Box-in-box package

Abstract

To provide a box-in-box package that allows easy access to consumer goods in an inner box when opening a hinge lid and has an inexpensive manufacturing process.SOLUTION: A rigid inner box 106 is made of foil press paperboard and includes a front wall, a back wall, a top wall, a bottom wall, and side walls with a single opening 110 extending across the top wall and partially into the front wall, the opening being a cutout in the foil press paperboard. A package reduces loss of flavor characteristics through a barrier, a simplified opening arrangement that eliminates a resealable pull tab that covers the opening, and greater physical protection for a product contained within the package. The package eliminates pull tab materials and specialized machinery and manufacturing processes required to produce the package with the resealable pull tab.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to packaging for consumer goods, and in particular to packaging for smoking articles. [Background technology]

[0002] Various packaging techniques are used for consumer goods. For example, in the case of cigarettes, packages are designed to maintain the flavor and freshness of the consumer goods while protecting the consumer goods from contamination. Known packages employ an outer container with a hinged lid that provides access to an inner container with an opening for accessing the consumer goods. The outer container is typically formed of rigid paperboard, cardboard, or other suitable material. The inner container is typically formed of a material or combination of materials having substantially less rigidity than the outer container. For example, inner containers are known to be formed of paperboard, packaging material, paper, and / or aluminum. In known designs, a label having an adhesive substance for sealing and resealing can be used to cover the opening of the inner container. Summary of the Invention

[0003] In one embodiment, a box-in-box package includes a rigid outer box and a rigid inner box. The rigid outer box is made of foil-stamped paperboard and includes a hinged lid configured to provide access to an interior volume of the outer box. The rigid inner box is made of foil-stamped paperboard and includes a front wall, a back wall, a top wall, a bottom wall, and side walls, wherein a single opening extends across the top wall and to a portion of the front wall, the opening being configured to provide access to consumer goods in the interior volume of the inner box. The opening in the inner box is configured to include a die-cut opening in the foil-stamped paperboard.

[0004] Some exemplary embodiments described herein relate to a box-in-box package, wherein the foil-stamped paperboard includes a foil layer between a paper layer and a paperboard layer, the outer surface of the paper layer being adhered to the inner surface of the foil layer with a first adhesive layer and the inner surface of the paperboard layer being adhered to the outer surface of the foil layer with a second adhesive layer, the box further includes a polypropylene layer on the outer surface of the paperboard layer, the polypropylene layer comprising a polypropylene film, the box further includes a polyester layer on the outer surface of the paperboard layer, the polyester layer comprising a metallized polyester material, the paperboard layer comprising Solid Bleached Sulfate (SBS) board stock, and the first adhesive layer comprising sodium silicate, the inner box containing a consumer good, the paper layer of the inner box being configured to be in direct contact with the consumer good.

[0005] In some exemplary embodiments, the inner box comprises a front panel, an upper panel, a rear panel, and a lower panel, the inner box further comprising side panels, the front panel comprising an upper front panel and a lower front panel, the inner box configured to contain tobacco in direct contact with the paper layer of the inner box and the paper layer of the outer box, the inner box comprising an upper front panel, a rear panel, a lower panel, and a lower front panel, the upper front panel being configured to be separated from the upper panel by a first horizontal fold line, the rear panel being separated from the second horizontal fold line by a second horizontal fold line, the second horizontal fold line being separated from the third horizontal fold line by a third horizontal fold line, the third horizontal fold line being separated from the fourth horizontal fold line by a fourth horizontal fold line, the fourth horizontal fold line being separated from the fourth horizontal fold line by a fourth horizontal fold line, the fourth horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the fifth horizontal fold line being separated from the fourth horizontal fold line by a fourth horizontal fold line, the fifth horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the fifth horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the fifth horizontal fold line being separated from the fourth horizontal fold line by a fourth horizontal fold line, the fifth horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the sixth ... seventh horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the eighth horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the eighth horizontal fold line being separated from the fourth horizontal fold line by a fifth horizontal fold line, the the lower panel is configured to be separated from the upper panel by two horizontal fold lines, the lower panel is configured to be separated from the rear panel by a third horizontal fold line, and the lower front panel is configured to be separated from the lower panel by a fourth horizontal fold line; the inner box comprises a first side panel and a second side panel, the first side panel is configured to be separated from the rear panel by a first longitudinal fold line, and the second side panel is configured to be separated from the rear panel by a second longitudinal fold line.

