Field of the Invention

The present invention relates to packaging inserts containing elongate elements, particularly but not exclusively to packaging inserts containing smoking articles.

Background

Many variations of packets for elongate elements, such as smoking articles, are employed. Improvements in these types of packaging are desired.

Summary of the Invention

According to a first aspect, the invention provides a packaging insert comprising a plurality of individual pockets each shaped to fit an elongate element, each pocket having a hexagonal cross section, wherein the packaging insert comprises a first web having a series of parallel grooves and a second web having a series of parallel grooves, the grooves of both the first web and the second web having a three-sided polygonal cross section, the first web and the second web are arranged to provide a series of individual pockets having a hexagonal cross section. For example, the grooves of the first web are arranged to face and align with the grooves of the second web to provide a series of individual pockets having a hexagonal cross section. If the areas of each web between the grooves are viewed as ridges, the ridges of the first web are arranged to face and align with the ridges of the second web.

In one embodiment, the grooves of the first web and the second web are equally spaced and equally shaped.

The packaging insert may also comprise one or more further webs having the same configuration as the first and second webs. For example, the packaging insert may further comprise a third web having a series of parallel grooves, the grooves having a three-sided polygonal cross section, the third web is arranged adjacent to the second web so as to provide a second series of individual pockets having a hexagonal cross section. The second series of individual pockets is formed by the second web and the third web. As a result, the convex faces of the grooves (also referred to as ridges) of the third web are arranged to face and align the convex faces of the grooves of the second web. A fourth web having a series of parallel grooves may also be added to the packaging insert of the present invention. The fourth web maybe arranged to provide a third series of individual pockets having a hexagonal cross section. In further embodiments, yet more webs may be added to the packaging insert of the present invention as described above providing further layers of individual pockets having a hexagonal cross section.

In one embodiment, the packaging insert further comprises a substantially flat web arranged adjacent to the first web providing a series of individual pockets having a semi-hexagonal cross section. These are not intended to hold an elongate element. This additional web provides a more uniform finish to the packaging insert and can provide improved structural integrity. In a further embodiment, the packaging insert further comprises a second substantially flat web arranged on the opposite face to the first substantially flat web providing a second series of individual pockets having a semi-hexagonal cross section. For example, in an embodiment where there are two webs having grooves, the second substantially flat web is arranged adjacent to the second web having grooves; in an embodiment where there are three webs having grooves, the second substantially flat web is arranged adjacent to the third web having grooves; and so on. The second substantially flat web also provides improved finish and increased structural integrity.

In one embodiment, the webs having grooves and the substantially flat webs have the same dimensions.

All webs employed in the present invention may be made of the same material or of different materials. Any suitable material maybe used including but not limited to thin walled card. For example, the webs may be impervious to water, moisture and/ or air. In such circumstances, the webs may be made of one material that is impervious to water, moisture and/or air. Alternatively, the webs may comprise any suitable base material, such as thin walled card, board, film or foil, and further comprise a layer or membrane that is impervious to water, moisture and/or air.

The webs employed in the present invention may be joined together. In one embodiment, the webs may be bonded together. Any suitable bonding means may be employed including but not limited to adhesive. For example, the first web and the second web may be joined together where the second web contacts with areas between the grooves of the first web. For example, a first web having grooves and ridges maybe joined to a second web where the second web contacts the ridges of the first web facing the second web. A first web having grooves and ridges may be joined to a second web having grooves and ridges where the ridges of the first web contact the ridges of the second web facing the first web.

The individual pockets are designed to hold an elongate element. In one embodiment, the length of each individual pocket is essentially the same length as the elongate element.

In one embodiment, each individual pocket is sealed allowing individual access to each pocket.

In accordance with embodiments of the invention, there is provided a packet comprising within it a packaging insert of the present invention.

In embodiments where the elongate elements are smoking articles, the packet may be any type of packet including but not limited to a soft cap packet or a flip top packet.

