The present invention relates to a two-pocket pouch, in particular a pouch for tobacco, each of the two pockets has a cover flap and an extension flap. The two pockets are symmetric about a mirror folding line. The inner surface of the extension flap adheres to the inner surface of the cover flap.

It is known to market consumer goods and in particular tobacco in pouches wherein the pouches contain a pouch front wall and a pocket rear wall which are connected to each other at the bottom and their sides but which are open at the upper edges of the pocket to form an opening to allow the consumer an access to the interior of the pouch and its contents. These known pouches further comprise a relatively long flap. This relatively long flap serves the consumer as a support and, if the consumer goods are tobacco, also as an aid to roll its own cigarettes. This relatively long flap is folded in the known products forward towards the front side of the pouch and then wrapped around the bottom of the pouch and is eventually connected to the pouch rear wall. Such a pouch has the advantage of providing a long flap to the consumer but has the disadvantage that two separate steps are needed to open the flap, namely a first step to open the closing mechanism on the pouch rear wall and then folding the flap around the pouch bottom in order to open the pouch and give the consumer access to the tobacco or other consumer articles.

It would be desirable to have a pouch which can be easily opened with one single action. Moreover, it would be desirable to have a back panel that is non-split. A non-split back panel or rear wall offers more space for both branding and information purposes. That means that the extension flap is not wrapped around the back panel as shown in Figure 1 , hereinafter referred to as wrapped-around solution. Furthermore, it would be desirable to provide a pouch, in particular a non-wrapped-around solution that provides storage room for wrapper paper or other small articles. Furthermore, it would be desirable to provide a pouch, in particular a non-wrapped-around solution that is easy to manufacture at high speeds.

Moreover, it would be desirable to provide a pouch that allows for better freshness and handling by the consumer.

According to the invention a two-pocket pouch comprising a first pocket and a second pocket is provided. The first pocket and the second pocket are symmetric about an optionally perforated mirror folding line and are optionally connected.

Each of the first and the second pocket comprises

- a pocket front wall and a pocket rear wall,

- an access opening, wherein the access opening is provided between the upper edges of the pocket front wall and the pocket rear wall, - a cover flap, wherein the cover flap extends from the pocket rear wall, and

- an extension flap, wherein the extension flap extends from the cover flap.

In the closed position of the pouch, the cover flap is folded over the pocket front wall. The cover flap may be connected to the pocket front wall by way of a connecting means. The extension flap is folded inwardly such that it is arranged between pocket front wall and the cover flap. The inner surface of the extension flap adheres to the inner surface of the cover flap. The adhesion preferably is peelable. In a preferred embodiment, the peelable adhesion is from 1 to 10 Newton for 35 millimeters as measured by the peel force test for pouches. Preferably, the peelable adhesion is not reclosable. Preferably, the peelable adhesion is at least one of a chemical connection such as an adhesive, thermo sealing, cold sealing, ultrasound sealing, a mechanical connection such as a hook and loop fastener, Velcro or a micro-suction surface, or an electrostatic connection. In the closed position of the pouch, the cover flap substantially covers the front wall of the pocket. Preferably, this from about 95 percent to about 100 percent of the surface area of the front wall of the pocket are covered by the cover flap. Preferably, the pocket front wall and the pocket rear wall are rectangular and have the same height. The pockets of the pouch preferably contain tobacco. The pocket front wall and the pocket rear wall are permanently sealed to each other on their side and bottom edges of the pocket front wall and the pocket rear wall by way of thermo sealing, cold sealing, ultrasound sealing or an adhesive. Preferably, the force for opening the permanent seal is from 20 to 30 Newton as measured by the peel force test for pouches.

Preferably, this adherence is peelable and extends along adherence zones along the side edges of the inner surfaces of the cover flap and the extension flap. Preferably, the adherence of the extension flap to the cover flap is peelable and extends along adherence zones along the side edges of the inner surfaces of the cover flap and the extension flap. The first pocket and the second pocket may be connected by way of a connecting means. The mirror folding line may be a line of weakening.