[0006] In some exemplary embodiments, a box blank is configured to form a box-in-box package, wherein the box blank is made of foil-stamped paperboard, the foil-stamped paperboard comprising a paper layer, a foil layer, and a paperboard layer, wherein the outer surface of the paper layer is adhered to the inner surface of the foil layer, the inner surface of the paperboard layer is adhered to the outer surface of the foil layer, the inner surface of the foil layer is adhered to the outer surface of the paper layer with a first adhesive layer, and the inner surface of the paperboard layer is adhered to the outer surface of the foil layer with a second adhesive layer. The box blank may further comprise a polypropylene layer on the outer surface of the paperboard layer, and may further comprise a polyester layer on the outer surface of the paperboard layer. The paperboard layer may comprise solid bleached sulfate (SBS) board stock, the second layer further comprising sodium silicate between the foil layer and the paper layer. The box blank may have fold lines configured to form body and lid panels, the body having a front panel, a bottom panel, a rear panel, side panels, and a dust flap, and the lid having a front panel, a top panel, a rear panel, side panels, and a dust flap.

[0007] In a further exemplary embodiment, the foil-stamped paperboard of the outer box and the inner box comprises a first layer comprising paperboard, a second layer comprising a paper layer and a foil layer, and an adhesive layer adhering the first layer and the second layer, wherein the foil layer is between the paperboard and the paper layer. [Brief explanation of the drawings]

[0008] The scope of the present disclosure is best understood from the following detailed description of the embodiments when read in conjunction with the accompanying drawings.

[0009] [Figure 1] FIG. 1 shows a box-in-box package where a hinged lid on the outer box opens and access to the consumer goods in the inner box is gained through a cutout in the top of the inner box.

[0010] [Figure 2]FIG. 2 is a plan view of a container outer box blank according to one embodiment of the present disclosure.

[0011] [Figure 3] FIG. 3 is a plan view of an inner box blank for a container according to one embodiment of the present disclosure.

[0012] [Figure 4A] FIG. 4A is a flow chart of a process for assembling a container according to an embodiment of the present disclosure. [Figure 4B] FIG. 4B is a flow chart of a process for assembling a container according to an embodiment of the present disclosure.

[0013] [Figure 5] FIG. 5 is a diagram showing the sequence of assembled states of the container according to the assembly process of FIGS. 4A and 4B.

[0014] [Figure 6] FIG. 6 is a diagram showing the ratio of the inner box to the outer box. DETAILED DESCRIPTION OF THE INVENTION

[0015] Reference will now be made in detail to various embodiments, including one or more examples illustrated in the figures. Each example is provided by way of explanation and not by way of limitation. For example, features and / or method steps illustrated or described as part of one embodiment and / or method can be used on or in combination with other embodiments and / or method steps to yield yet further embodiments or methods. The present disclosure is intended to include such modifications and variations.

[0016] Embodiments of the present disclosure relate to a box blank useful for forming a container for consumer goods having a rigid inner box and an outer box. The outer box includes a hinged lid that opens and closes to provide access to the inner box. The inner box includes a die-cut opening to provide access to the consumer goods. The package of the present disclosure provides a more durable package by protecting the product from physical damage during use, and can provide a less expensive packaging solution because fewer machines are required to create the package. Additionally, assembly of the package can be performed more quickly and with fewer materials than known resealable packaging designs.

