A method of forming a container for consumer goods

Abstract

According to the present disclosure, there is provided a method of making a container for consumer goods, the method comprising providing a blank (1) comprising a plurality of panels, wherein the plurality of panels includes at least one central panel (2), at least one first panel (3), at least one second panel (5), and at least one third panel (7). The at least one first panel (3) is connected to the at least one central panel (2) by a first fold line (4) and the at least one second panel (5) is connected to the at least one central panel (2) by a second fold line (6), wherein the first fold line (4) and the second fold line (6) extend along opposite sides of the at least one central panel (2). The at least one third panel (7) is connected to the at least one second panel (5) by a third fold line (8), wherein the second fold line (6) and the third fold line (8) extend along opposite sides of the at least one second panel (5). The method also comprises folding the laminar blank to form a container for consumer goods, wherein the folding comprises: folding the at least one second panel (5) about the second fold line (6) towards the at least one central panel (2); and folding the at least one first panel (3) about the first fold line (4) towards the at least one central panel (2) so that the at least one first panel (3) engages the at least one third panel (7) and folds the at least one third panel (7) about the third fold line (8) towards the at least one second panel (5).

Description

[0001] P / 90982.W001

[0002] - 1 -

[0003] A METHOD OF FORMING A CONTAINER FOR CONSUMER GOODS

[0004] The present disclosure relates to a method of forming a container for consumer goods, the method comprising folding a laminar blank to form the container. Containers formed according to the present invention find particular application as containers for aerosol-generating articles.

[0005] It is known to package consumer goods in containers formed from folded laminar blanks. By way of example, elongate smoking articles, such as cigarettes and cigars, are often sold in rigid box shaped containers, having a lid moveable relative to the box to permit access to the contents of the container. Examples of such containers include hinged lid containers having a box portion and a three-dimensional cup-shaped hinged lid connected to the box about a hinge line extending across the back wall of the container. In use, the lid is pivoted about the hinge line to open the container to provide access to the consumer goods held in the box. While it is generally desirable for the lids of such containers to be easily openable when an authorised user wishes to access the contents contained therein, it may also be desirable for the lid of the container to remain securely closed when access is not required or desired. For example, this may help to better preserve the contents of the container. This may also help to prevent an unauthorised individual from accessing the contents of the container.

[0006] Various mechanisms have been proposed for improving the interaction between the lid and the box of such containers, and in particular, for reducing the chances of the lid inadvertently moving away from the closed position during normal handling and for reducing the risk of unauthorised access of the container. Such mechanisms typically require additional portions, such as locking panels, that are formed on the laminar blank and are configured to interact with other parts of the assembled container. However, introducing additional panels to a laminar blank typically requires additional folding steps to fold the laminar blank to form the container. This can introduce additional complexity to the manufacturing process of forming the containers.

[0007] It would therefore be desirable to provide a method of forming a container that may accommodate such additional panels while reducing or minimising modifications to existing manufacturing processes and existing packaging equipment.

[0008] According to the present disclosure there is provided a method of making a container for consumer goods. The method may comprise providing a blank comprising a plurality of panels. The plurality of panels may include at least one central panel, at least one first panel, at least one second panel, and at least one third panel. The at least one first panel may be connected to the at least one central panel by a first fold line. The at least one second panel may be connected to the at least one central panel by a second fold line. The at least one third panel may be connected to the at least one second panel by a third fold line. The method may comprise folding the blank to form a container for consumer goods. The folding may comprise folding the at least one second panel about the second fold line towards the at least one central panel. The folding may comprise folding the at least one first panel about the first fold line towards the at least one central panel so that the at least one first panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

[0009] According to the present disclosure there is provided a method of making a container for consumer goods. The method comprises providing a blank comprising a plurality of panels. The plurality of panels includes at least one central panel, at least one first panel, at least one second panel, and at least one third panel. The at least one first panel is connected to the at least one central panel by a first fold line. The at least one second panel is connected to the at least one central panel by a second fold line. The at least one third panel is connected to the at least one second panel by a third fold line. The method also comprises folding the blank to form a container for consumer goods. The folding comprises folding the at least one second panel about the second fold line towards the at least one central panel. The folding also comprises folding the at least one first panel about the first fold line towards the at least one central panel so that the at least one first panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

[0010] According to the present disclosure there is provided a method of making a container for consumer goods. The method may comprise providing a blank comprising a plurality of panels. The plurality of panels may include at least one central panel, at least one first panel, at least one second panel, and at least one third panel. The at least one first panel may be connected to the at least one central panel by a first fold line. The at least one second panel may be connected to the at least one central panel by a second fold line. The first fold line and the second fold line may extend along opposite sides of the at least one central panel. The at least one third panel may be connected to the at least one second panel by a third fold line. The second fold line and the third fold line may extend along opposite sides of the at least one second panel. The method may comprise folding the blank to form a container for consumer goods. The folding may comprise folding the at least one second panel about the second fold line towards the at least one central panel. The folding may comprise folding the at least one first panel about the first fold line towards the at least one central panel so that the at least one first panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

[0011] According to the present disclosure there is provided a method of making a container for consumer goods. The method comprises providing a blank comprising a plurality of panels. The plurality of panels includes at least one central panel, at least one first panel, at least one second panel, and at least one third panel. The at least one first panel is connected to the at least one central panel by a first fold line. The at least one second panel is connected to the at least one central panel by a second fold line. The first fold line and the second fold line extend along opposite sides of the at least one central panel. The at least one third panel is connected to the at least one second panel by a third fold line. The second fold line and the third fold line extend along opposite sides of the at least one second panel. The method also comprises folding the blank to form a container for consumer goods. The folding comprises folding the at least one second panel about the second fold line towards the at least one central panel. The folding also comprises folding the at least one first panel about the first fold line towards the at least one central panel so that the at least one first panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

[0012] The engagement of the at least one first panel with the at least one third panel while folding the at least one first panel about the first fold line advantageously results in the folding of the at least one third panel about the third fold line without any additional steps in the manufacturing process. In other words, the method according to the present invention provides a passive folding of the at least one third panel about the third fold line as a result of actively folding the at least one first panel and the at least one second panel about the first and second fold lines respectively. Therefore, advantageously, the at least one third panel is automatically folded in the same process of folding the at least one first panel and the at least one second panel. Advantageously, this may minimise or eliminate the need for changes, additional tooling, and / or other types of hardware and software upgrade, to existing packaging equipment and processes that may already be configured to fold blanks comprising the at least one first panel and the at least one second panel but without the at least one third panel.

[0013] The at least one third panel may be folded in the opposite direction to the at least one second panel.

[0014] Preferably, the steps of folding the at least one first panel, the at least one second panel and the at least one third panel are performed concurrently. Advantageously, this may result in folding of the third panel about the third fold line without performing additional process-steps, through the use of existing process steps in a synchronous way.

[0015] The container may comprise a box for housing the consumer goods, the box comprising a box front wall, a box back wall, a box bottom wall and box side walls, and wherein a top face of the box is at least partially open to provide an access opening for accessing the consumer goods.

[0016] The at least one central panel may comprise a box bottom panel forming the box bottom wall, and a box back panel connected along a fold line to the box bottom panel, wherein the box back panel forms the box back wall.

[0017] The at least one central panel may comprise at least two box side panels connected along fold lines to the box back panel, and wherein each box side wall comprises at least one of the box side panels.

[0018] The at least one first panel may comprise a box front outer panel connected along the first fold line to the at least one central panel, and a box front inner panel connected along a box front fold line to the box front outer panel, wherein the box front outer panel and the box front inner panel together form the box front wall. The box front outer panel may be connected along the first fold line to the box bottom panel, wherein the step of folding the at least one first panel about the first fold line comprises folding the box front outer panel about the first fold line towards the at least one central panel.

[0019] The step of folding the blank to form a container for consumer goods may comprise folding the box front inner panel about the box front fold line so that the box front inner panel overlies the box front outer panel.

