WO2015040059A1

WO2015040059A1 - Method of securing sheet materials to form a container

Info

Publication number: WO2015040059A1
Application number: PCT/EP2014/069792
Authority: WO
Inventors: Arjen Hamilcar SLOOFF
Original assignee: Philip Morris Products S.A.
Priority date: 2013-09-17
Filing date: 2014-09-17
Publication date: 2015-03-26

Abstract

A method of forming a container (10) for consumer goods comprises providing a first sheet material (14) and a second sheet material (12), and applying a first transformable substrate (34) to at least a portion of the first sheet material (14) or at least a portion of the second sheet material (12). The second sheet material (12) is folded around the first sheet material (14) so that the first sheet material (14) and the folded second sheet material (12) form a container (10) for consumer goods. The first transformable substrate (34) is then transformed into an adhesive to adhere the first sheet material (14) to the folded second sheet material (12).

Description

METHOD OF SECURING SHEET MATERIALS TO FORM A CONTAINER

The present invention relates to a method of forming a container for consumer goods, in particular a method of securing a first sheet material to a second sheet material to form a container. The present invention also relates to a container for consumer goods comprising at least one transformable substrate located between an inner frame and a box portion. The present invention also relates to the use of a transformable substrate to secure an inner frame to an inner surface of a hinged lid box. The containers of the present invention find particular application as containers for smoking articles, such as for example cigarettes.

Consumer goods such as smoking articles are commonly packaged in rigid box shaped containers, such as hinged lid containers having a box portion and a lid connected to the box about a hinge line extending across the rear wall of the container. In some cases, the container further includes an inner frame wrapped around at least a portion of the consumer goods. This may provide further rigidity to the container and protect the consumer goods. Where the inner frame extends above an upper edge of the box portion, the inner frame also provides a surface against which the lid can close.

Typically, the box portion and the lid are formed from a single folded laminar blank. The inner frame is usually formed from a separate laminar blank and secured to the inside of the box portion by applying a liquid adhesive such that the liquid adhesive bonds the two surfaces together upon drying of the liquid adhesive downstream of the liquid adhesive application station. During the travel of a package with the liquid adhesive through the packaging machinery, the adhesive may contaminate the production line and necessitate regular cleaning of the manufacturing equipment. It would therefore be desirable to provide a method of securing an inner frame within a container which can support an uninterrupted production and a reduced requirement of cleaning.

According to a first aspect, the present invention provides a method of forming a container for consumer goods, the method comprising providing a first sheet material and a second sheet material, and applying a first transformable substrate to at least a portion of the first sheet material or at least a portion of the second sheet material. After the first transformable substrate has been applied, the second sheet material is folded around the first sheet material so that the folded second sheet material and the first sheet material form a container for consumer goods. The first transformable substrate is transformed into an adhesive to adhere the first sheet material to the folded second sheet material. According to the invention, the first transformable substrate may be transformed into an adhesive before, during or after the second sheet material is folded around the first sheet material. Alternatively, or in addition, the transformation may be staged, such that a first area of the transformable substrate is transformed at a first time and location and a second area of the transformable substrate is transformed at a second time and location. Obviously, multiple stages are also possible.

The term "transformable substrate" is used herein to mean any material which is substantially non-adhesive in its initial, untransformed state at the time it is applied to the first or second sheet material but becomes adhesive after transformation. In other words, the transformable substrate used in the present invention is a non-adhesive substrate which is transformed into an adhesive after being applied to the first or second sheet material. The transforming step preferably comprises exposing the transformable substrate to energy. This could be, for example, by exposure to at least one of heat, electromagnetic radiation, including microwave radiation, ultrasound, and chemical energy. Preferably, however, the transformable substrate is transformed into an adhesive by exposure to at least one of electromagnetic radiation, including microwave radiation, ultrasound, and chemical energy. The transformable substrate will only form a bond between the first and second sheet materials once it has been transformed into an adhesive. However, in some embodiments, the transformable substrate may be already slightly tacky in the initial substrate form, before the transformation into an adhesive that can after the transformation support a permanent connection between the first and second sheet material.