A further object of the invention is a method of preparing a pouch according to the invention comprising the steps of

providing a first rectangular sheet,

placing a second rectangular sheet on the first sheet, the second rectangular sheet having essentially the same width and being shorter than the first rectangular tube.

permanently sealing along the mirror folding line and the side edges to form the first and the second pocket, optionally weakening the mirror folding line

filling the consumer goods into the first and the second pocket, so that these consumer goods are within the first and the second pocket after the folding step, permanently or reclosably sealing the access opening to close the first and second pocket

folding the open end of the first rectangular sheet twice by about 180 degrees to form the cover and the extension flap, such that the extension flap is arranged between pocket front wall and cover flap,

adhering the inner surface of the extension flap to the inner surface of the cover flap,

optionally connecting the cover panel by way of a connecting means, folding the first and the second pocket about the mirror folding line, and optionally connecting the two pockets by way of a connecting means.

Thus the cover flap and the extension flap are non-wrapped solutions. That means that they are not folded around the bottom of the pouch as in the prior art. Instead the cover flap and the extension flap both being folded against each other and both lying on the pouch front wall adhering to one another along the adherence zones. This has the advantage to allow the consumer an easy opening of the flap and the pouch and an easy access to the pouch content such as loose tobacco. At the same time the long combined cover and extension flap and their advantages are maintained. Furthermore, due to the non-split back panel or rear wall of the pouch of the present invention, more space is available for both branding and information purposes.

Furthermore, in another embodiment, in its closed position, the adhered extension and cover flaps provide an additional pocket. This pocket can store consumer articles, in particular accessories such as cigarette paper or other wrappers.

Moreover, the pouch of the invention is easy to manufacture as the inner surface of the extension flap adheres to the inner surface of the cover flap forming adherence zones. The adherence zones are preferably located along the side edges of the inner surface of the cover flap and the inner surface of the extension flap.

The two pockets of the pouch of the invention are symmetric about the mirror folding line. Distributing the consumer articles in two pockets allows for better freshness and convenience. Also, two types of tobacco may be stored in the two pocket pouch of the invention.

The mirror folding line may be perforated.

This allows the consumer to detach the first pocket after consumption and have fresh tobacco in the second pocket until the depletion of the tobacco of the first pocket.

The first and the second pocket are adjacent. The mirror folding line, as herein referred to, corresponds to the horizontal symmetry axis between the two adjacent pockets.

Also, there may be several substantially parallel mirror folding lines, i.e. one, two, three or more mirror folding lines. The symmetry then is about the one or two central mirror folding lines.

The content of the first and of the second pocket are separated by a permanent seal.

Thus, in the closed position of the pouch, the two pockets are bent along the horizontal symmetry axis.

The mirror folding line may be weakened for convenient separation of the first and the second pocket by the consumer.

Weakening may be obtained by mechanical creasing, heat creasing or by mechanical perforation or by laser perforation or any other suitable means of weakening.

The first and the second pocket may be connected by a suitable connecting means. The connecting means may be reclosable, permanent or tearable, for example in the form of a tax stamp or a polymeric adherend.

The reclosable or resealable connecting means includes a pressure sensitive adhesive. A pressure sensitive adhesive is an adhesive which forms a bond when pressure is applied to marry the adhesive with the adherend. Solvent, water, or heat is not needed to activate the adhesive. Pressure sensitive adhesives (PSAs) are known to possess properties such as: (1 ) aggressive tack at room temperature, (2) adherence to a substrate with no more than finger pressure, (3) sufficient ability to hold onto an adherend, and/or (4) sufficient cohesive strength to be removed cleanly from the adherend. Furthermore, the pressure sensitive adhesive can be a single adhesive or a combination of two or more pressure sensitive adhesives. Pressure sensitive adhesives are usually based on an elastomer that may be compounded with a tackifier. Useful elastomers include acrylics, rubbers, styrene block copolymers or vinyl ethers, for example. Pressure sensitive adhesives are commercially available from 3M Company, St. Paul, MN.

The pouch can be made of flexible plastic sheets, laminate sheets, for example laminates made from layers of paper, metal, plastics and combinations thereof.

The pocket front wall and the pocket rear wall are connected to each other at the bottom and at their side edges. For example, pouch side walls can be present extending between the side edges of pouch front wall and pouch rear wall. The upper ends of pouch front wall and pouch rear wall are not connected to each other with the consequence that an access opening results which allows the consumer to access the contents of the pouch.