[0020] Preferably, the step of folding the box front inner panel about the box front fold line is performed before the step of folding the box front outer panel about the first fold line. Preferably, the step of folding the at least one first panel about the first fold line comprises folding the box front outer panel about the first fold line towards the at least one central panel so that the box front inner panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

[0021] The container may comprise a lid flap, wherein the lid flap is hingedly connected to the box back wall and comprises a lid top wall, a lid front wall, and at least one locking panel, wherein the lid flap is movable between a closed position in which the lid top wall overlies the access opening and an open position in which the access opening is at least partially uncovered.

[0022] The at least one second panel may comprise a lid top panel forming the lid top wall and connected along the second fold line to the at least one central panel, and at least one lid front panel forming at least part of the lid front wall, wherein the at least one lid front panel is connected along a first lid fold line to the lid top panel.

[0023] The at least one lid front panel may comprise a first lid front panel connected along the first lid fold line to the lid top panel, and a second lid front panel connected along a second lid fold line to the first lid front panel. Advantageously, providing a plurality of lid front panels together forming at least part of the lid front wall may facilitate opening and closing of the container. For example, the lid front wall may bend along the second fold line during opening and closing of the container.

[0024] The at least one third panel may be connected along the third fold line to the second lid front panel.

[0025] The at least one lid front panel may comprise a tertiary lid front panel connected along a tertiary fold line to the second lid front panel. The at least one third panel may be connected along the third fold line to the tertiary lid front panel.

[0026] The at least one third panel may form at least one locking panel connected to the at least one lid front panel along the third fold line. The at least one locking panel may be a single locking panel. The at least one lid front panel may comprise at least two locking panels each connected to the at least one lid front panel along a third fold line.

[0027] The step of folding the at least one second panel about the second fold line may comprise folding the lid top panel along the second fold line and folding the at least one lid front panel along the first lid fold line. At least one of the steps of folding the lid top panel along the second fold line and folding the at least one lid front panel along the first lid fold line may be performed concurrently with the step of folding the box front outer panel about the first fold line.

[0028] The step of folding the lid top panel along the second fold line may be performed before the step of folding the at least one lid front panel along the first lid fold line, wherein the step of folding the at least one lid front panel along the first lid fold line is performed concurrently with the step of folding the box front outer panel about the first fold line.

[0029] The steps of folding the lid top panel along the second fold line, folding the at least one lid front panel along the first lid fold line, and folding the box front outer panel about the first fold line may all be performed concurrently with each other.

[0030] Preferably, the at least one locking panel is folded along the third fold line in the opposite direction to the lid top panel and the at least one lid front panel.

[0031] Preferably, the at least one locking panel is folded about the third fold line towards the at least one lid front panel so that the at least one locking panel overlies the at least one lid front panel. In embodiments in which the at least one lid front panel comprises a second lid front panel, preferably the at least one locking panel overlies the second lid front panel. In embodiments in which the at least one lid front panel comprises a tertiary lid front panel, preferably the at least one locking panel overlies the tertiary lid front panel.

[0032] Preferably, the box front inner panel comprises a top edge and a bottom edge, wherein the at least one locking panel is folded so that the at least one locking panel engages the bottom edge of the box front inner panel when the lid flap is in the closed position to prevent movement of the lid flap from the closed position to the open position. Advantageously, this may reduce the risk of unauthorised access to the contents of the container.

[0033] The box front inner panel may be connected along the top edge of the box front inner panel to the box front outer panel, wherein the box front inner panel is folded about the box front fold line such that the bottom edge of the box front inner panel is spaced apart from the box bottom wall. Preferably, the at least one locking panel is sized to fit within the space between the bottom edge of the box front inner panel and the box bottom wall when the lid flap is in the closed position.

[0034] The box front outer panel may comprise at least one slit defining at least one release button, wherein the at least one release button overlies the at least one locking panel when the lid flap is in the closed position so that depressing the at least one release button disengages the at least one locking panel from the bottom edge of the box front inner panel.

[0035] The at least one third panel may comprise a release tool panel. Advantageously, the release tool panel may form a release tool that may be used to disengage the at least one locking panel from the box front inner panel.

[0036] Preferably, the release tool panel is detachable from the remainder of the blank. Preferably, the release tool panel is connected along part of the third fold line to the at least one lid front panel. Preferably, the part of the third fold line along which the release tool panel is connected to the at least one lid front panel forms a line of weakening. For example, the line of weakening may comprise a perforation.

[0037] Preferably, the release tool panel is detachably connected to the at least one locking panel. Preferably, the release tool panel is connected along at least one line of weakening to the at least one locking panel.

[0038] The step of providing a blank may comprise providing a single blank for forming the box and the lid flap.

[0039] The method of making a container may further comprise providing a plurality of consumer goods, wherein the step of folding the blank comprises folding the blank around the plurality of consumer goods to form a container housing the plurality of consumer goods.

[0040] The plurality of consumer goods may comprise a plurality of aerosol-generating articles. The aerosol-generating articles may be elongate aerosol-generating articles. Exemplary aerosolgenerating articles may include cigarettes, cigars, cigarillos or other aerosol generators that rely on heating rather than burning tobacco, for example through an electrical heat source or carbon heat source. It will be appreciated that through appropriate choices of the dimensions thereof, containers according to the invention may be designed for different numbers of conventional size, king size, super-king size, slim or super-slim aerosol generating articles.

[0041] The plurality of consumer goods may comprise a plurality of nicotine-containing consumer goods. The nicotine-containing consumer goods may be aerosol-generating articles. The nicotine-containing consumer goods may be oral nicotine-containing consumer goods, such as nicotine-containing products intended to be sucked or chewed. The oral nicotine-containing products may comprise tobacco. The oral nicotine-containing products may comprise snus or snuff. The oral nicotine-containing consumer goods may be free from tobacco.

[0042] The blank may be a first blank, the method further comprising providing a second blank and folding the second blank to form an inner frame, wherein the step of folding the first blank comprises folding the first blank around the inner frame to form the container.

[0043] The step of folding the second blank to form an inner frame may comprise folding the second blank around a plurality of consumer goods. The step of folding the first blank may comprise folding the first blank around the inner frame and the consumer goods to form the container.

[0044] The step of folding the second blank to form the inner frame may be performed before the step of folding the first blank.

[0045] The method of making a container may further comprise the step of providing an outer wrapper around the container. The step of providing an outer wrapper may comprise wrapping an outer wrapper around the container. Preferably, the step of wrapping the outer wrapper around the container is performed after the step of folding the blank. Methods of forming a container according to the present disclosure may include forming containers comprising a moveable lid flap that covers an access opening when in the closed position, and at least one locking panel that engages a portion of a box front inner panel when the lid flap is in the closed position. Advantageously, the locking panel reduces or minimises the risk of accidental or unauthorised opening of the lid flap.

[0046] Containers formed according to methods of the present disclosure may comprise a release button for disengaging the at least one locking panel from the box front inner panel. The presence of the release button may require a user to use both hands to simultaneously depress the release button and move the lid flap into an open position. In other words, the presence of the release button makes it difficult for a user to open the container using only one hand. Advantageously, this further reduces or minimise the risk of accidental or unauthorised opening of the lid flap.

[0047] Containers formed according to methods of the present disclosure may comprise a release tool that may be used to disengage the at least one locking panel from the box front inner panel. Advantageously, requiring the use of a release tool to disengage the at least one locking panel may further reduce or minimise the risk of accidental or unauthorised opening of the lid flap.

[0048] Advantageously, re-engagement of the at least one locking panel with the box front inner panel may provide an audible ‘click’ to indicate to a user that the container has been locked.