By applying a transformable substrate in an untransformed state to the first or second sheet material, the method according to the present invention advantageously reduces or eliminates the risk of contamination of the production line with a sticky adhesive. In particular, by separating the steps of applying the transformable substrate and transforming the transformable substrate into an adhesive, the method according to the present invention ensures that the only transformable substrate which is transformed into an adhesive is the transformable substrate that has been applied to the first or second sheet material. Any excess transformable substrate which is applied accidentally to manufacturing equipment at the application stage can remain untransformed, since the transformation step can be conducted downstream in the production line. Thus, the present invention significantly reduces production line downtime by reducing or eliminating the need to clean excess sticky adhesive from the manufacturing equipment.

As discussed above, the transforming step can include exposing the first transformable substrate to at least one of heat, electromagnetic radiation, and ultrasound. For example, in some embodiments the transforming step comprises exposing the first transformable substrate to a temperature of between about 120 degrees Celsius and about 220 degrees Celsius. Alternatively, or in addition, the transforming step can comprise exposing the first transformable substrate to at least one of visible light and ultraviolet light or microwave radiation. Alternatively, or in addition, the transforming step may comprise exposing the first transformable substrate to chemical energy. In other words, the first transformable substrate may be contacted with one or more additional materials that undergo a chemical reaction with the first transformable substrate and transform the first transformable substrate into an adhesive. Therefore, in some embodiments the applying step comprises applying the first transformable substrate to the first sheet material, the method further comprising a step of applying a second transformable substrate to the second sheet material, and wherein the transforming step comprises bringing the first transformable substrate into contact with the second transformable substrate so that a chemical reaction between the first and second transformable substrates forms the adhesive.

The first transformable substrate, and the second transformable substrate where present, can be applied to the first sheet material or the second sheet material at any stage prior to folding the second sheet material around the first sheet material. For example, where the first or second sheet material may be pulled and cut from a substantially continuous roll of sheet material, the transformable substrate may be applied after the material has been pulled from the roll but before it has been cut. Alternatively, the transformable substrate can be applied to the sheet material after it has been cut to the appropriate size and shape for forming the container, but before the sheet material has been folded. In a further alternative, in embodiments in which the first sheet material is folded, the transformable substrate may be applied to the first sheet material after it has been folded but before the second sheet material is folded around the first sheet material. It yet another embodiment, where the sheet material is supplied as a continuous web on a roll, the transformable substrate may be already applied on the rolled sheet material during conversion of the sheet material, for example with print, embossing or other embellishments. Preferably, in such an embodiment registration marks are provided to align the position of the transformable substrate, print, embossing or other embellishments on the sheet material.

The first sheet material typically comprises first and second surfaces, and in those embodiments in which a transformable substrate is applied to the first sheet material the applying step may comprise applying the transformable substrate over at least about 60 percent of the first surface, preferably at least about 70 percent of the first surface, more preferably at least about 80 percent of the first surface, most preferably at least about 90 percent of the first surface. The transformable substrate may be applied over the entire first surface. Providing a transformable substrate over most or all of the first surface has the advantage of increasing the structural integrity of the container without incorporating additional sheet material. It is not possible to achieve such high levels of coverage using existing processes, which use a liquid adhesive, without contamination of manufacturing equipment. Additionally, or alternatively, the transforming step may comprise selectively transforming only selected areas of the transformable substrate. Such selective transformation of the transformable substrate may be desirable where it is necessary to prevent unwanted adhesion of the first sheet material to parts of the second sheet material. For example, in some embodiments it may be preferable to apply the transformable substrate over the entire first surface of the first sheet material to simplify the application step. However, where the first material defines an inner frame that forms part of a hinged lid box, the inner frame may be arranged so that an upper portion of the inner frame extends beyond an upper edge of the box portion of the container to provide a surface against which the lid closes. In such an embodiment, the transformable substrate on the upper portion of the inner frame should remain untransformed so that the lid is not adhered to the inner frame in the closed position. Therefore, only the area of transformable substrate between the inner frame and the box portion is selectively activated. An alternative is to apply the transformable substrate only to those areas of the first surface of the inner frame that contact the box portion of the container. Again, in such an embodiment, where the first sheet material for the inner frame is supplied as a continuous web on a roll, the transformable substrate may be already applied on the first sheet material before rolling the web onto the roll, completely covering the first sheet material. This has the advantage that no registration between the first sheet material and the cutting that cuts inner frame shapes from the continuous web of first sheet material is required.

