Patent Publication Number: US-2012042883-A1

Title: Composite Packaging System For Particulate Smokable Product

Description:
TECHNICAL FIELD 
     The present invention relates generally to the field of sealed packaging systems for organic material. More particularly, the invention concerns protective packaging systems for aggregates of particulate smokable product. 
     BACKGROUND OF THE INVENTION 
     Organic smokable product, such as tobacco, legal non-tobacco herbs, or the like, continue to be enjoyed by consumers worldwide. Optimizing the smoking characteristics of organic material requires maintaining its freshness and flocculence from the time the product is packaged until the time the consumer uses the product. Protecting the freshness of the product helps maximize its flavor and burn characteristics at the time of its use. Protecting the flocculence, or light fluffiness, of an aggregate of particulate smokable product helps ensure that, when placed into a cigar wrapper and smoked by the consumer, it will draw properly and thereby produce a smoother smoking experience. 
     Various packaging systems exist which provide for the sealed encapsulation of loose particulate smokable product. However, these systems generally lack features that enable the attractive, compact, sealed packaging of small quantities of particulate smokable product, such as those quantities appropriate for a single consumer-rolled cigar, while substantially protecting the product from being crushed or powderized during shipment, retail display or handling by the consumer. Prior packaging solutions for particulate smokable product are commonly designed to contain large quantities of the smokable product, for example, enough to fill numerous rolled cigars. Prior solutions featuring flexible, single-layer packaging of large quantities of particulate smokable product can leave the product vulnerable to being crushed and powderized not only by external forces, but also under its own weight. 
     Moreover, prior packaging systems adapted to contain smaller quantities of smokable product generally do not include features to facilitate the evenly-distributed placement of the product along the length of an open cigar wrapper directly from the packaging. 
     Accordingly, what is needed is a low-cost, light-weight, compact, robust and attractive packaging system for a small aggregate of particulate smokable product which maintains the freshness and flocculence of the product, while facilitating the evenly-distributed placement of the product along the length of an open cigar wrapper directly from the packaging. 
     SUMMARY OF THE INVENTION 
     The shortcomings of the prior art are overcome and additional advantages are provided by the provision of a composite packaging system for particulate smokable product. The composite packaging system generally comprises an aggregate of particulate smokable product, a bag element, an envelope element and at least one externally viewable image disposed on the envelope element. 
     The smokable product is generally comprised of legal smokable non-tobacco herbs, but can also be comprised of smokable tobacco, or a combination thereof. In embodiments, the aggregate is flocculent and typically weighs between approximately 1.5 and 2.5 grams. In certain embodiments, the aspect ratio between the aggregate length and the aggregate width is greater than approximately 5. In further embodiments, the aggregate length is less than approximately 5.5 inches and the aggregate width is less than approximately 1 inch. 
     The bag element is substantially comprised of organic polymeric film, and has a mouth portion, a floor portion, a first lateral edge, a second lateral edge and a distribution zone generally adjacent the floor portion and extending generally from the first lateral edge toward the second lateral edge. The aggregate is approximately evenly distributed within the distribution zone. The bag element is in a rolled configuration wherein it is rolled multiple times about its distribution zone. 
     The bag element of certain embodiments may include an adhesive strip, which is typically disposed on the outer surface of the bag element at a location proximate the mouth portion and contacting the outer surface at an additional location. This adhesive strip may thereby releasably secure the bag element in its rolled configuration. 
     The envelope element is typically comprised of a first side sheet and a second side sheet adjoined generally at their respective peripheries, thereby forming a hermetically sealed cavity. The aggregate and bag element are snugly retained within this cavity. The envelope element is substantially comprised of metallized organic polymeric film. 
     In particular embodiments, the aspect ratio between the envelope width and the envelope thickness is typically greater than approximately 3, and the aspect ratio between the envelope length and the envelope width is typically greater than approximately 2.5. 