[0049] Advantageously, forming a box front inner panel with which the at least one locking panel engages minimises visibility of the locking mechanism from the outside of the container. Advantageously, this may further reduce or minimise the risk of unauthorised opening of the lid flap, since it may not be immediately apparent how the container may be opened. For example, the container may be arranged so that the only element of the locking mechanism that is visible from the outside of the container is the release button. Alternatively, in embodiments in which the at least one locking panel is disengaged using a release tool, the locking mechanism may be entirely hidden when the lid flap is in the closed position.

[0050] The terms “side”, “top”, “bottom”, “front”, “back” and other terms used herein to describe relative positions of the components of containers formed according to the present disclosure refer to the container in an upright position where the lid top wall faces upwards. When describing containers according to the present disclosure, these terms are used irrespective of the orientation of the container being described. The “bottom” of the container refers to the facet of the container opposite the “top” of the container.

[0051] The term “height” is used herein to refer to dimensions extending between the top and the bottom. The term “width” is used herein to refer to dimensions extending between two sides. The term “depth” is used herein to refer to dimensions extending between the front and the back. Height, width and depth are orthogonal to each other.

[0052] The term “panel” is used herein to refer to a portion of the blank or the container formed from a single, continuous portion of material. A panel may depend from one or more other panels. The term “wall” refers more generally to a facet of the container, and a wall may be formed from a single panel, or a wall may be formed from two or more abutting or overlapping panels.

[0053] The term “depending” is used herein to describe a physical connection between two elements of a blank or a container. In more detail, the term “depending” is used to indicate that there is a material continuity between two elements, such as two walls or panels of a container or a blank. This includes both cases wherein a wall or a panel depends directly from an adjacent wall or panel as well as cases wherein an intermediate wall or panel effectively connects two walls or panels.

[0054] By way of example, a side wall or side panel may depend directly from an adjacent front wall or front panel. In such case, the wall or panel typically depends along a fold line from the adjacent wall. As an alternative, especially in containers having curved or bevelled edges, a side wall or side panel may depend indirectly from a front wall or front panel. In such case a curved or bevelled edge wall or panel connects the side wall or side panel and the front wall or front panel. In the case of a bevelled edge, both side wall or side panel and front wall or front panel may depend from the connecting bevelled edge wall or panel along respective fold lines. This also applies to optional components of containers according to the present disclosure, for example to a reinforcing member provided in the form of an inner frame.

[0055] The term “inner” is used herein to refer to a component or a surface of a component of the assembled container that is facing towards the interior of the container, for example towards the consumer goods, when the container is in the closed position. The term “outer” is used herein to refer a component or a surface of a component of the container that is facing towards the exterior of the container. For example, the box front wall has an inner panel that is facing the inside of the box and any consumer goods contained within the box, and an outer panel overlying the inner panel and facing towards the exterior of the box. It should be noted that an inside or an outside surface is not necessarily equivalent to a particular side of a blank used in assembly of the container. Depending on how the blank is folded around the consumer goods, areas that are on the same side of the blank can either face towards the inside or the towards the outside of the container.

[0056] The term “fold line” is used herein to describe any line of a blank about which the blank is folded. The fold line may be defined by a line of weakness to assist with the folding action. For example, a line of weakness may be formed by scoring, perforating, or ablating a portion of a blank. Alternatively, a fold can be formed without the presence of a weakening line, depending for example on the pliability of the blank material and other material characteristics.

[0057] The blank may be formed from any suitable materials including, but not limited to, a cellulose based material, plastic, metal, or any combinations thereof. Preferably, the blank is formed from a cellulose based material. Preferably, the blank is formed of a sheet of material. The sheet may be a sheet of cellulose based material. More specifically, the sheet may be a paper sheet or a paperboard sheet, that is, a sheet made of paper of paperboard. Preferably, the sheet has a basis weight of between 200 grams per square metre and 400 grams per square metre, more preferably a basis weight of between 220 grams per square metre and 300 grams per square metre. However, it can be appreciated that sheets with a higher or lower basis weight can be used to form the blank.

[0058] Preferably, the sheet has a thickness of between 170 micrometres and 400 micrometres. However, it can be appreciated that sheets with a higher or lower thickness can be used to form the blank.

[0059] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0060] Example 1 : A method of making a container for consumer goods, the method comprising: providing a blank comprising a plurality of panels, wherein the plurality of panels includes at least one central panel, at least one first panel, at least one second panel, and at least one third panel, wherein the at least one first panel is connected to the at least one central panel by a first fold line, wherein the at least one second panel is connected to the at least one central panel by a second fold line, wherein the at least one third panel is connected to the at least one second panel by a third fold line; and folding the blank to form a container for consumer goods, wherein the folding comprises: folding the at least one second panel about the second fold line towards the at least one central panel; and folding the at least one first panel about the first fold line towards the at least one central panel so that the at least one first panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

[0061] Example 2: The method of making a container according to Example 1 , wherein the at least one third panel is folded in the opposite direction to the at least one second panel.

[0062] Example 3: The method of making a container according to Example 1 or 2, wherein the steps of folding the at least one first panel, the at least one second panel and the at least one third panel are performed concurrently.

[0063] Example 4: The method of making a container according to any preceding Example, wherein the container comprises a box for housing the consumer goods, the box comprising a box front wall, a box back wall, a box bottom wall and box side walls, and wherein a top face of the box is at least partially open to provide an access opening for accessing the consumer goods.

[0064] Example 5: The method of making a container according to Example 4, wherein the at least one central panel comprises: a box bottom panel forming the box bottom wall; and a box back panel connected along a fold line to the box bottom panel, wherein the box back panel forms the box back wall.

[0065] Example 6: The method of making a container according to Example 5, wherein the at least one central panel comprises at least two box side panels connected along fold lines to the box back panel, and wherein each box side wall comprises at least one of the box side panels. Example 7: The method of making a container according to Example 4, 5 or 6, wherein the at least one first panel comprises: a box front outer panel connected along the first fold line to the at least one central panel; and a box front inner panel connected along a box front fold line to the box front outer panel, wherein the box front outer panel and the box front inner panel together form the box front wall.

[0066] Example 8: The method of making a container according to Examples 5 and 7 or Examples 6 and 7, wherein the box front outer panel is connected along the first fold line to the box bottom panel, and wherein the step of folding the at least one first panel about the first fold line comprises folding the box front outer panel about the first fold line towards the at least one central panel.

[0067] Example 9: The method of making a container according to Example 7 or 8, wherein the step of folding the blank to form a container for consumer goods comprises folding the box front inner panel about the box front fold line so that the box front inner panel overlies the box front outer panel.

[0068] Example 10: The method of making a container according to Example 9, wherein the step of folding the box front inner panel about the box front fold line is performed before the step of folding the box front outer panel about the first fold line.

[0069] Example 11 : The method of making a container according to any of Examples 4 to 10, wherein the container further comprises a lid flap, wherein the lid flap is hingedly connected to the box back wall and comprises a lid top wall, a lid front wall, and at least one locking panel, wherein the lid flap is movable between a closed position in which the lid top wall overlies the access opening and an open position in which the access opening is at least partially uncovered.

[0070] Example 12: The method of making a container according to Example 11 , wherein the at least one second panel comprises: a lid top panel forming the lid top wall and connected along the second fold line to the at least one central panel; and at least one lid front panel forming at least part of the lid front wall, wherein the at least one lid front panel is connected along a first lid fold line to the lid top panel.

[0071] Example 13: The method of making a container according to Example 12, wherein the at least one lid front panel comprises: a first lid front panel connected along the first lid fold line to the lid top panel; and a second lid front panel connected along a second lid fold line to the first lid front panel.

[0072] Example 14: The method of making a container according to Example 12 or 13, wherein the at least one third panel forms at least one locking panel connected to the at least one lid front panel along the third fold line.

[0073] Example 15: The method of making a container according to Example 14, wherein the step of folding the at least one second panel about the second fold line comprises folding the lid top panel along the second fold line and folding the at least one lid front panel along the first lid fold line. Example 16: The method of making a container according to Example 15, wherein at least one of the steps of folding the lid top panel along the second fold line and folding the at least one lid front panel along the first lid fold line is performed concurrently with the step of folding the box front outer panel about the first fold line .