The method according to the present invention may further comprise the steps of providing one or more consumer goods and folding the first sheet material around the consumer goods to form an inner frame.

In some embodiments of the present invention the container is a hinged lid box, as discussed above. In these embodiments, the folded second sheet material forms a box portion and a lid portion connected to the box portion along a hinge line, and the transforming step adheres the first sheet material to an inner surface of the box portion. In those embodiments in which the first sheet material is folded to form an inner frame, the inner frame is adhered to an inner surface of the box portion.

Suitable materials that can be used as a transformable substrate in the present invention include polyethylene, polypropylene, biaxially oriented polypropylene, cast polypropylene, polyvinylidene chloride, wax (mineral or natural based), polyurethane, polytetrafluoroethylene, acrylics, and combinations thereof. The transformable substrate can be applied as a film, an extrusion, a lacquer (water-based, solvent-based or light cured) or a dispersion. When applied as a liquid, the transformable substrate can be applied using any suitable coating method, such as air knife coating, anilox coating, curtain coating, single or multilayer slide coating, flexo coating, gap coating, gravure coating, immersion (dip) coating, knife-over-roll coating, metering rod (Meyer bar) coating, reverse roll coating, roller coating, rotary screen coating, silk screen coating and slot die (extrusion) coating.

Transformable substrates suitable for use in the present invention may have a thermal conductivity of at least about 3x10-4 calories per s.cm. degrees C, more preferably a thermal conductivity of at least about 12x10-4 calories per s.cm. degrees C. The thermal conductivity may be less than about 0.08 calories per s.cm. degrees C, preferably less than about 0.3 calories per s.cm. degrees C. A transformable substrate having a thermal conductivity within these ranges is particularly advantageous where the transformable substrate is transformed by exposure to heat, since a low thermal conductivity reduces the time required for the transforming step.

Additionally, or alternatively, the transformable substrates may have a heat capacity at 25 degrees C and under standard conditions of at least about 0.2 J/(g.K), preferably at least about 0.5 J/(g.K), more preferably at least about 0.9 J/(g.K). The heat capacity may be less than about 1.6 J/(g.K). A transformable substrate having a heat capacity within these ranges is particularly advantageous where the transformable substrate is transformed by exposure to heat, since a low heat capacity reduces the energy input required for the transforming step.

Additionally, or alternatively, transformable substrates may have a melting temperature of at least about 30 degrees C, preferably at least about 40 degrees C, more preferably at least about 50 degrees C, even more preferably at least about 60 degrees C. The melting temperature may be less than about 150 degrees C, preferably less than about 120 degrees C, more preferably less than about 100 degrees C, even more preferably less than about 80 degrees C. Melting temperatures within these ranges advantageously minimise the heating required in embodiments in which the transformable substrate is applied as a liquid, while also ensuring that the transformable substrate remains solid at lower temperatures.

The present invention also extends to containers of consumer goods formed in accordance with the above method in any of its embodiments, as well as the intermediate containers that are formed after the second sheet material has been folded around the first sheet material but before the transformable substrate has been transformed.

Therefore, according to a second aspect the present invention provides a container of consumer goods, the container comprising a box portion and a lid portion connected to the box portion along a hinge line. The container also comprises an inner frame positioned within the box portion. At least one transformable substrate is provided on the inner frame or the box portion and arranged so that the transformable substrate overlies at least a portion of the inner frame and underlies at least a portion of the box portion. The transformable substrate can be activated by exposure to at least one of heat, electromagnetic radiation, ultrasound and chemical energy, as described previously. The transformable substrate can comprise any of the materials listed above.

The inner frame is preferably formed from a folded sheet material having a first surface and a second surface, wherein the transformable substrate is applied over at least about 60 percent of the first surface, preferably at least about 70 percent of the first surface, more preferably at least about 80 percent of the first surface, most preferably at least about 90 percent of the first surface. The transformable substrate may be applied over the entire first surface. Alternatively, in some embodiments, the transformable substrate is applied only to those areas of the first surface that overlap the box portion of the container.