     In some embodiments, the envelope includes a pouch portion with a proximal end and a tear-away portion thereat. The tear-away portion is at least partially separable from the pouch portion by way of lateral tearing from a first edge notch toward a second edge notch. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings in which: 
         FIG. 1  is a diagrammatic front view of a composite packaging system for particulate smokable product; 
         FIG. 2  is a diagrammatic side view of the embodiment of  FIG. 1 ; 
         FIG. 3  is a diagrammatic cross-sectional view taken along line  3 - 3  of  FIG. 2 , showing a bag element in rolled configuration and containing an aggregate of particulate smokable product where the bag element is retained within a hermetically sealed cavity of an envelope element; 
         FIG. 4  is a diagrammatic top view of the embodiment of  FIG. 1 ; 
         FIG. 5  is an enlarged diagrammatic cross-sectional view taken along line  5 - 5  of  FIG. 1 ; 
         FIG. 6  is a diagrammatic front view of an aggregate of particulate smokable product, shown in generally flocculent form; 
         FIG. 7  is a diagrammatic end view of the aggregate of  FIG. 6 ; 
         FIG. 8  is a diagrammatic front view of a bag element in an unfolded precursor configuration in which the distribution zone of the bag element is filled with an aggregate of particulate smokable product; 
         FIG. 9  is a diagrammatic end view of the bag element of  FIG. 8 ; 
         FIG. 10  is a diagrammatic front view of a bag element in folded configuration and containing an aggregate of particulate smokable product; 
         FIG. 11  is a diagrammatic end view of the bag element of  FIG. 10 ; and 
         FIG. 12  is a diagrammatic perspective view of a bag element in rolled configuration containing an aggregate of particulate smokable product, where the outer lip of the bag element is partially pulled back. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, like reference numerals designate identical or corresponding features throughout the several views. 
     Referring to  FIGS. 1-4 , there is shown generally at  20  a composite packaging system for particulate smokable product. The composite packaging system  20  comprises an aggregate  22  of particulate smokable product, a wrapping or bag element  24 , an envelope element  26 , and at least one externally viewable image  30  disposed on the envelope element  26 . The aggregate  22  is generally flocculent. The composite packaging system  20  is adapted to maintain the flocculence and freshness of the particulate smokable product throughout the shipment, retail display and consumer handling of the packaged product. Moreover, the adaptations described herein provide for these advantages even when the packaging system is maintained in a vertical orientation (as depicted, for example, in  FIGS. 1 and 2 ), for extended periods of time. 
     The smokable product is generally comprised of legal smokable non-tobacco herb, but can also be comprised of smokable tobacco, or a combination of the two. The term particulate smokable product is used herein to describe, for example, a collection of particles of smokable plant matter, each particle generally ranging in size from a blade of grass to a bud or small grain. The average size of each particle varies depending upon the particular product, and the selected plant matter may be, for example, cut or ground to produce the desired particle size. 
     Turning to  FIGS. 6 and 7  for illustration, in embodiments, the aggregate  22  typically weighs between approximately 1.5 and 2.5 grams, which is a quantity generally found to be sufficient to fill a single consumer-rolled cigar. In certain embodiments, the aspect ratio between the aggregate length  52  and the aggregate width  54  is greater than approximately 5. In further embodiments, the aggregate length  52  is less than approximately 5.5 inches and the aggregate width  54  is less than approximately 1 inch. Since the average consumer-rolled cigar is less than 5.5 inches in length, the ability to place the aggregate  22  directly from the packaging into an open cigar wrapper helps ensure an even distribution of the particulate smokable product along the length of the resulting cigar, once rolled. 
     Referring now to  FIGS. 8 and 9 , the wrapping or bag element  24  is substantially comprised of organic polymeric film. The bag element  24  has a mouth portion  38 , a floor portion  40 , a first lateral edge  42 , a second lateral edge  44  and a distribution zone  46  generally adjacent the floor portion  40  and extending generally from the first lateral edge  42  toward the second lateral edge  44 . The aggregate  22  is approximately evenly distributed within the distribution zone  46 , which tends to give the aggregate  22  an elongated profile. 
     As shown, for example, in FIGS.  5  and  10 - 12 , the bag element  24  is in a rolled configuration wherein it is rolled multiple times about the distribution zone  46 . As a result, the bag element and the aggregate contained therewithin typically have a round or slightly oblong cross section. When a non-bag wrapping (not shown) is used in place of a bag element  24 , the wrapping is in wrapping engagement with the aggregate  22 . The bag element  24  may be considered a more specialized wrapping for the aggregate  22 , but with additional features. 