[0074] Example 17: The method of making a container according to Example 14, 15 or 16, wherein the at least one locking panel is folded along the third fold line in the opposite direction to the lid top panel and the at least one lid front panel.

[0075] Example 18: The method of making a container according to Example 17, wherein the at least one locking panel is folded about the third fold line towards the at least one lid front panel so that the at least one locking panel overlies the at least one lid front panel.

[0076] Example 19: The method of making a container according to any of Examples 14 to 18, wherein the box front inner panel comprises a top edge and a bottom edge, and wherein the at least one locking panel is folded so that the at least one locking panel engages the bottom edge of the box front inner panel when the lid flap is in the closed position to prevent movement of the lid flap from the closed position to the open position.

[0077] Example 20: The method of making a container according to Example 19, wherein the box front inner panel is connected along the top edge of the box front inner panel to the box front outer panel, wherein the box front inner panel is folded about the box front fold line such that the bottom edge of the box front inner panel is spaced apart from the box bottom wall, and wherein the at least one locking panel is sized to fit within the space between the bottom edge of the box front inner panel and the box bottom wall when the lid flap is in the closed position.

[0078] Example 21 : The method of making a container according to Example 20, wherein the box front outer panel comprises at least one slit defining at least one release button, and wherein the at least one release button overlies the at least one locking panel when the lid flap is in the closed position so that depressing the at least one release button disengages the at least one locking panel from the bottom edge of the box front inner panel.

[0079] Example 22: The method of making a container according to any of Examples 11 to 21 , wherein the step of providing a blank comprises providing a single blank for forming the box and the lid flap.

[0080] Example 23: The method of making a container according to any preceding Example, further comprising providing a plurality of consumer goods, wherein the step of folding the blank comprises folding the blank around the plurality of consumer goods to form a container housing the plurality of consumer goods.

[0081] Example 24: The method of making a container according to any preceding Example, wherein the blank is a first blank, the method further comprising providing a second blank and folding the second blank to form an inner frame, wherein the step of folding the first blank comprises folding the first blank around the inner frame to form the container. Example 25: The method of making a container according to Example 24, wherein the step of folding the second blank to form an inner frame comprising folding the second blank around a plurality of consumer goods.

[0082] Example 26: The method of making a container according to Example 24 or 25, wherein the step of folding the second blank to form the inner frame is performed before the step of folding the first blank.

[0083] Example 27: The method of making a container according to any preceding Example, further comprising the step of providing an outer wrapper around the container.

[0084] Examples will now be further described with reference to figures in which:

[0085] Figure 1 shows a simplified version of a laminar blank for forming a container according to the present disclosure;

[0086] Figure 2 shows a side-view of the laminar blank of Figure 1 ;

[0087] Figure 3 shows a method of folding the laminar blank of Figures 1 and 2 according to the present disclosure;

[0088] Figure 4 shows a first laminar blank for forming a container according to a first embodiment of the present disclosure;

[0089] Figure 5 shows a second laminar blank for forming an inner frame for the container according to the first embodiment of the present disclosure;

[0090] Figure 6 shows a perspective view of the assembled container according to the first embodiment of the present disclosure with the lid flap in a closed position;

[0091] Figure 7 shows the container of Figure 6 with the lid flap in a partially open position;

[0092] Figure 8 shows the container of Figure 6 with the lid flap in an open position;

[0093] Figure 9 shows a first laminar blank for forming a container according to a second embodiment of the present disclosure;

[0094] Figure 10 shows a second laminar blank for forming an inner frame for the container according to the second embodiment of the present disclosure;

[0095] Figure 11 shows a perspective view of the assembled container according to the second embodiment of the present disclosure with the lid flap in a closed position;

[0096] Figure 12 shows the container of Figure 11 with the lid flap in a partially open position;

[0097] Figure 13 shows the container of Figure 11 with the lid flap in an open position;

[0098] Figure 14 shows a first laminar blank for forming a container according to a third embodiment of the present disclosure;

[0099] Figure 15 shows a second laminar blank for forming an inner frame for the container according to the third embodiment of the present disclosure;

[0100] Figure 16 shows a perspective view of the assembled container according to the third embodiment of the present disclosure with the lid flap in the closed position;

[0101] Figure 17 shows the container of Figure 16 with a release tool removed from a box; Figure 18 shows the container of Figure 16 with the release tool inserted into the box in a first position;

[0102] Figure 19 shows the container of Figure 16 with the release tool inserted into the box in a second position;

[0103] Figure 20 shows the container of Figure 16 with the lid flap in a partially open position; and

[0104] Figure 21 shows the container of Figure 16 with the lid flap in the open position.

[0105] Figures 1 to 21 illustrate several embodiments of laminar blanks for use in methods according to the present disclosure and containers formed from the laminar blanks. In the Figures illustrating laminar blanks, solid lines are used to denote the edges of the laminar blank and cut lines formed in the laminar blank. Dashed lines are used to denote weakened lines along which the laminar blank is folded to form the container. For convenience, the dashed lines will be referred to as “fold lines” even when referring to the unfolded laminar blank. Dotted lines are used to denote a weakened line, such as a perforation line, along which a portion of the laminar blank may be detached from the remainder of the laminar blank.

[0106] Figures 1 and 2 show a simplified version of a laminar blank 1 to illustrate a method of folding a laminar blank according to the present disclosure. The laminar blank 1 comprises a plurality of panels, which includes at least one central panel 2, at least one first panel 3 connected to the at least one central panel 2 along a first fold line 4, at least one second panel 5 connected to the at least one central panel 2 along a second fold line 6, and at least one third panel 7 connected to the at least one second panel 5 along a third fold line 8. As will be described in more detail with reference to the specific embodiments of Figures 4 to 21 , the at least one third panel 7 may be configured to form at least one locking panel which is configured to form a locking mechanism for a container formed by folding the laminar blank 1. The locking mechanism is configured to prevent an unauthorised individual from accessing goods stored within the container.

[0107] Figure 3 shows a method of folding the laminar blank 1 of Figures 1 and 2 according to the present invention. As shown in steps 1 and 2 of Figure 3, the at least one second panel 5 is folded towards the at least one central panel 2 about the second fold line 6. Concurrently, the at least one first panel 3 is also folded towards the at least one central panel 2 about the first fold line 4. As shown in step 3 of Figure 3, the at least one first panel 3 engages with the at least one third panel 7 and therefore starts to fold the at least one third panel 7 about the third fold line 8 towards the at least one second panel 5. Therefore, the at least one third panel 7 is folded in an opposite direction to the at least one second panel 5. As shown in steps 4 to 8 of Figure 3, the folding is continued until the at least one third panel 7 overlies the at least one second panel 5 and the at least one first panel 3 overlies the at least one third panel 7.

[0108] Advantageously, the engagement of the at least one first panel 3 with the at least one third panel 7 during folding of the at least one first panel 3 and the at least one second panel 5 automatically results in the folding of the at least one third panel 7 without requiring a separate step to fold the at least one third panel 7. Therefore, advantageously, a laminar blank comprising at least one third panel 7 can be folded using a method according to the present invention without requiring any additional steps in the manufacturing process when compared to a similar laminar blank without at least one third panel. Advantageously, this may avoid or minimise the need for changes, additional tooling, or other types of hardware and software upgrade to existing processes and packaging equipment.

[0109] Figure 4 shows a laminar blank 10 for forming a first embodiment of a container 100 that may be formed according to the method of the present disclosure. Figure 5 shows a second laminar blank 50 for forming an inner frame 150 for the container 100.

[0110] The first laminar blank 10 comprises a box bottom panel 19 and a box back panel 14 connected to the box bottom panel 19 along a fold line. In the container 100, the box bottom panel 19 and the box back panel 14 form a box bottom wall and a box back wall respectively.