The packaging inserts of the present invention may also be designed so as to facilitate further processing of the packaging insert. For example, in one embodiment of the present invention is provided a packaging insert comprising a first web having a series of parallel grooves and a second web having a series of parallel grooves, the first web and the second web both having an area without grooves, the area without grooves on the first web is arranged to face and align the area without grooves on the second web. Where the two areas without grooves are aligned with each other provides an area without pockets. This arrangement allows the packaging insert to be folded along an axis located in the area without pockets. Accordingly, a first series of individual pockets located on one side of the area without pockets is folded to face a second series of individual pockets on the other side of the area without pockets. This arrangement may provide a further series of individual pockets (with a hexagonal cross-section) between the first series and the second series. In one embodiment of the invention, the packaging insert comprises a single elongate element in one or more of the individual pockets. For example, the packaging insert may comprise an elongate element in each of the individual pockets. In the present invention, the elongate elements may be positioned in the pockets by any conventional method. For example, the elongate elements may be inserted into a completed packaging insert of the invention. Alternatively, the elongate elements may be put in position during assembly of the packaging insert. In one embodiment in which the packaging insert comprises a first web and a second web having grooves with a three-sided polygonal cross section arranged to provide a series of hexagonal pockets, an elongate element is positioned in a groove of the first web before the second web is arranged adjacent to the first web so as to provide a series of individual pockets. In a further aspect of the invention is provided a packet comprising a packaging insert of the present invention as described above. For example, the packet may be a flip top packet or a soft cap packet.

In a further aspect of the invention is provided a process for preparing a packaging insert of the present invention, the process comprising providing a first web having grooves with a three-sided polygonal cross section and a second web having grooves with a three-sided polygonal cross section, and arranging the first web and the second web to provide a series of parallel individual pockets having a hexagonal cross section.

In one embodiment, the process further comprises subsequently inserting an elongate element into one or more of the pockets. In an alternative embodiment, the process comprises placing an elongate element into one or more of the grooves before arranging the first web and the second web to provide a series of parallel individual pockets.

In a further aspect of the invention is provided the use of a packaging insert according to any embodiment of the present invention for protecting elongate elements during storage and/ or transportation.

Brief Description of the Drawings Figure 1 shows a packaging insert according to one embodiment of the present invention comprising a first web and a second web.

Figure 2 shows a packaging insert according to one embodiment of the present invention comprising a first web, a second web, and a third web.

Figure 3 shows a packaging insert according to one embodiment of the present invention and how it may be inserted into a flip top packet.

Figures 4a and 4b show a packaging insert according to one embodiment of the present invention and how it may be inserted into a soft cap packet and a flip top packet respectively.

Figures 5a and 5b show a packaging insert according to one embodiment of the present invention and how it may be folded.

Figures 6a and 6b show a packaging insert according to one embodiment of the present invention and how it may be folded.

Figures 7a, 7b, and 7c show a packaging insert according to one embodiment of the present invention and how it may be incorporated into a packet having a flip top lid.

Figures 8a, 8b, 8c show how a packaging insert according to one embodiment of the present invention may be assembled.

Figures 9a and 9b show how an elongate element may be positioned in an individual pocket provided in a packaging insert according to one embodiment of the present invention.

Detailed Description

The present invention provides a way of packaging elongate elements in a manner that provides protection from bending and/or crushing during transportation and/ or storage of the elements. It also provides a way of packaging elongate elements, in particular smoking articles, in a manner that improves customer experience both during the opening and withdrawing of the element from its container and preserving the element for longer in its desired state ready for use. In this respect, a packaging insert may be employed that retains one or more elongate element and improves the protection provided by the packaging as a whole. Such a packaging insert may then be incorporated into a packet.

Elongate elements may be, but are not limited to, any cylindrical article.