According to a third aspect the present invention also extends to the use of a transformable substrate to secure an inner frame to an inner surface of a hinged lid box.

The term "hinged lid box" is used herein to mean a container having a box portion and a lid portion connected to the box portion along a hinge line extending across the rear wall of the container. The inner frame, once secured to the inner surface of the hinged lid box, forms part of the container.

The terms "front", "rear", "top", "bottom", "side", "left", "right" and other terms used to describe relative positions of the components of containers in accordance with any aspect of the present invention refer to the container in an upright position with the opening through which the consumer goods are removed at the top end and, where present, a hinge line on the rear of the container.

The term "longitudinal" refers to a direction from bottom to top or vice versa. The term "transverse" refers to a direction perpendicular to the longitudinal direction.

The term "panel" refers to a portion of the container formed from a single, continuous portion of material. The term "wall" refers more generally to a facet of the assembled container, for example the "front wall" defines a front facet of the container. A wall may be formed from a single panel, or a wall may be formed from two or more abutting or overlapping panels.

In any of the aspects and embodiments described above, the one or more consumer goods may comprise a bundle of smoking articles, such as a bundle of cigarettes. Preferably, the method according to the invention comprises the further comprises the step of providing one or more consumer goods; and folding the first sheet material around the one or more consumer goods so that the first sheet material forms an inner frame at least partially surrounding the one or more consumer goods;

However, containers in accordance with the present invention can also be used with a variety of consumer goods other than smoking articles. Containers formed in accordance with the present invention are preferably rectangular parallelepipeds each comprising two wider walls spaced apart by two narrower walls. The two wider walls will usually be the front and rear walls and the two narrower walls will usually be side walls.

The container may be formed from any suitable material including, but not limited to, cardboard, paperboard, paper, cellulosic material, plastic, metal, or combinations thereof. Preferably, each of the first and second sheet materials comprises a folded laminar cardboard blank, wherein the cardboard preferably has a basis weight of between about 100 grams per square metre and about 350 grams per square metre. However, more generally, either of the first or second sheet material could be one of inner liner, inner frame, blank, outer wrapper, bundle paper or display carton.

In some embodiments, each assembled and filled container is wrapped in an outer wrapper. The outer wrapper is preferably a transparent polymeric film of, for example, high or low density polyethylene, polypropylene, oriented polypropylene, polyvinylidene chloride, cellulose film, or combinations thereof. The outer wrapper is applied in a conventional manner and may include a tear tape. In addition, the outer wrapper may be printed with images, consumer information or other data.

As described above, containers according to any aspect of the invention may be in the shape of a rectangular parallelepiped and they may comprise right-angled longitudinal and right- angled transverse edges. Alternatively, the containers may comprise one or more rounded longitudinal edges, rounded transverse edges, bevelled longitudinal edges or bevelled transverse edges, or combinations thereof. For example, the containers may comprise, without limitation:

- One or two longitudinal rounded or bevelled edges on the front wall, and/or one or two longitudinal rounded or bevelled edges on the rear wall.

- One or two transverse rounded or bevelled edges on the front wall, and/or one or two transverse rounded or bevelled edges on the rear wall.

- One longitudinal rounded edge and one longitudinal bevelled edge on the front wall, and/or one transverse rounded edge and one transverse bevelled edge on the rear wall.

- One or two transverse rounded or bevelled edges on the front wall and one or two longitudinal rounded or bevelled edges on the front wall.

- Two longitudinal rounded or bevelled edges on a first side wall or two transverse rounded or bevelled edges on a second side wall.

Where the container comprises one or more bevelled edges, preferably the bevelled edge has a width of between about 1 millimetre and about 10 millimetres, preferably between about 2 millimetres and about 6 millimetres. Alternatively, the container may comprise a double bevel formed by three parallel creasing or scoring lines that are spaced such that two distinct bevels are formed on the edge of the container.