[0111] A box front outer panel 16 has a bottom edge 18 and a top edge 20, wherein the box front outer panel 16 is connected by a fold line along the bottom edge 18 to the box bottom panel 19. A box front inner panel 22 is connected along a fold line to the top edge 20 of the box front outer panel 16. A bottom edge 24 of the box front inner panel 22 is formed by an edge of the laminar blank 10. In the container 100, the box front outer panel 16 overlies the box front inner panel 22, and the box front outer panel 16 and the box front inner panel 22 together form a box front wall.

[0112] A pair of slits 23 in the box front outer panel 16 define a pair of release buttons 25 between each slit 23 and the bottom edge 18 of the box front outer panel 16. The function of the release buttons 25 is described below with reference to Figures 6 to 8.

[0113] A pair of first box side panels 26 are connected along fold lines to side edges of the box back panel 14 and a pair of second box side panels 28 are connected along fold lines to side edges of the box front outer panel 16. In the container 100, the first box side panels 26 overlap the second box side panels 28 to form box side walls. The box bottom wall, box back wall, box front wall and box side walls together form a box 102 for containing consumer goods. A top face of the box 102 is open to provide an access opening for accessing the consumer goods. In the embodiment shown in Figures 6 to 8, the box 102 contains two bundles 104 of aerosol-generating articles, but the skilled person will appreciate that other types of consumer goods may be contained in the box 102.

[0114] A lid top panel 30 is connected along a fold line to a top edge of the box back panel 14, the lid top panel 30 forming a lid top wall. An upper panel 32 has a top edge 34 and a bottom edge 36, and is connected by a fold line along the top edge 34 to the lid top panel 30. A cut line 38 in the lid top panel 30 defines a pull-tab 40 connected to the top edge 34 of the upper panel 32 along a fold line.

[0115] A pair of lower panels 42 are connected along fold lines to the bottom edge 36 of the upper panel 32. The upper panel 32 and the lower panels 42 together form a lid front wall. The lower panels 42 are spaced apart from each other to define an aperture 44 in the lid front wall. As described in further detail below with reference to Figures 6 to 8, the aperture 44 facilitates access to the consumer goods contained within the box 102.

[0116] A pair of locking panels 46 are connected along fold lines to a bottom edge 48 of the lower panels 42. Each locking panel 46 has a trapezoidal shape. In the container 100, the locking panels 46 are folded to overlie the respective lower panels 42. The lid top wall, the lid front wall and the locking panels 46 together form a lid flap 106. As described in further detail below, the lid flap 106 is moveable between a closed position in which the lid top wall overlies the access opening of the box 102 and an open position in which the access opening is at least partially uncovered to allow access to the consumer goods contained within the box 102.

[0117] Figure 5 shows a second laminar blank 50 for forming the inner frame 150 of the container 100. The second laminar blank 50 comprises a frame front panel 52, a pair of frame side panels 54 connected along fold lines to the frame front panel 52, and a pair of frame pull-tabs 56 connected along fold lines to the frame front panel 52. The second laminar blank 50 is folded around the consumer goods to form the inner frame 150, and the inner frame 150 and the consumer goods are positioned within the box 102.

[0118] Comparing the laminar blank 10 with the simplified version of a laminar blank 1 shown in Figures 1 and 2, the box back panel 14 corresponds to the at least one central panel 2. The box bottom panel 19, the box front outer panel 16 and the box front inner panel 22 together correspond to the at least one first panel 3, and a fold line 21 between the box bottom panel 19 and the box back panel 14 corresponds to the first fold line 4. The lid top panel 30, the upper panel 32 and the pair of lower panels 42 together correspond to the at least one second panel 5, and a fold line 31 between the lid top panel 30 and the box bottom panel 19 corresponds to the second fold line 6. The pair of locking panels 46 correspond to the at least one third panel 7 and the fold lines 48 correspond to the third fold line 8.

[0119] The laminar blank 10 may be folded using a method according to an embodiment of the present invention to form the container 100. For example, the method may begin with the positioning of the consumer goods and the inner frame 150 on the box back panel 14, which corresponds to the at least one central panel 2. Next, the box front inner panel 22 is folded about the top edge 20 of the box front outer panel 16 until the box front inner panel 22 overlies the box front outer panel 16 to form the box front wall. The box bottom panel 19 and the box front wall, which together correspond to the at least one first panel 3, are folded towards the consumer goods and the inner frame 150. Simultaneously, the lid top panel 30, the upper panel 32 and the pair of lower panels 42, which together correspond to the at least one second panel 5, are folded towards the consumer goods and the inner frame 150. During these simultaneous folding steps, the box front inner panel 22 of the box front wall engages the locking panels 46, which correspond to the at least one third panel 7, and folds the locking panels 46 about the fold lines 48 until the locking panels 46 overlie the lower panels 42. Therefore, advantageously, when the laminar blank 10 is folded using a method according to the present invention, the presence of locking panels 46 does not require an additional folding step, since the locking panels 46 are automatically folded as a result of simultaneously folding the remaining panels.

[0120] Figure 6 shows the container 100 with the lid flap 106 in the closed position. As illustrated by the dotted hidden lines, the two locking panels 46 abut the bottom edge 24 of the box front inner panel 22 when the lid flap 106 is in the closed position. The abutment between the two locking panels 46 and the box front inner panel 22 prevents movement of the lid flap 106 from the closed position. To open the container 100, a user must simultaneously depress the two release buttons 25, which pushes the two locking panels 46 inwardly to disengage them from the bottom edge 24 of the box front inner panel 22. With the release buttons 25 depressed and the locking panels 46 disengaged, the user may pull upwardly on the pull-tab 40 to begin moving the lid flap 106 from the closed position towards the open position.

[0121] Figure 7 shows the container 100 with the lid flap 106 in an intermediate position between the closed position shown in Figure 6 and the open position shown in Figure 8. As the lid flap 106 is moved from the closed position, the lid top panel 30 pivots along the fold line between the lid top panel 30 and the box back panel 14, and the upper panel 32 pivots along the fold line between the upper panel 32 and lid top panel 30 and along the fold lines between the upper panel 32 and each of the lower panels 42. Advantageously, the pivoting of the lid top panel 30 and the upper panel 32 allow the lower panels 42 to slide in a linear motion between the box front wall and the inner frame 150. When the bottom edges 48 of the lower panels 42 reaches the top of the box front wall, the entire lid front wall is released from the box 102 and the lid flap 106 can be moved into the open position shown in Figure 9. With the lid flap 106 in the open position, the user can access the consumer goods contained within the box 102. By pulling on one or both of the frame pull-tabs 56 the user may slide the inner frame 150 upwardly to lift the consumer goods partially out of the box 102, which may aid removal of the consumer goods from the box 102.

[0122] To close the container 100, the user reverses the steps described with reference to Figures 6 to 8 until the locking panels 46 re-engage the bottom edge 24 of the box front inner panel 22. Advantageously, to provide the user with an indication that the container 100 has been fully closed, the re-engagement of the locking panels 46 with the bottom edge 24 of the box front inner panel 22 may provide an audible ‘click’.

[0123] Figure 9 shows a first laminar blank 300 for forming a second embodiment of a container 400 that may be formed according to the method of the present disclosure. Figure 10 shows a second laminar blank 350 for forming an inner frame 450 for the container 400. The container 400 formed by folding and combining the first and second laminar blanks 300, 350 is shown in Figures 11 to 13. The first and second laminar blanks 300, 350 and the container 400 are similar to the first and second laminar blanks 10, 50 and the container 100 of Figures 4 to 8, and like reference numerals are used to designate like parts. The first laminar blank 300 comprises a box bottom panel 19 and a box back panel 14 connected to the box bottom panel 19 along a fold line. In the container 400, the box bottom panel 19 and the box back panel 14 form a box bottom wall and a box back wall respectively.