     The bag element  24  provides several significant advantages to the composite packaging system  20 , which include the following. First, during the packaging process, the floor portion  40  facilitates the formation of particulate smokable product into an elongated, evenly-distributed aggregate  22 . Second, the aggregate  22  can be more easily handled while its weight is measured and adjusted prior to the product becoming hermetically sealed within the envelope element  26 . Third, in its rolled configuration (shown, for example, in  FIG. 12 ) the bag element  24  provides increased structural rigidity to the packaging system  20 , both in compression and bending, thereby helping to maintain the even distribution and flocculence of the product within the packaging throughout the shipping, retail display, and consumer handling of the packaged product. Fourth, the organic polymeric film of the bag element  24  provides a second barrier to keep the particulate smokable product fresh over extended periods of time. Fifth, the bag element  24  can be removed from the envelope element  26  and facilitate the even placement of the aggregate  22  onto an open cigar wrapper by allowing the aggregate  22 , without a change in its dimensions, to drop directly from the region of the floor portion  40  through the mouth portion  38 . 
     Turning now to  FIGS. 5 and 8  for illustration, the bag element  24  of certain embodiments may include an adhesive strip  48 . The adhesive strip  48  is typically disposed on the outer surface  50  of the bag element  24  at a location proximate the mouth portion  38  and contacting the outer surface  50  at an additional location (such a location shown, for example, in  FIG. 5 ). This adhesive strip  48  may thereby releasably secure the bag element  24  in its rolled configuration. As illustrated in  FIG. 12 , a further advantage of this arrangement is that the consumer can unroll the bag element  24  more quickly and easily by running his or her finger circumferentially along the outer surface  50  of the bag element  24  until that finger catches the free outer lip  74 . As indicated by the arrow with the dashed line, the outer lip  74  can then be used to pull the adhesive strip  48 , which is disposed proximate the opposite lip (not shown) of mouth portion  38 , away from the additional location along outer surface  50 , thereby releasing the bag element  24  from its rolled configuration. 
     Turning to  FIGS. 3 and 5  for illustration, within the envelope element  26  is a hermetically sealed cavity  28 , within which the aggregate  22  and bag element  24  are snugly retained. In most embodiments, the envelope element  26  is typically comprised of a first side sheet  32  and a second side sheet  34  sealingly adjoined generally at their respective peripheries (such peripheries illustrated, for example, at  36 ), thereby forming the hermetically sealed cavity  28 . 
     The envelope element  26  is substantially comprised of metallized organic polymeric film, which provides the packaging system a second barrier for maintaining the freshness of the product, a second layer of structural rigidity (for example, in compression and bending), as well as external surfaces upon which to print and display attractive and informative externally viewable image  30 . The metallized organic polymeric film is typically a metallized polyester film. In certain embodiments, the first side sheet  32  and second side sheet  34  are each comprised of three layers, for example, a layer of PET, a layer of metal foil and a layer of LLDPE. 
     Returning to  FIGS. 1 and 3  for illustration, in particular embodiments, the envelope element  26  has an envelope length  58 , an envelope width  60  and an envelope thickness  62 . In such embodiments, the aspect ratio between the envelope width  60  and the envelope thickness  62  is typically greater than approximately 3, and the aspect ratio between the envelope length  58  and the envelope width  60  is typically greater than approximately 2.5. Further, in certain embodiments, the envelope length  58  is less than approximately 6.5 inches, the envelope width  60  is less than approximately 2.25 inches, and the envelope thickness  62  is less than approximately 0.65 inches. 
     As illustrated in  FIG. 1 , in some embodiments, the envelope element  26  includes a pouch portion  64  with a proximal end  66  and a tear-away portion  68  thereat. The tear-away portion  68  is at least partially separable from the pouch portion  64  by way of lateral tearing of the tear-away portion from a first edge notch  70  toward a second edge notch  72 . 
     In combination, the bag element  24 , the envelope element  26 , and the dimensions and aspect ratios described herein provide for a sealed packaging system  20  which is more slender, compact and attractive, yet rigid enough to protect the flocculence of the aggregate of particulate smokable product from packaging until use. 
     The foregoing detailed description is intended merely to provide examples, and is in no way intended to limit the scope of the appended claims to these described embodiments. Accordingly, modifications to the embodiments described are possible, and it should be clearly understood that the invention may be practiced in many different ways than the embodiments specifically described below, and still remain within the scope of the claims.