an elongated slot  161  defined by a slot cut-out  162  and an opening created by a slot flap  170  opening. The slot  161  is of variable size depending on the position of the slot flap  170 . The slot cut-out  162  is an opening defined by parallel short and long sides  164 ,  166  spaced apart by ends  172 ,  174 . Preferably, the slot  161  is centered end-to-end on the slot panel  160  to align with the catch panel  110  and is parallel to the sides. Preferably, the slot  161  is closer to the fifth fold line  178  side-to side. Preferably, the slot  161  is spaced about one-third of the slot panel  160  width from the fifth fold line  178 . 
     Preferably, slits  171 ,  173  extend from the slot cut-out ends  172 ,  174  beyond the long side  166  of the slot cut-out  162  to a flap flex line  168  parallel to and spaced apart from the long side  166  by about a distance equal to the width of the slot cut-out  162 . The portion of the slot panel  160  within the region defined by the long side  166 , slit extensions  171 ,  173  of the ends  172 ,  174  and the flap flex line  168  is the slot flap  170  which resists movement and holds the pull tab tuck portion  108  and catch panel  110  in the slot  161 . When the slot flap  170  opens from the force of a user pulling the pull tab  104  grip portion  106 , the slot  161  opening widens in the direction from the short side  164  to the perforated line  168 . Preferably, the slot  161  lengthens in the end-to-end direction from the slot flap  170  opening due to the direction of the slit extensions  171 ,  173 , for example, when the slit extensions  171 ,  173  are non-parallel and taper outward toward the fifth fold line  178 . When the slot flap  170  closes, the slot cut-out  162  remains open. 
     In a preferred embodiment, the slot cut-out  162 , the slot flap  170  and the slot  161  are substantially trapezoidal. Preferably, the slot cut-out ends  172 ,  174  meet the long side  166  at an angle from about 30 degrees to about 60 degrees, for example, from about 40 to about 50 degrees. Preferably, the slit extensions  171 ,  173  meet the flap flex line  168  at an angle from about 30 degrees to about 60 degrees, for example, from about 40 to about 50 degrees. Also preferably, the slot cut-out ends are the same length as each other and the slit extensions  171 ,  173  are the same length as each other. However, it is also preferred that each corner where a slit extension  171 ,  173  meets the flap flex line  168 , is slightly rounded. Such a rounded corner can, for example, prevent tearing of the slot panel  160  at the corners of the slot flap  170 . In a preferred embodiment, the flap flex line  168  is a perforated line. 
     The middle panel  190  has an inner surface  290 , an outer surface  390  and is at the opposite side of the blank  100  from the pull tab panel  104 . 
       FIG. 2A  shows the preferred embodiment of the blank  100  for forming a sleeve having articles  400  attached to the front panel  140  inner surface  240  and the slot panel  160  inner surface  260 . Preferably, each article  400  is a packet  402  such as a foil pack, blister pack or the like to contain one or more consumer products in an interior space. In a preferred embodiment, the consumer products include smokeless tobacco products such as pouched smokeless tobacco (snus), other flavor pouches or flavored smokeless tobacco pouches such as described in commonly-owned U.S. Patent Application Publication Nos. 2008/03178911 and 2008/0202536 the entire contents of which are incorporated herein by reference. 
       FIG. 2B  shows a tray shaped packet  402 . The packet  402  includes a removable front cover  410  and a back base  420 . Preferably, the base  420  has a flange around a periphery of an opening to an interior space of the packet  402  containing consumer products. Preferably, the front cover  410  is hermetically sealed to the flange and the front cover  410  preferably has a thumb tab  414  for a user to grip the front cover  410  during removal of the cover  410  from the base  420  to access the interior space. 
     The packet back  422  is preferably removably attached to the inner surface  240  of the front panel  140  and/or the inner surface  260  of the slot panel  160  with an adhesive  440  or the like (for example, glue, quick-release glue, tape, VELCRO, etc.). The adhesive is preferably of limited strength such that the packet  402  can be easily removed from the surface  240 ,  260  by a user. Preferably, the adhesive  440  is in bonding regions  430  of the inner surfaces  240 ,  260 , which do not interfere with folding of the blank  100  and latching of the catch panel  110  to form the sleeve and package. As shown in  FIG. 2A , for example, the backs  422  of two articles  400  are bonded to the inner surface  260  of the slot panel  160  in bonding regions  430  by quick release glue  440  while the backs  422  outside of the bonding regions  430  are not bonded to the inner surface  260 . In this way, the articles  400  overlap the slot  161  but the catch panel  110  can still slide through the slot  161  and releaseably latch thereto beneath the backs  422  of the attached articles  400 . 