[0124] A box front outer panel 16 has a bottom edge 18 and a top edge 20, wherein the box front outer panel 16 is connected by a fold line along the bottom edge 18 to the box bottom panel 19. A box front inner panel 22 is connected along a fold line to the top edge 20 of the box front outer panel 16. A bottom edge 24 of the box front inner panel 22 is formed by an edge of the laminar blank 10. In the container 100, the box front outer panel 16 overlies the box front inner panel 22, and the box front outer panel 16 and the box front inner panel 22 together form a box front wall.

[0125] A first slit 23 in the box front outer panel 16 defines a release button 25 between the slit 23 and the bottom edge 18 of the box front outer panel 16. A second slit 323 in the box front outer panel 16 defines a false button 325. The functions of the release button 25 and the false button 325 are described below with reference to Figures 11 to 13.

[0126] A pair of first box side panels 26 are connected along fold lines to side edges of the box back panel 14 and a pair of second box side panels 28 are connected along fold lines to side edges of the box front outer panel 16. In the container 400, the first box side panels 26 overlap the second box side panels 28 to form box side walls. The box bottom wall, box back wall, box front wall and box side walls together form a box 402 for containing consumer goods. A top face of the box 402 is open to provide an access opening for accessing the consumer goods. In the embodiment shown in Figures 11 to 13, the box 402 contains two bundles 104 of aerosolgenerating articles, but the skilled person will appreciate that other types of consumer goods may be contained in the box 402.

[0127] A lid top panel 30 is connected along a fold line to a top edge of the box back panel 14, the lid top panel 30 forming a lid top wall. An upper panel 32 has a top edge 34 and a bottom edge 36, and is connected by an arcuate fold line along the top edge 34 to the lid top panel 30. The function of the arcuate shape of the fold line along the top edge 34 will be described below with reference to Figures 11 to 13. A cut line 38 in the lid top panel 30 defines a pull-tab 40 connected to the top edge 34 of the upper panel 32 along a fold line.

[0128] A single lower panel 342 is connected along a fold line to the bottom edge 36 of the upper panel 32. The upper panel 32 and the lower panel 342 together form a lid front wall.

[0129] A single locking panel 346 is connected along a fold line to a bottom edge 48 of the lower panel 342. The locking panel 346 has a trapezoidal shape. In the container 400, the locking panel 346 is folded to overlie the lower panel 342. The lid top wall, the lid front wall and the locking panel 346 together form a lid flap 406. As described in further detail below, the lid flap 406 is moveable between a closed position in which the lid top wall overlies the access opening of the box 402 and an open position in which the access opening is at least partially uncovered to allow access to the consumer goods contained within the box 402. Figure 10 shows a second laminar blank 350 for forming the inner frame 450 of the container 400. The second laminar blank 350 comprises a frame front panel 52, a pair of frame side panels 54 connected along fold lines to the frame front panel 52, and a frame pull-tab 56 connected along a fold line to the frame front panel 52. The second laminar blank 350 is folded around the consumer goods to form the inner frame 450, and the inner frame 450 and the consumer goods are positioned within the box 402. The skilled person will appreciate that the second laminar blank 50 and the inner frame 150 of the embodiment of Figures 4 to 8 may be used instead of the second laminar blank 350 and the inner frame 450.

[0130] Comparing the laminar blank 300 with the simplified version of a laminar blank 1 shown in Figures 1 and 2, the box back panel 14 corresponds to the at least one central panel 2. The box bottom panel 19, the box front outer panel 16 and the box front inner panel 22 together correspond to the at least one first panel 3, and a fold line 21 between the box bottom panel 19 and the box back panel 14 corresponds to the first fold line 4. The lid top panel 30, the upper panel 32 and the lower panel 342 together correspond to the at least one second panel 5, and a fold line 31 between the lid top panel 30 and the box bottom panel 19 corresponds to the second fold line 6. The locking panel 46 corresponds to the at least one third panel 7 and the fold line 48 corresponds to the third fold line 8.

[0131] The laminar blank 300 may be folded using a method according to an embodiment of the present invention to form the container 400. For example, the method may begin with the positioning of the consumer goods and the inner frame 450 on the box back panel 14, which corresponds to the at least one central panel 2. Next, the box front inner panel 22 is folded about the top edge 20 of the box front outer panel 16 until the box front inner panel 22 overlies the box front outer panel 16 to form the box front wall. The box bottom panel 19 and the box front wall, which together correspond to the at least one first panel 3, are folded towards the consumer goods and the inner frame 450. Simultaneously, the lid top panel 30, the upper panel 32 and the lower panel 342, which together correspond to the at least one second panel 5, are folded towards the consumer goods and the inner frame 450. During these simultaneous folding steps, the box front inner panel 22 of the box front wall engages the locking panel 46, which corresponds to the at least one third panel 7, and folds the locking panel 46 about the fold line 48 until the locking panel 46 overlies the lower panel 342. Therefore, advantageously, when the laminar blank 300 is folded using a method according to the present invention, the presence of locking panel 46 does not require an additional folding step, since the locking panel 46 is automatically folded as a result of simultaneously folding the remaining panels.

[0132] With reference to Figures 11 to 13 the steps for opening the container 400 will now be described.

[0133] Figure 11 shows the container 400 with the lid flap 406 in the closed position. As illustrated by the dotted hidden lines, the locking panel 346 abuts the bottom edge 24 of the box front inner panel 22 when the lid flap 406 is in the closed position. The abutment between the locking panel 346 and the box front inner panel 22 prevents movement of the lid flap 406 from the closed position. To open the container 400, a user must depress the release button 25, which pushes the locking panel 346 inwardly to disengage the locking panel 346 from the bottom edge 24 of the box front inner panel 22. With the release button 25 depressed and the locking panel 346 disengaged, the user may pull upwardly on the pull-tab 40 to begin moving the lid flap 406 from the closed position towards the open position.

[0134] The false release button 325 does not overlie the locking panel 346 and therefore reduces the risk of an unauthorised user opening the container 400 by making it more difficult to determine how the container 400 may be opened. Specifically, the false button 325 may mislead an unauthorised user into attempting to open the container 400 by using the false button 325 instead of the release button 25. Furthermore, the longer and U-shaped slit 323 defining the false button 325 may advantageously draw an unauthorised user’s attention away from the release button 25 defined by the smaller, linear slit 23.

[0135] Advantageously, when the lid flap 406 is in the closed position shown in Figure 11 , the arcuate shape of the fold line extending along the top edge 34 of the upper panel 32 biases the lid front wall against the inside of the box front wall. Advantageously, this facilitates engagement of the locking panel 346 with the bottom edge 24 of the box front inner panel 22 and reduces the risk of an unauthorised user attempting to force open the container 400 by inserting a finger or tool between the box front wall and the lid front wall. The skilled person will appreciate that the arcuate fold line may be applied to other embodiments described herein, including the embodiments of Figures 4 to 8.

[0136] Figure 12 shows the container 400 with the lid flap 406 in an intermediate position between the closed position shown in Figure 11 and the open position shown in Figure 13. As the lid flap 406 is moved from the closed position, the lid top panel 30 pivots along the fold line between the lid top panel 30 and the box back panel 14, and the upper panel 32 pivots along the fold line between the upper panel 32 and lid top panel 30 and along the fold line between the upper panel 32 and the lower panel 342. Advantageously, the pivoting of the lid top panel 30 and the upper panel 32 allows the lower panel 342 to slide in a linear motion between the box front wall and the inner frame 450. When the bottom edge 48 of the lower panel 342 reaches the top of the box front wall, the entire lid front wall is released from the box 402 and the lid flap 406 can be moved into the open position shown in Figure 13. With the lid flap 406 in the open position, the user can access the consumer goods contained within the box 402. By pulling on the frame pull-tab 56 the user may slide the inner frame 450 upwardly to lift the consumer goods partially out of the box 402, which may aid removal of the consumer goods from the box 402.