Examples of suitable elongate elements include but are not limited to smoking articles and electronic cigarettes. As used herein, the term "smoking article" includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products. The smoking article maybe provided with a filter for the gaseous flow drawn by the smoker. Other suitable elongate elements include any delicate or degradable items such as but not limited to halogen bulbs and glass ampules. Glass test-tubes containing one, two, three or more smoking articles may also be appropriate.

In the following examples, the invention is described in the context of packaging inserts containing smoking articles, although the invention should not to be viewed as limited as such. The packaging inserts of the invention are applicable to any suitable elongate element.

Figure 1 shows a packaging insert 160 of one embodiment of the present invention comprising a plurality of individual pockets 168 having a hexagonal cross section. The packaging insert 160 is formed of a first web 161 and a second web 162 both having a series of parallel grooves 163, 165 having a three-sided polygonal cross section. The grooves 163 of the first web align and face the grooves 165 of the second web resulting in a series of parallel individual pockets 168, each one shaped to receive and contain a single elongate element 167. The areas of each web 164, 166 between each groove may be viewed as ridges.

Figure 2 shows how the packaging insert of Figure 1 may be modified. In Figure 2 is shown a packaging insert 170 comprising a plurality of individual pockets 1711, 1712. The packaging insert is formed of a first web 171, a second web 172, and a third web 173 all having a series of parallel grooves 174, 175, 176 and ridges 177, 178, 179 having a three-sided polygonal cross section. The grooves 174 of the first web align and face the grooves 175 of the second web resulting in a series of parallel individual pockets 1711 having a hexagonal cross section, each one shaped to receive and contain a single elongate element 1710. The ridges 179 of the third web align and face the ridges 178 of the second web resulting in a series of parallel individual pockets 1712, each one shaped to receive and contain a single elongate element 1710.

Figure 3 shows how a packaging insert 180 according to one embodiment of the present invention having a plurality of individual pockets 182, each having a hexagonal cross section maybe incorporated into a packet 181, such as but not limited to a cigarette packet. In Figure 3, the packet has a flip top lid 183 but the packaging inserts of the present invention are also useful in the context of other types of packet.

Figures 4a and 4b also show how a packaging insert 190 according to one embodiment of the present invention having a plurality of individual pockets 193, each having a hexagonal cross section may be incorporated into a packet 191 or 192, such as but not limited to a cigarette packet. In Figure 4a, the packet 191 is a simple three dimensional rectangle with one open end. Such a packet may optionally be

subsequently filled with smoking articles and covered all over thus covering the open end shown in Fig. 4a. In Figure 4b, the packet 192 comprises a flip top lid 194. It would be appreciated by the skilled person that the packaging inserts of the present invention are suitable for use in all kinds of packets, not just those exemplified in the present application. Figure 5a shows the end cross section of a packaging insert 50 according to one embodiment of the present invention comprising two series of parallel individual pockets 51 having a hexagonal cross section. The first series of pockets is labelled 501. The second series of pockets is labelled 502. Each pocket 51 contains a single smoking article 52. The packaging insert further comprises a flat web 53. Each series of individual pockets 501, 502 is positioned on the face of the flat web in such a way that all the pockets are arranged in parallel. In addition, a part of the flat web 503 is left without pockets. The packaging insert 50 can then be folded (book-style) as shown in Figure 5b. The packaging insert is folded along an axis running along the area 503 of the flat web 53 without pockets to provide a packaging insert having two layers of individual pockets having a hexagonal cross section.

Figure 6a shows a packaging insert 60 according to one embodiment of the present invention. The packaging insert 60 comprises a series of individual pockets 61 having a hexagonal cross section. Each pocket 61 contains a smoking article 62 such as but not limited to a cigarette. This embodiment does not comprise a flat web. It is still however folded (book-style) as shown in Figure 6b to provide a packaging insert 60 having two layers of individual pockets 61 having a hexagonal cross section. Each pocket contains a smoking article 62. Figures 7a, 7b, and 7c show how a packaging insert 70 according to one embodiment of the present invention may be incorporated into a packet 71 such as but not limited to a cigarette packet. The packaging insert 70 comprises three layers of individual pockets having a hexagonal cross section. Although not shown in Figures 7a- 7c, the packaging insert 70 maybe formed of three webs having equally spaced grooves, each groove possessing a three-sided polygonal cross section, the three webs arranged to provide the individual pockets having a hexagonal cross section. Although not shown in Figures 7a-7C, the packaging insert 70 is used to hold/store smoking articles such as but not limited to cigarettes.