[0017] A box-in-box package includes a rigid outer box and a rigid inner box, the rigid outer box being made of foil-stamped paperboard and including a hinged lid configured to provide access to an interior volume of the outer box, the rigid inner box being made of foil-stamped paperboard and including a front wall, a back wall, a top wall, a bottom wall, and side walls, with a die-cut opening extending across the top wall and to a portion of the front wall, the opening being configured to provide access to consumer goods in the interior volume of the inner box. The package can provide an improved barrier to loss of flavor characteristics, a simplified opening arrangement that eliminates a resealable pull tab covering the opening, better physical protection of the product contained in the package, a unique method of opening and closing the package, and a cheaper manufacturing process by eliminating packaging materials and processing processes for assembling packages containing tobacco products such as cigarettes.

[0018] FIG. 1 is a diagram illustrating the layout of a container for consumer goods according to one embodiment of the present disclosure. As shown in FIG. 1 , the container 100 comprises a rigid outer box 102, which includes a hinged lid 104 configured to provide access to a rigid inner box 106 and a body 105 in which the inner box 106 is deposited. The inner box 106 has a die-cut opening 110 configured to provide access to a consumer good 112 stored or contained within an interior volume 109. The inner box 106 is large enough to slidably and snugly fit within the interior volume 108 of the outer box 102. The inner box 106 can be securely held within the outer box 102 via contact friction between the surfaces of the inner box 106 and the outer box 102. The opening 110 in the inner box 106 is a cutout that forms a through-hole in one or more panels of a blank forming the inner box 106. The inner box 106 does not include a resealable label (pull tab or cover) over the opening 110. The inner box 106 can contain unpackaged consumer goods, such as smoking articles, and thus provide quick access to the consumer goods therein. In the case of smoking articles, because the smoking articles are not enclosed in a bundle wrap, a consumer can access the items by opening the outer box without having to remove the bundle wrap for a resealable pull tab on the opening. The inner box can provide other benefits, such as an improved barrier to the product's flavor profile, a simplified consumer opening process by eliminating a resealable label, a more durable package, and / or a package that can be assembled with fewer machines.

[0019] The inner box 106 and the outer box 102 are made of foil-stamped paperboard and include a paper layer, a foil layer, and a paperboard layer. To provide rigidity to the inner and outer boxes, the paperboard layer preferably has a thickness of at least 0.010 inches, e.g., 10-point or 12-point paperboard. The paperboard layer can be formed of solid bleached sulfate (SBS) paperboard, such as Promina SBS C1S Paperboard. The paperboard can be embossed with designs, lettering, patterns, and / or symbols, as desired. The paperboard can include ink, varnish, metallization, or other suitable materials for product identification. Once the container 100 is fully assembled, the outer box 102 can be wrapped in a covering layer, such as polypropylene film, with or without tear tape to allow the polypropylene film to be torn.

[0020] The paper layer of the foil-stamped paperboard can be, for example, a type of tissue paper suitable for wrapping cigarette bundles, and the paper layer can be 10-pound or 32-pound paper. The foil layer can be a thin sheet of metal foil, such as aluminum, having a thickness of at least 0.003 inches. For example, the foil layer can be aluminum foil having a thickness of 0.0035 inches. Because the paper layer of the foil-stamped paperboard is the inner layer that directly contacts the consumer goods inside the inner box, the consumer goods do not need to be wrapped in bundle wrap. The paperboard and foil layers can be adhered to each other via an adhesive, such as a polyvinyl alcohol (PVA)-based adhesive, cold glue, hot-melt glue, or other suitable material.

[0021] According to another embodiment, the foil-stamped paperboard can include an additional layer formed on the outer surface of the paperboard layer. For example, the additional layer can include a polypropylene film or MET material, such that the layer structure of the inner box 106 includes bundle wrap / board / film or bundle wrap / board / metallized polyester (MET), and more specifically, the layer structure includes paper / foil / board / film or paper / foil / board / MET.