[0137] To close the container 400, the user reverses the steps described with reference to Figures 11 to 13 until the locking panel 346 re-engages the bottom edge 24 of the box front inner panel 22. Advantageously, to provide the user with an indication that the container 400 has been fully closed, the re-engagement of the locking panel 346 with the bottom edge 24 of the box front inner panel 22 may provide an audible ‘click’.

[0138] Figure 14 shows a first laminar blank 500 for forming a third embodiment of a container 600 that may be formed according to the method of the present disclosure. Figure 15 shows a second laminar blank 550 for forming an inner frame 650 for the container 600. The container 600 formed by folding and combining the first and second laminar blanks 500, 550 is shown in Figures 16 to 21.

[0139] The first laminar blank 500 comprises a box bottom panel 19 and a box back panel 14 connected to the box bottom panel 19 along a fold line. In the container 600, the box bottom panel 19 and the box back panel 14 form a box bottom wall and a box back wall respectively.

[0140] A box front outer panel 16 has a bottom edge 18 and a top edge 20, wherein the box front outer panel 16 is connected by a fold line along the bottom edge 18 to the box bottom panel 19. A box front inner panel 22 is connected along a fold line to the top edge 20 of the box front outer panel 16. A bottom edge 24 of the box front inner panel 22 is formed by an edge of the laminar blank 10. In the container 500, the box front outer panel 16 overlies the box front inner panel 22, and the box front outer panel 16 and the box front inner panel 22 together form a box front wall. A cut-out 23 in the box front outer panel 16 and the box front inner panel 22 forms a cut-out 103 in the box front wall of the container 600.

[0141] A pair of first box side panels 26 are connected along fold lines to side edges of the box back panel 14 and a pair of second box side panels 28 are connected along fold lines to side edges of the box front outer panel 16. In the container 600, the first box side panels 26 overlap the second box side panels 28 to form box side walls. The box bottom wall, box back wall, box front wall and box side walls together form a box 602 for containing consumer goods. A top face of the box 602 is open to provide an access opening for accessing the consumer goods. In the embodiment shown in Figures 16 to 21 , the box 602 contains two bundles 604 of aerosolgenerating articles, but the skilled person will appreciate that other types of consumer goods may be contained in the box 602.

[0142] A lid top panel 30 is connected along a fold line to a top edge of the box back panel 14, the lid top panel 30 forming a lid top wall. An upper panel 32 has a top edge 34 and a bottom edge 36, and is connected by an arcuate fold line along the top edge 34 to the lid top panel 30. A cut line 38 in the lid top panel 30 defines a pull-tab 40 connected to the top edge 34 of the upper panel 32 along a fold line.

[0143] A lower panel 542 is connected along a fold line to the bottom edge 36 of the upper panel 32. The upper panel 32 and the lower panel 542 together form a lid front wall of the container 600.

[0144] A locking panel 546 having a trapezoidal shape is connected along a fold line to a bottom edge 48 of the lower panel 542. In the container 600, the locking panel 546 is folded to overlie the lower panel 542. The lid top wall, the lid front wall and the locking panel 546 together form a lid flap 606. As described in further detail below, the lid flap 606 is moveable between a closed position in which the lid top wall overlies the access opening of the box 602 and an open position in which the access opening is at least partially uncovered to allow access to the consumer goods contained within the box 602.

[0145] A release tool panel 547 is connected along a perforation line to the locking panel 546 and the bottom edge 48 of the lower panel 542. A pull-tab 49 extends from a top edge of the release tool panel 547. When the first laminar blank 500 is folded to form the container 600, the first laminar blank 500 is folded along the bottom edge 48 of the lower panel 542 so that the release tool panel 547 and the locking panel 546 overlie the lower panel 542.

[0146] Figure 15 shows a second laminar blank 550 for forming the inner frame 650 of the container 600. The second laminar blank 550 comprises a frame front panel 52, a pair of frame side panels 54 connected along fold lines to the frame front panel 52, and a frame pull-tab 56 connected along a fold line to the frame front panel 52. The second laminar blank 550 is folded around the consumer goods to form the inner frame 650, and the inner frame 650 and the consumer goods are positioned within the box 602.

[0147] Comparing the laminar blank 500 with the simplified version of a laminar blank 1 shown in Figures 1 and 2, the box back panel 14 corresponds to the at least one central panel 2. The box bottom panel 19, the box front outer panel 16 and the box front inner panel 22 together correspond to the at least one first panel 3, and a fold line 21 between the box bottom panel 19 and the box back panel 14 corresponds to the first fold line 4. The lid top panel 30, the upper panel 32 and the lower panel 542 together correspond to the at least one second panel 5, and a fold line 31 between the lid top panel 30 and the box bottom panel 19 corresponds to the second fold line 6. The locking panel 546, the release tool panel 547 and the pull-tab 49 together correspond to the at least one third panel 7 and the fold line 48 corresponds to the third fold line 8.

[0148] The laminar blank 500 may be folded using a method according to an embodiment of the present invention to form the container 600. For example, the method may begin with the positioning of the consumer goods and the inner frame 550 on the box back panel 14, which corresponds to the at least one central panel 2. Next, the box front inner panel 22 is folded about the top edge 20 of the box front outer panel 16 until the box front inner panel 22 overlies the box front outer panel 16 to form the box front wall. The box bottom panel 19 and the box front wall, which together correspond to the at least one first panel 3, are folded towards the consumer goods and the inner frame 650. Simultaneously, the lid top panel 30, the upper panel 32 and the lower panel 542, which together correspond to the at least one second panel 5, are folded towards the consumer goods and the inner frame 650. During these simultaneous folding steps, the box front inner panel 22 of the box front wall engages the locking panel 546 and the release tool panel 547, which together with the pull-tab 49 correspond to the at least one third panel 7, and folds the locking panel 546 and the release tool panel 547 about the fold line 48 until the locking panel 546 and the release tool panel 547 overlie the lower panel 542. Therefore, advantageously, when the laminar blank 500 is folded using a method according to the present invention, the presence of locking panel 546 and the release tool panel 547 does not require an additional folding step, since the locking panel 546 and the release tool panel 547 are automatically folded as a result of simultaneously folding the remaining panels.

[0149] With reference to Figures 16 to 21 the steps for opening the container 600 will now be described.

[0150] Figure 16 shows the container 600 with the lid flap 606 in the closed position. Before opening the container 600 for the first time, a user may pull upwardly on the pull-tab 49 to detach the release tool panel 547 from the lower panel 542 and the locking panel 546. The detached release tool panel 547 may be removed from the box 602 and forms a release tool 608, as shown in Figure 17. The release tool 608 has a generally rectangular shape comprising a cut-out 610 in a bottom corner of the release tool 608. The cut-out 610 has a size and shape corresponding to the size and shape of the locking panel 546.

[0151] With the release tool panel 547 detached from the lower panel 542 and the locking panel 546, the locking panel 546 abuts the bottom edge 24 of the box front inner panel 22 when the lid flap 606 is in the closed position, as illustrated by the dotted hidden lines in Figure 17. The abutment between the locking panel 546 and the box front inner panel 22 prevents movement of the lid flap 606 from the closed position.

[0152] Advantageously, when the lid flap 606 is in the closed position shown in Figure 17, the arcuate shape of the fold line extending along the top edge 34 of the upper panel 32 biases the lid front wall against the inside of the box front wall. Advantageously, this facilitates engagement of the locking panel 546 with the bottom edge 24 of the box front inner panel 22 and reduces the risk of an unauthorised user attempting to force open the container 600 by inserting a finger between the box front wall and the lid front wall.

[0153] To open the container, the user must first insert an end of the release tool 608 opposite the cut-out 610 into the box 602 between the box front wall and the lid front wall, as illustrated by the arrow 612 in Figure 18. The release tool 608 must be inserted into the box 602 at an end opposite to the locking panel 546, so that the release tool 608 is not engaged with the locking panel 546. This position of the release tool 608 within the box 602 will be referred to as the first position.