       FIG. 3  illustrates the pull tab panel  104  partially folded back along the first fold line  128  in the direction of arrow “A” and the back cover panel  130  partially folded forward in the direction of arrow “B” along the second fold line  138 . The first fold line  128  forms a leading edge to be inserted first into slot  161  (see  FIG. 6 ). The outer surface  304  of the pull tab  104  is brought to face the outer surfaces  310  and  330  of the catch panel  110  and the back cover panel  130 . The first  116 ,  122  and second  118 ,  124  parts of the first  112  and second  114  ends of the catch panel  110  preferably overhang beyond the ends of the folded back pull tab panel  104  to the locking points  120 ,  126 . 
       FIG. 4  illustrates the middle panel  190  partially folded forward along the fifth fold line  178  in a direction “C”. The middle panel  190  is folded along the fifth fold line  178  such that the inner surface  290  of the middle panel  190  faces the inner surface  260  of the slot panel  160  ( FIG. 5 ). Preferably, when articles  400  are attached to the slot panel  160  as described above with reference to  FIG. 2 , the inner surface  290  of the middle panel  190  overlies the fronts  412  of the attached articles  400 . 
       FIG. 5  illustrates the slot panel partially folded forward along the fourth fold line  158  in a direction indicated by arrow “D”. The outer surface  390  of the middle panel  190  ( FIG. 1B ) faces the inner surface  240  of the front panel  140 . Preferably, when articles  400  are attached to the front panel  140  as described above with reference to  FIG. 2 , the outer surface  390  of the middle panel  190  overlies the fronts  412  of the attached articles  400 . 
     The binding panel  150  is preferably folded forward about the third fold line  148  in a direction “E” to space the slot panel  160  apart from the front panel by the width of the binding panel  150  at one side of the front panel  140  adjacent the binding panel  150  as shown in  FIG. 5 . At the other side of the front panel  140  at the second fold line  138  the front panel  140  comes into close proximity to the slot panel  160  spaced apart therefrom by the middle panel  190  at the fifth fold line  178 . 
     When articles  400  are attached to the front panel  140  and/or the slot panel  160 , the articles  400  may also space the front panel  140  apart from the slot panel  160  (see, for example,  FIG. 7 ). 
       FIG. 6  shows the blank  100  folded so the middle panel  190  inner surface  290  faces the slot panel  160  inner surface  260  and the middle panel  190  outer surface  390  faces the front panel  140  inner surface  240 . A user can grasp the folded panels  140 ,  160 ,  190  for example, in the vicinity of the binding panel  150 , with one hand while grasping the pull tab panel  104  with the other hand. The back cover panel  130  folded about the second fold line  138  (in a direction of arrow “B” ( FIG. 3 )) closes the sleeve  480  to form a package  500  ( FIG. 7 ). 
     The pull tab panel  104  is folded in a direction of arrow “A” ( FIG. 3 ) along the first fold line  128  so its outer surface  304  ( FIG. 1B ) faces the outer surface  310  of the catch panel  110  and the outer surface  330  of back cover panel  130 . The first fold line  128  forms a leading edge to slideably insert the tuck portion  108  of the pull tab panel  104  and the catch panel  110  into the slot  161  in the slot panel  160 . The inner surface  230  of the back cover overlies a lower portion of the outer surface  360  of the slot panel  160  to close the sleeve  480 . 
     More specifically, when the leading edge  128  enters the slot cut-out  162 , the first parts  116 ,  122  of the catch panel  110  ends  112 ,  114  slideably engage the ends  172 ,  174  of the slot cut-out  162  while the leading edge  128  wedges the slot flap  170  open. Preferably, the locking points  120 ,  126  are spaced apart by a distance greater than the long side  166  of the slot cut-out  162 , but not too much larger as to inhibit entry and release of the catch panel  110 . The first parts  116 ,  122  slideably engage the slit extensions  171 ,  173  as the catch panel widens to the locking points  120 ,  126 . After the locking points  120 ,  126  pass through the slot  161  which is enlarged due to the deflection of the slot flap  170  about the flap flex line  168 , the slot flap  170  returns to its starting position and captures the catch panel  110 . The catch panel  110  is substantially inserted through the slot  161  and back cover  130  corner stops  111 ,  113  meet respective distal slot corner stops  117 ,  119  to prevent the sleeve  480  from closing further. Meanwhile frictional forces of the second parts  118 ,  124  against the respective slot ends  172 ,  174  hold the catch panel  110  in the slot  161  latching the sleeve  480  closed. The frictional forces of the slot long side  166  against the catch panel  110  inner surface  210  and the short side  164  against the pull tab  104  inner surface  204  also hold the catch panel  110  in the slot  161 . 
     Although a user&#39;s fingers are shown in broken lines in  FIG. 6  the blank  100  supporting articles  400  can be folded to form the sleeve  480  and package  500  by automated mechanization at high speed for manufacturing large quantities of the blanks  100 , sleeves  480  and/or packages  500  for marketing, distribution or the like. 