[0022] Box-in-box packaging does not include a resealable pull tab attached to the outer or inner box. Instead, the opening of the inner box is a cutout in the foil-stamped paperboard, which allows easy access to the consumer goods inside the inner box when the hinged lid is opened. The cutout therefore eliminates the need for a pull tab, simplifying the manufacturing process by eliminating pull tab materials and the specialized machinery and manufacturing processes required to produce packages with resealable pull tabs.

[0023] FIG. 2 is a plan view of a container outer box blank according to one embodiment of the present disclosure. As shown in FIG. 2, the blank 500 forming the outer box 102 includes an upper panel 502, a lower panel 504, an upper front panel 506, a lower front panel 508, a lower rear panel 510, and an upper rear panel 512. The upper panel 502 includes a front flap 513. The outer box blank is made of foil-stamped paperboard, with the paperboard layer adhered to a foil layer that is adhered to a paper layer. The upper panel 502 and the lower panel 504 include left and right dust flaps. The upper panel 502 includes a left dust flap 514 and a right dust flap 516, and the lower panel 504 includes a left dust flap 518 and a right dust flap 520. The top 562 of the box blank 500 includes an upper panel 502, an upper rear panel 512, and an upper front panel 508, with their associated side flaps and dust flaps configured to fold together to form the hinged lid 104 of the assembled box 102. The bottom 564 of the box blank 500 includes a lower panel 504, a lower front panel 506, and a lower rear panel 510, with their associated side flaps and dust flaps (described below) configured to fold together to form the main body 105 of the assembled box 102.

[0024] The upper rear panel 512, the lower front panel 508, and the lower rear panel 510 include left and right flaps. For example, the upper front panel 506 includes left and right side flaps 522, 524, the upper rear panel 512 includes left and right side flaps 526, 528, the lower front panel 508 includes left and right side flaps 530, 532, and the lower rear panel 510 includes left and right side flaps 534, 536.

[0025] Each panel and associated left and right side flap of the outer box 102 is separated from adjacent panels and their associated left and right flaps by a horizontal fold line. The front flap 513 and the upper front panel 506 are separated by a horizontal fold line 539. The upper front panel 506, left side flap 522, and right side flap 524 are separated from the upper panel 502, left dust flap 514, and right dust flap 516, respectively, by a horizontal fold line 538. The upper panel 502, left dust flap 514, and right dust flap 516 are separated from the upper rear panel 512, left side flap 526, and right side flap 528, respectively, by a horizontal fold line 540. The upper rear panel 512, left side flap 526, and right side flap 528 are separated from the lower rear panel 510, left side flap 534, and right side flap 536, respectively, by horizontal fold lines 542. The lower rear panel 510, left side flap 534, and right side flap 536 are separated from the lower panel 504, left dust flap 518, and right dust flap 520, respectively, by horizontal fold lines 544. The lower panel 504, left dust flap 518, and right dust flap 520 are separated from the lower front panel 508, left side flap 530, and right side flap 532, respectively, by horizontal fold lines 546.

[0026] Each side flap and dust flap of the outer box 102 is separated from its associated and adjacent panels by a vertical fold line. The upper front panel 506 is separated from left and right side flaps 522, 524 by a vertical fold line 548. The right side flap 524 has a pre-cut edge 525 extending at an angle of approximately -45° from a horizontal fold line 539. The left side flap 522 has a pre-cut edge 523 extending at an angle of approximately -135° from the horizontal fold line 539. The upper panel 502 is separated from the left and right dust flaps 514, 516 by a vertical fold line 550. The upper rear panel 512 is separated from the left and right side flaps 526, 528 by a vertical fold line 552. The left side flap 526 has a pre-cut edge 527 that extends at an angle of approximately -50° from the horizontal fold line 542. The right side flap 528 of the upper rear panel 512 has a pre-cut edge 529 that extends at an angle of approximately -140° from the horizontal fold line 542. The lower rear panel 510 is separated from the left and right side flaps 534, 536 by a vertical fold line 554. The left side flap 534 has a pre-cut edge 535 that extends at an angle of approximately -45° from the horizontal fold line 542. The right side flap 536 of the lower rear panel 510 has a pre-cut edge 537 that extends at an angle of approximately -135° from the horizontal fold line 542. The lower panel 504 is separated from the left and right dust flaps 518, 520 by a vertical fold line 556. The lower front panel 508 is separated from a left side flap 530 and a right side flap 532 by a vertical fold line 558. The left side flap 530 and the right side flap 532 extend beyond an edge 560 of the lower front panel 508. The left side flap 530 has a pre-cut edge 531 that extends from the lower edge 560 of the lower front panel 508 at an angle of approximately -45°, and in this embodiment, -39°. The right side flap 532 has a pre-cut edge 533 that extends from the edge 560 of the front panel 508 at an angle of approximately -135°, and in this embodiment, -129°.