As described above, containers according to any aspect of the invention find particular application as packs for elongate smoking articles such as, for example, cigarettes, cigars or cigarillos. It will be appreciated that through appropriate choices of the dimensions, containers according to the invention may be designed for different numbers of conventional size, king size, super-king size, slim or super-slim cigarettes. Alternatively, other consumer goods may be housed inside the packages and containers.

Through an appropriate choice of the dimensions of the containers according to the present invention, they may be designed to hold different total numbers of smoking articles, or different arrangements of smoking articles. For example, through an appropriate choice of the dimensions thereof, containers according to the invention may be designed to hold a total of between five and thirty smoking articles.

The smoking articles may be arranged in different collations, depending on the total number of smoking articles. For example, the smoking articles may be arranged in a single row of five, six, seven, eight, nine or ten. Alternatively, the smoking articles may be arranged in two or more rows. The two or more rows may contain the same number of smoking articles. For example, the smoking articles may be arranged in: two rows of five, six, seven, eight, nine or ten; three rows of five or seven; or four rows of four, five or six. Alternatively, the two or more rows may include at least two rows containing different numbers of smoking articles to each other. For example, the smoking articles may be arranged in: a row of five and a row of six (5-

6) ; a row of six and a row of seven (6-7); a row of seven and a row of eight (7-8); a middle row of five and two outer rows of six (6-5-6); a middle row of five and two outer rows of seven (7-5-

7) ; a middle row of six and two outer rows of five (5-6-5); a middle row of six and two outer rows of seven (7-6-7); a middle row of seven and two outer rows of six (6-7-6); a middle row of nine and two outer rows of eight (8-9-8); or a middle row of six with one outer row of five and one outer row of seven (5-6-7).

Containers according to the present invention may hold smoking articles of the same type or brand, or of different types or brands. In addition, both filterless smoking articles and smoking articles with various filter tips may be contained, as well as smoking articles of differing length (for example, between about 40 mm and about 180 mm), diameter (for example, between about 4 mm and about 9 mm). In particular, the container may comprise smoking articles with recessed filters. In addition, the smoking articles may differ in strength of taste, resistance to draw and total particulate matter delivery. Preferably, the dimensions of the containers are adapted to the length of the smoking articles, and the collation of the smoking articles. Typically, the dimensions of the container are between about 0.5 mm to about 5 mm larger than the dimensions of the package or packages of smoking articles housed inside the container.

Preferably, containers according to the invention have a height of between about 40 mm and about 150 mm, more preferably a height of between about 50 mm and about 125 mm, wherein the height is measured in the longitudinal direction between the top and bottom edges of the front wall or the rear wall, whichever is longest.

Preferably, containers according to the invention have a width of between about 12 mm and about 150 mm, more preferably a width of between about 40 mm and about 125 mm, wherein the width is measured from one side wall to the other side wall of the container.

Preferably, containers according to the invention have a depth of between about 6 mm and about 150 mm, more preferably a depth of between about 12 mm and about 25 mm, wherein the depth is measured from the front wall to the rear wall of the container.

Preferably, the ratio of the height of the container to the depth of the container is in between about 0.3 to 1 and about 10 to 1 , more preferably between about 2 to 1 and about 8 to 1 , most preferably between about 3 to 1 and 5 to 1 .

Preferably, the ratio of the width of the container to the depth of the container is in between about 0.3 to 1 and about 10 to 1 , more preferably between about 2 to 1 and about 8 to 1 , most preferably between about 2 to 1 and 3 to 1 .

Where the container houses smoking articles, the container may further comprise compartments (for example for waste such as ash or butts) or other consumer goods, for example matches, lighters, extinguishing means, breath-fresheners or electronics. The other consumer goods may be attached to the outside of the container, contained within the container along with the package of smoking articles, in a separate compartment of the container or combinations thereof.

The exterior surfaces of containers according to the invention may be printed, embossed, debossed or otherwise embellished with manufacturer or brand logos, trademarks, slogans and other consumer information and indicia.

The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 shows a hinged lid container including an inner frame; and

Figure 2 shows a method of forming a hinged lid container in accordance with the present invention.