The packet 71 shown in Figures 7a-7c is formed of one flat piece of material such as but not limited to card. The material is shaped so that it can be folded (for example see Figure 7b) so as to encompass the packaging insert 70 in the packet 71. The final packet 71 is shown in Figure 7c (packaging insert 70 not visible inside the packet).

Figures 8a, 8b, and 8c show how packaging inserts according to one

embodiment of the invention may be arranged to provide layers of individual pockets each having a hexagonal cross section. A first packaging inset 81 having a single layer of parallel individual pockets according to the invention is provided. The packaging insert 81 may be formed of two webs (not shown in Figures 8a-8c) having a series of parallel grooves arranged to provide the hexagonal shaped individual pockets. As shown in Figure 8b, a second similar packaging insert 82 formed of a single layer of parallel individual pockets is fed to the first packaging insert 81. The first packaging insert 81 and the second packaging insert 82 are arranged so that the pockets of the second layer 82 fit into the spaces between the pockets of the first layer 81. The packaging insert 81, 82 shown in Figure 8b has two layers of hexagonal shaped pockets. As shown in Figure 8c, a third packaging insert 83 is fed to the packaging insert 81, 82 and arranged so that the pockets of packaging insert 83 fit into the spaces between the pockets of the second packaging insert 82. The packaging insert 81, 82, 83 shown in Figure 8c has three layers of individual pockets.

In Figures 8a-8c, each of the packaging inserts 81, 82 and 83 are fed to a platform 84 on which the packaging insert 81, 82, 83 is formed. The platform 84 has the ability to be lowered. For example, the platform is lowered after the first packaging insert 81 has been positioned on the platform 84 so as to allow the second packaging insert 82 to be fed on top of the first (see Figure 8a). Again, the platform may be lowered (Figure 8b) after the second packaging insert 82 has been positioned on the first packaging insert 81 so as to allow the third packaging insert to be fed on top of the packaging insert 81, 82. The platform 84 also has the ability to be raised so as to move the packaging insert 81, 82, 83 on for further processing. For example, the platform 84 may raise the packaging insert 81, 82, 83 to the same level as a second conveyor belt 86 which allows the packaging insert to be pushed by a machinery arm 87 on to the second conveyor belt for further packaging (see Figure 8c). As shown in Figures 8a and 8b, the packaging inserts 81, 82, and 83 maybe fed to the platform 84 by a first conveyor belt 85.

Figures 9a and 9b show how a packaging insert according to one embodiment of the invention may be prepared and how smoking article may be positioned in the individual pockets of such an insert. Figure 9a shows a packaging insert prepared by a first web having grooves 91 and a second web having grooves 92. Smoking articles 93 are fed by a roller 94 into the grooves of the second web 92. A first web 91 having grooves is then fed to the second web 92, the first web 91 and the second web 92 are arranged so as to provide a series of hexagonal individual pockets 94 each containing a smoking article. Figure 9b shows an alternative process for preparing a similar packaging insert according to one embodiment of the present invention. The packaging insert shown in Figure 9b is made up of a first web 91 having grooves and a second web 92 having grooves. The first web 91 and the second web 92 are first arranged so that the grooves of each align and face each other providing a series of parallel individual pockets 94 having a hexagonal cross section. A smoking article 93 is then inserted into each individual pocket 94 via one of the pocket's 94 open ends.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior methods for manufacturing packaging inserts containing elongate elements. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/ or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and

modifications maybe made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.