[0027] The pre-cut edges of the flaps associated with the lower front panel 508 and the lower rear panel 510 are complementary to the pre-cut angles of the flaps associated with the upper front panel 506 and the upper rear panel 512 so that when the box is in the closed position, the sides of the top hinge of the box mate with the sides of the body of the box.

[0028] The outer box 102 has dimensions suitable to provide a snug fit with the inner box 106 when placed within the outer box 102. The outer box 102 has a width W common to each of the upper panel 502, the lower panel 504, the upper front panel 506, the lower front panel 508, the lower rear panel 510, and the upper rear panel 512. OB The lower rear panel 510 has a length (L OB-TBP ) is substantially longer than the length L OB-BBP L OB-BBP and L OB-TBP The sum of the lower front panel (L) is approximately equal to the length of the cigarette pack, e.g., the length of the inner box 106. OB-BFP ) 508 is the length of the upper front panel (L OB-TFP )506. OB-BFP and L OB-TFP The sum of L OB-BBP and L OB-TBP According to one embodiment, L OB-BBP =75.10mm, L OB-TBP =11.40mm, L OB-BFP = 55.5 mm, and L OB-TFP The depth or thickness of the outer box 102 is the width (W) of the side flaps and dust flap. OB-FLP ) and the length of the upper panel (L OB-TP ) 502 and the lower panel (L OB-BP ) 504 (e.g., the shortest edge). OB-TP =L OB-BP =W OB-FLP =21.9mm.

[0029] Figure 3 is a plan view of a blank that forms the inner box 106 of a container according to an embodiment of the present disclosure. As shown in Figure 3, the blank 600 that forms the inner box 106 includes an upper panel 602, a lower panel 604, an upper front panel 606, a lower front panel 608, and a rear panel 610. The inner box opening 110 extends across the upper front panel 606 and the upper panel 602. The inner box blank is made of foil-stamped paperboard, with the paperboard layer bonded to a foil layer that is bonded to a paper layer that establishes the product side of the assembled inner box 106.

[0030] Each panel is separated from adjacent panels by a horizontal fold line. The upper front panel 606 is separated from the upper panel 602 by a horizontal fold line 612. The upper panel 602 is separated from the rear panel 610 by a horizontal fold line 614. The rear panel 610 is separated from the lower panel 604 by a horizontal fold line 616. The lower panel 604 and the lower front panel 608 are separated by a horizontal fold line 618.

[0031] Each panel includes an associated side flap. The upper front panel 606 includes a left side flap 620 and a right side flap 622. The left side flap 620 has a pre-cut edge 621 extending at an angle of approximately 45° from the horizontal fold line 612. The right side flap 622 has a pre-cut edge 623 extending at an angle of approximately 135° from the horizontal fold line 612. The upper panel 602 includes a left side flap 624 and a right side flap 626. The left side flap 624 has a pre-cut edge 625 extending at an angle of approximately 45° from the horizontal fold line 614. The right side flap 626 has a pre-cut edge 627 extending at an angle of approximately 135° from the horizontal fold line 614. The back panel 610 includes a left side flap 628 and a right side flap 630. The front panel 608 includes a left side flap 632 and a right side flap 634 .