Figure 1 shows a container 10 formed from an outer blank 12 and an inner blank 14. The outer blank 12 is folded to form a box portion 16 and a lid portion 18, the lid portion 18 being connected to the box portion 16 by a hinge line extending across the rear wall of the container The inner blank 14 is folded to form an inner frame 20 which is contained within the outer blank 12 and affixed to an inner surface of the box portion 16. The inner frame 20 includes a cut-out 22 formed therein for accessing the consumer goods contained within the inner frame 20. The inner frame 20 may also include a flap for covering the cut-out 22 when the container 10 is closed.

Figure 2 shows an exemplary process for forming the hinged lid container 10, in accordance with the present invention. In a first step, a plurality of smoking articles 30 are gathered together to form a bundle 32. In a second step, a transformable substrate 34 is applied to the area of the inner blank 14 that will ultimately contact the inner surface of the box portion 16 of the container 10. Next, the inner blank 14 is folded around the bundle 32 of smoking articles 30 to form the inner frame 20. The outer blank 12 is then folded around the inner frame 20 and the bundle 32 of smoking articles 30 to form the container 10. In a final step, which is not shown in Figure 2, the box portion 16 is heated at the front wall of the container 10 to transform the transformable substrate 34 into an adhesive that bonds the inner frame 20 to the inner surface of the box portion 16.

Claims

1. A method of forming a container for consumer goods, the method comprising:

providing a first sheet material and a second sheet material;

applying a first transformable substrate to at least a portion of the first sheet material or at least a portion of the second sheet material;

folding the second sheet material around the first sheet material so that the first sheet material and the folded second sheet material form a container for consumer goods; and

transforming the first transformable substrate into an adhesive to adhere the first sheet material to the folded second sheet material.

2. A method according to claim 1 , wherein the transforming step comprises selectively transforming only selected areas of the first transformable substrate into adhesive.

3. A method according to claim 1 or 2, wherein the transforming step comprises exposing the first transformable substrate to energy.

4. A method according to claim 3, wherein the energy is at least one of electromagnetic radiation, ultrasound and chemical energy.

5. A method according to claim 3, wherein the transforming step comprises exposing the first transformable substrate to a temperature of between about 120 degrees Celsius and about 220 degrees Celsius.

6. A method according to any preceding claim, wherein the applying step comprises applying the first transformable substrate to the first sheet material, the method further comprising a step of applying a second transformable substrate to the second sheet material, and wherein the transforming step comprises bringing the first transformable substrate into contact with the second transformable substrate so that a chemical reaction between the first and second transformable substrates forms the adhesive.

7. A method according to any preceding claim, wherein the first sheet material comprises first and second surfaces, and wherein the applying step comprises applying the first transformable substrate over at least 90 percent of the first surface of the first sheet material.

8. A method according to any preceding claim, wherein the container is a hinged lid box, the folded second sheet material forming a box portion and a lid portion connected to the box portion along a hinge line, and wherein the transforming step adheres the first sheet material to an inner surface of the box portion.

9. A method according to any preceding claim, wherein the one or more consumer goods comprise a bundle of smoking articles and wherein the method further comprises the steps of:

- providing one or more consumer goods; and

- folding the first sheet material around the one or more consumer goods so that the folded first sheet material forms an inner frame at least partially surrounding the one or more consumer goods.

10. A container of consumer goods formed according to the method of any preceding claim.

1 1. A container for consumer goods, the container comprising:

a box portion;

a lid portion connected to the box portion along a hinge line;

an inner frame positioned within the box portion;

one or more consumer goods positioned within the inner frame and the box portion; and at least one transformable substrate provided on the inner frame or the box portion and arranged so that the transformable substrate overlies at least a portion of the inner frame and underlies at least a portion of the box portion.

12. A container according to claim 1 1 , wherein the at least one transformable substrate can be transformed into an adhesive by exposure to energy comprising at least one of heat, electromagnetic radiation, ultrasound and chemical energy.

13. A container according to claim 1 1 or 12, wherein the inner frame is formed from a folded sheet material having a first surface and a second surface, and wherein the at least one transformable substrate is applied over at least 90 percent of the first side of the sheet material.

14. A container according to any of claims 1 1 to 13, wherein the one or more consumer goods comprise a bundle of smoking articles.

15. Use of a transformable substrate to secure an inner frame to an inner surface of a hinged lid box.