[0154] From the first position, the user must slide the release tool 608 towards the same end of the box 602 as the locking panel 546, as illustrated by the arrow 613 in Figure 19. The position of the release tool 608 shown in Figure 19 will be referred to as the second position. As the release tool 608 slides from the first position to the second position, the release tool 608 engages a sloped edge 146 of the locking panel 546. Once the release tool 608 is engaged with the sloped edge 146 of the locking panel 546, further sliding of the release tool 608 into the second position moves the locking panel 546 away from the box front wall until the release tool 608 is positioned between the locking panel 546 and the box front wall and the locking panel 546 is disengaged from the bottom edge 24 of the box front inner panel 22.

[0155] Advantageously, inserting the release tool 608 into the box 602 directly into the second position will position the release tool 608 between the lower panel 542 and the locking panel 546, which prevents disengagement of the locking panel 546 from the bottom edge 24 of the box front inner panel 22, thereby preventing opening of the container 600. Accordingly, the container 600 can only be unlocked by first inserting the release tool 608 into the first position, then sliding the release tool 608 into the second position.

[0156] Once the release tool 608 has been moved from the first position to the second position so that the locking panel 546 is disengaged from the bottom edge 24 of the box front inner panel 22, the user may pull upwardly on the pull-tab 40 to begin moving the lid flap 606 from the closed position towards the open position.

[0157] Figure 20 shows the container 600 with the lid flap 606 in an intermediate position between the closed position shown in Figure 17 and the open position shown in Figure 21. As the lid flap 606 is moved from the closed position, the lid top panel 30 pivots along the fold line between the lid top panel 30 and the box back panel 14, and the upper panel 32 pivots along the fold line between the upper panel 32 and lid top panel 30 and along the fold line between the upper panel 32 and the lower panel 542. Advantageously, the pivoting of the lid top panel 30 and the upper panel 32 allows the lower panel 542 to slide in a linear motion between the box front wall and the inner frame 650. When the bottom edge 48 of the lower panel 442 reaches the top of the box front wall, the entire lid front wall is released from the box 602 and the lid flap 606 can be moved into the open position shown in Figure 21. With the lid flap 606 in the open position, the user can access the consumer goods 604 contained within the box 602. By pulling on the frame pull-tab 56 the user may slide the inner frame 650 upwardly to lift the consumer goods 604 partially out of the box 602, which may aid removal of the consumer goods 604 from the box 602.

[0158] To close the container 600, the user reverses the steps until the locking panel 546 reengages the bottom edge 24 of the box front inner panel 22. Advantageously, to provide the user with an indication that the container 600 has been fully closed, the re-engagement of the locking panel 546 with the bottom edge 24 of the box front inner panel 22 may provide an audible ‘click’. Once the container 600 has been closed, the release tool 608 may be stored within the box 602 by inserting the release tool 608 between the box front wall and the lid front wall in the same orientation as the release tool panel 547 before the release tool panel 547 is detached from the lower panel 542 and the locking panel 546. Advantageously, the cut-out 610 in the release tool 608 accommodates the locking panel 546 when the release tool 608 is stored in the box 602.

[0159] The skilled person will appreciate that the first laminar blank 500 may be manufactured without the release tool panel 547. In this case, a release tool may be manufactured separately and provided with the rest of the container 600 to the user. Alternatively, the container 600 may be provided without a release tool and the user may instead use another item as a release tool, such as a credit card or similar.

Claims

CLAIMS1. A method of making a container for consumer goods, the method comprising: providing a blank comprising a plurality of panels, wherein the plurality of panels includes at least one central panel, at least one first panel, at least one second panel, and at least one third panel, wherein the at least one first panel is connected to the at least one central panel by a first fold line, wherein the at least one second panel is connected to the at least one central panel by a second fold line, wherein the first fold line and the second fold line extend along opposite sides of the at least one central panel, wherein the at least one third panel is connected to the at least one second panel by a third fold line, and wherein the second fold line and the third fold line extend along opposite sides of the at least one second panel; and folding the blank to form a container for consumer goods, wherein the folding comprises: folding the at least one second panel about the second fold line towards the at least one central panel; and folding the at least one first panel about the first fold line towards the at least one central panel so that the at least one first panel engages the at least one third panel and folds the at least one third panel about the third fold line towards the at least one second panel.

2. The method of making a container according to claim 1 , wherein the at least one third panel is folded in the opposite direction to the at least one second panel.

3. The method of making a container according to claim 1 or 2, wherein the steps of folding the at least one first panel, the at least one second panel and the at least one third panel are performed concurrently.

4. The method of making a container according to any preceding claim, wherein the container comprises a box for housing the consumer goods, the box comprising a box front wall, a box back wall, a box bottom wall and box side walls, and wherein a top face of the box is at least partially open to provide an access opening for accessing the consumer goods.

5. The method of making a container according to claim 4, wherein the at least one central panel comprises: a box bottom panel forming the box bottom wall; anda box back panel connected along a fold line to the box bottom panel, wherein the box back panel forms the box back wall.

6. The method of making a container according to claim 5, wherein the at least one central panel comprises at least two box side panels connected along fold lines to the box back panel, and wherein each box side wall comprises at least one of the box side panels.

7. The method of making a container according to claim 4, 5 or 6, wherein the at least one first panel comprises: a box front outer panel connected along the first fold line to the at least one central panel; and a box front inner panel connected along a box front fold line to the box front outer panel, wherein the box front outer panel and the box front inner panel together form the box front wall.

8. The method of making a container according to claims 5 and 7 or claims 6 and 7, wherein the box front outer panel is connected along the first fold line to the box bottom panel, and wherein the step of folding the at least one first panel about the first fold line comprises folding the box front outer panel about the first fold line towards the at least one central panel.

9. The method of making a container according to claim 7 or 8, wherein the step of folding the blank to form a container for consumer goods comprises folding the box front inner panel about the box front fold line so that the box front inner panel overlies the box front outer panel, optionally wherein the step of folding the box front inner panel about the box front fold line is performed before the step of folding the box front outer panel about the first fold line.

10. The method of making a container according to any of claims 4 to 9, wherein the container further comprises a lid flap, wherein the lid flap is hingedly connected to the box back wall and comprises a lid top wall, a lid front wall, and at least one locking panel, wherein the lid flap is movable between a closed position in which the lid top wall overlies the access opening and an open position in which the access opening is at least partially uncovered.11 . The method of making a container according to claim 10, wherein the at least one second panel comprises: a lid top panel forming the lid top wall and connected along the second fold line to the at least one central panel; andat least one lid front panel forming at least part of the lid front wall, wherein the at least one lid front panel is connected along a first lid fold line to the lid top panel.

12. The method of making a container according to claim 11 , wherein the at least one lid front panel comprises: a first lid front panel connected along the first lid fold line to the lid top panel; and a second lid front panel connected along a second lid fold line to the first lid front panel.

13. The method of making a container according to claim 11 or 12, wherein the at least one third panel forms at least one locking panel connected to the at least one lid front panel along the third fold line, optionally wherein the step of folding the at least one second panel about the second fold line comprises folding the lid top panel along the second fold line and folding the at least one lid front panel along the first lid fold line, optionally wherein at least one of the steps of folding the lid top panel along the second fold line and folding the at least one lid front panel along the first lid fold line is performed concurrently with the step of folding the box front outer panel about the first fold line .

14. The method of making a container according to claim 13, wherein the at least one locking panel is folded along the third fold line in the opposite direction to the lid top panel and the at least one lid front panel, optionally wherein the at least one locking panel is folded about the third fold line towards the at least one lid front panel so that the at least one locking panel overlies the at least one lid front panel.

15. The method of making a container according to claim 13 or 14, wherein the box front inner panel comprises a top edge and a bottom edge, and wherein the at least one locking panel is folded so that the at least one locking panel engages the bottom edge of the box front inner panel when the lid flap is in the closed position to prevent movement of the lid flap from the closed position to the open position.

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