[0032] The lower panel 604 includes a left dust flap 636 and a right dust flap 638 .

[0033] The inner box 106 has dimensions suitable for containing a desired number (e.g., count) of consumables, which according to one embodiment are tobacco products. The inner box 106 has a width W equal to the width of each of the upper panel 602, the lower panel 604, the upper front panel 606, the lower front panel 608, and the rear panel 610. IB The rear panel 610 has a height or length (L) sufficient to enclose the consumer goods. IB-BKP The length (L IB-TFP ) and lower front panel (L IB-BFP )608 is the total length of L IB-BKP According to one embodiment of the present disclosure, L IB-BKP =83.6mm, L IB-TFP = 27.2 mm, and L IB-BFP The depth or thickness of the inner box 106 is the width W shared by the side flaps and the dust flap. IB-FLP and the upper panel (L IB-TP ) 602 and the lower panel (L IB-BP ) 604 and the length (e.g., shortest end) of the IB-TP =L IB-BP =W IB-FLP =20.55mm.

[0034] According to an embodiment of the present disclosure, the sum of the lengths of the upper rear panel 512 and the lower rear panel 510 of the outer box 102 is at least equal to the length of the rear panel 610 of the inner box 106, where (L OB-TBP +L OB-BBP =L IB-BKP ), and in one embodiment, the sum of the lengths is greater, where (L OB-TBP +L OB-BBP >L IB-BKP ) so that proper fitting of the inner box 106 within the outer box 102 and closure of the hinged lid 104 can be achieved.

[0035] Each side flap and dust flap of the inner box 106 is separated from its associated and / or adjacent panels by a vertical fold line. The upper front panel 606 is separated from the left and right side flaps 620, 622 by a vertical fold line 640. The upper panel 602 is separated from the left and right side flaps 624, 626 by a vertical fold line 642. The rear panel 610 is separated from the left and right side flaps 628, 630 by a vertical fold line 644. The lower panel 604 is separated from the left and right dust flaps 636, 638 by a vertical fold line 646. The lower front panel 608 is separated from the left and right side flaps 632, 634 by a vertical fold line 648.

[0036] 4A and 4B are a flowchart of a manufacturing process for a container according to one embodiment of the present disclosure, and FIG. 5 is a diagram illustrating a sequence of assembled states of the container according to the assembly process of FIGS. 4A and 4B. As shown in FIGS. 4A and 4B, the process includes a first step (S700) in which the inner box 106 is assembled from the inner box blank 600 by folding the left side flap 628 and the right side flap 630 along a vertical fold line so that they are substantially perpendicular to the rear panel 610. In step S702, the dust flaps 636 and 638 of the lower panel 604 are folded about the vertical fold line 646 so that they are substantially planar with the lower panel 604. According to one embodiment, adhesive can be applied to the dust flaps 636 and 638 so that they adhere to the lower panel 604 when folded. As shown in State 1 of Figure 5, the lower portion 650, including the lower panel 604 and the lower front panel 608, is folded about the horizontal fold line 616 so as to be substantially perpendicular to the lower panel 604 (S704). A consumer good or product is then placed in the area enclosed by the left side flap 628, the right side flap 630, and the lower panel 604 (S706). The upper portion 652, including the upper panel 602 and the upper front panel 606, is folded about the horizontal fold line 614 so as to be substantially perpendicular to the rear panel 610 (S708, State 2). The lower front panel 608 is folded about the horizontal fold line 618 so as to be parallel to the rear panel 610 (S710, State 3). The upper front panel 606 is folded about the horizontal fold line 612 so as to be parallel to the rear panel 610 and planar with the lower front panel 608 (S712, State 4).