       FIG. 6  illustrates the latching and unlatching of the catch panel  110  in the slot  161  to open and close the package  500 . As is evident in  FIG. 6 , a slight bowing of the catch panel  110  and back cover panel  130  facilitates slipping the leading edge  128  into the slot cut-out  162  such that the straightened catch panel  110  and back cover panel  130  hold the catch panel  110  and tuck portion  108  of the pull tab  104  in the slot  161 . 
     The package  500  of articles  400  in the sleeve  480  formed of the blank  100  ( FIG. 1A ) is shown in a side elevational view in  FIG. 7 . The front panel  140  outer surface  340  forms the front of the package  500 . An article  400  is attached to the inner surface  240  of the front panel  140  with releasable adhesive  440 . The middle panel  190  divides the sleeve  480  recess  460  in two and the middle panel  190  outer surface  390  faces the articles  400  attached to the front panel  140 . Articles  400  attached to the inner surface  260  of the slot panel  160  with releasable adhesive  440  are inverted relative to the articles  400  attached to the front panel  140  and spaced apart therefrom by the middle panel  190 . The middle panel  190  inner surface  290  faces those articles  400  attached to the slot panel  160 . The slot panel  160  outer surface  360  forms a portion of the back of the package  500  from the pull tab panel  104  to the binding panel  150 . The back cover  130  outer surface  330  forms the remaining portion of the back of the package  500  with the grip portion  106  of the pull tab panel  104  overlying a portion of the back cover  130  ( FIG. 8A ) The binding panel  150  outer surface  350  forms a top of the package  500 . The catch panel  110  and the tuck portion  108  of the pull tab  104  are on the inside of the sleeve  480  between the slot panel  160  inner surface  260  and an article  400  attached to the slot panel  160  when the sleeve  480  is closed as shown in  FIG. 7 . 
       FIG. 8A  shows the back of the package  500  formed of the sleeve  480  open at both ends and containing articles  400 . 
       FIG. 8B  shows a front, top and side perspective view of the package  500  formed of the sleeve  480  open at both ends and containing articles  400 . As is evident from  FIGS. 8A and 8B , pull tab  104 , catch  110 , back cover  130 , front  140 , binding  150 , slot  160  and middle  190  panels form respective grip and catch portions of a latch, back cover, front, top, slotted back and dividing walls of the sleeve  500 . 
     A user can tug on the pull tab panel  104  grip portion  106  which protrudes from the slot  161  to overcome the frictional forces to unlatch the catch panel  110  from the slot  161  and open the sleeve  480 . Preferably, the user can fold back the back cover panel  130  about the second fold line  138  and fold back the front  140 , binding  150 , slot  160  and middle  190  panels about the third  148 , fourth  158  and fifth  178  fold lines to access articles  400  ( FIG. 2 ) packaged in the sleeve  480 . 
     In a preferred embodiment the middle panel  190  can be a tear-off panel and may be a coupon, advertisement, game piece of the like.  FIG. 9  shows the fifth fold line  178  can be a perforated easy tear line. In such an embodiment, the user can open the package  500  ( FIGS. 8A and 8B ) to access articles  400  such as shown in  FIG. 2 , and remove the middle panel  190 . The remaining panels can be re-closed by the user. 
     As can be seen in  FIGS. 6 and 7 , the latching mechanism of the package  500  can operate without the middle panel  190 . That is, the middle panel  190  does not form an outside wall of the sleeve  480  and is not a part of the latch. The latch, as described above, includes inserting the catch panel  110  and tuck portion  108  of the tab panel  104  into the slot  161  of the slot panel  160 . 
     The latch design can be adapted to different packaging concepts. Referring now to  FIG. 10 , for example, in an embodiment, a blank can comprise a slot panel  160 ′ having a slot  161 ′ as described above to accept a catch panel  110 ′ with locking points  120 ′,  126 ′ to releaseably engage ends of the slot  161 ′. The catch panel  110 ′ can be connected at one side to a pull tab  104 ′ at a fold line  128 ′. At the other side of the catch panel, second parts of first and second ends can attach directly to the slot panel  160 ′. The catch panel  110 ′ can be latched in the slot  161 ′ of the slot panel  160 ′ having the pull tab  104 ′ protruding outwardly from the slot  161 ′ to form a cylindrical (for example, elliptical cylinder) sleeve  480 ′ having the slot panel  160 ′ form the wall of the sleeve  480 ′ surrounding a recess  460 ′ open at the top and bottom. The latch can be adapted to other packaging concepts such as cubic openable boxes, rectangular cuboids, trianguloids (triangular prism, triangular pyramid, etc.) and various others. 
     While the invention has 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.