The inner surface of the extension flap adheres to the inner surface of the cover flap.

The adhering surfaces are hereinafter referred to as adherence zones. The adherence zones can be defined, that means local in the form of spots or thin or broader lines for example along the side edges of the extension flap. Various portions of the inner surface of the extension flap may form adherence zones, for example 25 percent, preferably 50 percent, more preferably 75 percent of the inner surface of the extension flap or more adhere to the inner surface of the cover flap.

Preferably, the adherence zones are lines along the side edges of the cover flap and the extension flap. The length of the adherence zones may vary, for example, the adherence zone may extend 25 percent, preferably 50 percent more preferably 75 percent and most preferably along entire length of the side edge of the extension flap. That means, in the case of an extension flap whose side edge is 43 millimeters, the adherence zone may be from about 10 millimeters to up to 43 millimeters.

These lines may vary in their broadness, for example from about 1 millimeters to about 10 millimeters, preferably from about 2 to about 5 millimeters.

The inner surface of the extension flap can also adhere substantially throughout the inner surface of the extension flap. That means that about the entire inner surface of the extension flap adheres to the inner surface of the cover flap, for example more than 90 percent, preferably more than 95 percent and even more preferably more than 99 percent of the inner surface of the extension flap adheres to the inner surface of the cover flap.

The adherence may be permanent. Permanent adherence as used herein requires an opening force of from more than about 15 Newton to about 40 Newton, preferably from about 20 Newton to about 30 Newton for 35 millimeters peeling distance.

Preferably the adherence is peelable. Peelable adherence as used herein requires an opening force from about 0.5 to about 15 Newton, preferably from about 1 to about 10 Newton, more preferable from about 2 to 6 Newton.

The opening force is determined using the peel force test for pouches.

The peel force test for pouches measures the force needed to separate adhered surfaces, for example to separate sealed surfaces.

Two clamps are placed on a pouch of the invention as shown in Figure 4 to pull the adhered zones. A load cell measures the force to pull apart the peelably adhered zones for 35 millimeters distance, hereinafter referred to as peeling distance. Ten samples are measured during 30 minutes testing time and the average opening force is calculated. The testing is performed on a Tensile testing machine, for example commercially available under the tradename Instron 5566. Samples are conditioned for at least 24 hours at 22 ± 2 °C and 60 ± 5 % relative humidity before testing. The Tensile testing machine is set at 10 Newton in respect of the load cell, the speed is set at 150 millimeters per minute, the peeling distance is set at 35 millimeters. The evaluation can be made using acquisition software, for example commercially available under the tradename Bluewhill. The peelable adhesion of the inner surface of the extension flap and the inner surface of the cover flap can be reclosable. This means that after the peeling of the extension flap from the cover flap, the extension flap does re-adhere to the cover flap when folded back.

Preferably, the peelable adhesion of the inner surface of the extension flap and the inner surface of the cover flap are not reclosable. This means that after the peeling of the extension flap from the cover flap, the extension flap does not re-adhere to the cover flap when folded back.

Permanent adhesion can be obtained using for example thermo sealing, cold sealing, ultrasound sealing or an adhesive.

Peelable adhesion is at least one of a chemical connection such an adhesive, thermos sealing, cold sealing, ultrasound sealing, a mechanical connection such as a hook and loop fastener, Velcro or a micro-suction surface, or an electrostatic connection.

Preferably, in the closed position of the pouch, the cover flap substantially covers the pocket panel. Substantial coverage means a coverage of more than half of the surface of the pocket panel, preferably more than 75 percent, more preferably more than 90 percent and even more preferably more than 95 percent of the surface of the pocket panel. The pocket panel is the consumer good containing part of the front panel in its fully filled state.

The consumer goods are preferably tobacco, more preferably loose fine cut tobacco for roll-your-own cigarettes or make-your-own cigarettes.

Terms such as "front", "rear", "top", "bottom", "side", "upper", "lower", "height", "width",

"depth" and other terms used to describe relative positions of the components of the pouch according to the invention refer to the pouch in an upright position with the consumer goods housed in the pouch and with the opening of the pouch at the top and the consumer goods accessible from the top.