[0037] Adhesive may be applied to the left and right side flaps 624, 626 of the upper panel 602. The left and right side flaps 624, 626 of the upper panel 602 are folded across the longitudinal fold line 642 and adhered to the side flaps 628, 630 of the rear panel 610 (S714, State 5). Adhesive may be applied to the side flaps 632, 634 of the lower front panel 608 and the left and right side flaps 620, 622 of the upper front panel 606. The side flaps 632, 634 of the lower front panel 608 are folded about the longitudinal fold line 648 and adhered to the left and right side flaps 628, 630 of the rear panel 610, respectively (S716, State 6). The left and right side flaps 620, 622 of the upper front panel 606 are folded about the vertical fold line 640 and adhered to the left and right side flaps 628, 630, respectively, of the rear panel 610 (S718, State 6). Note that the left and right side flaps 620, 622 of the upper front panel 606 are planar with and do not overlap the side flaps 624, 626 of the upper panel 602 due to the pre-cut angles of their respective edges.

[0038] The outer box 102 is assembled from the outer box blank 500 by folding the left and right side flaps 534, 536 of the lower rear panel 510 along the vertical fold line 554 so that the left and right side flaps 534, 536 are substantially perpendicular to the lower rear panel 510 (S720). The left and right dust flaps 518, 520 of the lower panel 504 are folded along the vertical fold line 556 so that they are substantially planar with each other and parallel to the lower panel 504 (S722, State 7). According to one embodiment, the left and right dust flaps 518, 520 can be coated with adhesive to adhere to the lower rear panel 510 when folded. The lower portion 505 of the outer box 102, including the lower panel 504 and the lower front panel 508, is folded along the horizontal fold line 544 so that the lower portion 505 is substantially perpendicular to the lower rear panel 510 (S724, State 7). The assembled inner box 106 is placed within the region of the outer box 102 bounded by the left and right side flaps 534, 536 and the lower panel 504 (S726, State 8). The lower front panel 508 is folded along the horizontal fold line 546 so that the panel is substantially parallel to the lower rear panel 510 (S728, State 9). The left and right side flaps 530, 532 of the lower front panel 508 may be coated with adhesive. Then, the side flaps 530 and 532 are folded along the vertical fold lines 558 and adhered to the left side flap 534 and right side flap 536 of the lower rear panel 510, respectively (S730).

[0039] The top 503 of the outer box 102, including the upper panel 502 and the upper front panel 506, is folded along the horizontal fold line 540 so as to be substantially perpendicular to the lower rear panel 510 (S732, state 9). The left and right side flaps 526, 528 of the upper rear panel 512 are folded along the vertical fold line 552 so as to be planar with the left and right side flaps 534, 536, respectively, of the lower rear panel 510 (S734). Note that the angled edges of the left and right side flaps 534, 536 of the lower rear panel 510 and the left and right side flaps 526, 528 of the upper rear panel 512 are pre-cut so as not to overlap, allowing the opening of the hinge-lid 104 of the outer box 102 to be operable. The upper front panel 506 is folded along the horizontal fold line 538 so that the upper front panel 506 is parallel to the lower rear panel 510 and planar with the lower front panel 508 (S736, state 16). Adhesive is applied to the left and right side flaps 522, 524 of the upper front panel 506. The left and right side flaps 522, 524 of the upper front panel 506 are then folded along the vertical fold line 548 and adhered to the folded left and right side flaps 526, 528, respectively, of the upper rear panel 512 (S738, state 10). According to another embodiment, the front flap 513 can be adhered to the back surface 147 of the upper front panel 506 after being folded along the horizontal fold line 539.

[0040] 6 shows an assembled packing 900 with an opening 908 of an inner box 904 located within an outer box 902. The outer box has a hinged lid 906 that can be opened to provide access to the consumer goods in the inner box 904.

[0041] It will be apparent to those skilled in the art that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the present invention is indicated by the appended claims from the foregoing description, and all changes that come within the meaning and scope and range of equivalency are intended to be embraced therein.

Claims

1. A box-in-box package, The package includes a hard outer box and a hard inner box, the rigid outer box is made of foil-stamped paperboard and includes a hinged lid configured to provide access to an interior volume of the outer box; the rigid inner box is made of foil-stamped paperboard and includes a front wall, a back wall, a top wall, a bottom wall, and side walls, wherein a single opening extends across the top wall and into a portion of the front wall, the opening being configured to provide access to consumer goods in an interior volume of the inner box; The opening of the inner box is configured to include a cutout in the foil-stamped paperboard.

2. The box-in-box package of claim 1, the foil-stamped paperboard includes a foil layer; the foil layer is configured to be between a paper layer and a paperboard layer; The outer surface of the paper layer is bonded to the inner surface of the foil layer with a first adhesive layer, and the inner surface of the paperboard layer is bonded to the outer surface of the foil layer with a second adhesive layer.

3. The box-in-box package according to claim 2, Further comprising a polypropylene layer on the outer surface of the paperboard layer.

4. The box-in-box package according to claim 3, The polypropylene layer comprises a polypropylene film.

5. The box-in-box package according to claim 2, Further comprising a polyester layer on the outer surface of the paperboard layer.

6. The box-in-box package according to claim 5, The polyester layer comprises a metallized polyester material.

7. The box-in-box package according to claim 2, The paperboard layer comprises Solid Bleached Sulfate (SBS) boardstock.

8. The box-in-box package according to claim 2, The first adhesive layer comprises sodium silicate.

9. The box-in-box package according to claim 2, The inner box contains consumer goods, The paper layer of the inner box is configured to be in direct contact with the consumer goods in the inner box.

10. The box-in-box package according to claim 2, The inner box comprises a front panel, an upper panel, a rear panel, and a lower panel.

11. The box-in-box package of claim 10, The inner box further comprises side panels.

12. The box-in-box package of claim 10, The front panel comprises an upper front panel and a lower front panel.

13. The box-in-box package according to claim 2, The inner box is configured to contain tobacco that is in direct contact with the paper layer of the inner box and the paper layer of the outer box.

14. The box-in-box package of claim 1, the inner box comprises an upper front panel, a rear panel, a lower panel, and a lower front panel; the upper front panel is configured to be separated from the upper panel by a first horizontal fold line; the rear panel is configured to be separated from the upper panel by a second horizontal fold line; the lower panel is configured to be separated from the rear panel by a third horizontal fold line; The lower front panel is configured to be separated from the lower panel by a fourth horizontal fold line.

15. 15. The box-in-box package of claim 14, the inner box comprises a first side panel and a second side panel; the first side panel is configured to be separated from the rear panel by a first longitudinal fold line; The second side panel is configured to be separated from the rear panel by a second longitudinal fold line.

16. A box blank, configured to form the box-in-box package of claim 1; the box blank is made of foil-stamped paperboard; The foil-stamped paperboard comprises a paper layer, a foil layer, and a paperboard layer; an outer surface of the paper layer adhered to an inner surface of the foil layer, an inner surface of the paperboard layer adhered to the outer surface of the foil layer, and the inner surface of the foil layer adhered to the outer surface of the paper layer with a first adhesive layer; The inner surface of the paperboard layer is configured to be adhered to the outer surface of the foil layer with a second adhesive layer.

17. 17. The box blank of claim 16, Further comprising a polypropylene layer on the outer surface of the paperboard layer.

18. 18. The box blank of claim 17, The polypropylene layer comprises a polypropylene film.

19. 17. The box blank of claim 16, Further comprising a polyester layer on the outer surface of the paperboard layer.

20. 17. The box blank of claim 16, The paperboard layer comprises Solid Bleached Sulfate (SBS) boardstock.

21. 17. The box blank of claim 16, The second layer further comprises sodium silicate between the foil layer and the paper layer.

22. 17. The box blank of claim 16, Equipped with fold lines, the fold lines are configured to form panels in the body and lid; the main body portion includes a front panel, a lower panel, a rear panel, side panels, and a dust flap; The lid comprises a front panel, an upper panel, a rear panel, side panels, and a dust flap.

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