Preferably the pouch front wall and the pouch rear wall are both rectangular. Further preferably, pouch front wall and the pouch rear wall do have the same height. It is more preferred that pouch rear wall and pouch front wall are both rectangular and of same size and are directly connected to each other at their side edges and their lower edges.

Preferably, the extension flap and the cover flap have a width which corresponds essentially to the width of the pocket rear wall. This has the advantage that, when the cover flap and the extension flap are folded, the pocket is substantially completely closed, reducing the likelihood of consumer goods falling out of open gaps at the top of the pouch.

The pocket front wall starts at its bottom and ends at its upper edge. The pocket rear wall starts at its bottom and ends where the cover flap starts. There is not necessarily a folding line or hinge line between pocket rear wall and cover flap but more preferred the cover flap is just a continuation of the pocket rear wall. The cover flap in turn ends where the extension flap starts. The extension flap ends either at its upper edge or where an optional further, second extension flap starts. The further, second extension flap ends either at its upper edge or where an optional third extension flap starts. The third extension flap ends at its upper edge.

Preferably, in the upper third of the pocket rear wall or, alternatively, at the end of the pocket rear wall and the beginning of the cover flap there is provided a first folding line. At the end of the cover flap and the beginning of the extension flap there is provided a second folding line. Optionally, at the end of the extension flap and the beginning of the further, second extension flap there is provided a third folding line. Further optionally, at the end of the second extension flap and the beginning of the third extension flap there is provided a fourth folding line.

In case of cover flap and only one extension flap the distance between first and second folding lines preferably is about 3 to about 8 centimeters, more preferably about 4 to about 7 centimeters, and even more preferably about 5 to about 6 centimeters. In case of cover flap and two or three extension flaps the distance between second and third folding lines is about 3 to about 7 centimeters, preferably about 4 to about 7 centimeters, and more preferably about 5 to about 6 centimeters and the distance between third and fourth folding lines is about 3 to about 6 centimeters, preferably about 4 to about 6 centimeters, and more preferably about 4 to about 5 centimeters.

Preferably, only the cover flap and the extension flap are present. In that case the cover flap and the extension flap are bent forward around the first folding line and towards the pocket front wall. The extension flap is then bent inwardly by about 180° around the second folding line such that it is lying on the pouch front wall and essentially parallel to the pouch front wall and the cover flap. The inner surface of the extension flap is adhered to the inner surface of the cover flap along adherence zones preferably along the side edges of the extension and cover flaps.

In the event that two extension flaps are present, the cover flap and the first extension flaps are bent the same way as described above in the preceding paragraph and the second extension flap is then bent by about 180° such that it is lying between and parallel to cover flap and first extension flap. In the event that three extension flaps are present they and the cover flap are bent in a similar way as described above with the result that all extension flaps and the cover flap are arranged in the closed position of the pouch in a more or less parallel arrangement. Preferably, the one extension flap depends from the cover flap or panel. If not specified otherwise, the description refers to one extension flap.

The bent and folded cover and extension flaps lying on the pocket front wall may then be connected to the pocket in a reclosable or a not reclosable manner by way of a connecting means. The reclosable connection can be obtained by at least one of a chemical connection such as an adhesive, a mechanical connection such as a hook and loop fastener, a sticker or a micro-suction surface, or an electrostatic connection. The reclosable connection is either between the cover flap and the pocket, more preferably the pocket front wall, or between the extension flap and the pocket, more preferably the pocket front wall, or between both the cover flap and the extension flap and the pocket, more preferably the pocket front wall. For example, it is preferred that an adhesive is applied to the cover flap such that it comes into contact with the pocket, more preferably the pocket front wall, and closes the pocket. The adhesive is of such a nature that it allows a repeated opening and closing of the pocket.

The not reclosable connecting means may be a paper sticker, preferably in the form of a tax stamp.

In the same way, the first and the second pocket may be connected by way of reclosable or not reclosable connecting means.

What is described herein for the opening of the first or the second pocket, also applies to the opening of the connecting means that may be applied to connect the first and second pocket.

Preferably, the pocket is provided with a sticker which allows repeated opening and closing of the pocket. Part of such a sticker is in a fixed connection to the cover flap such that it is permanently connected to the cover flap and cannot be removed during normal operation conditions of the pouch. A further part of the sticker which is not connected to the cover flap is provided with an adhesive which gets in contact with the pouch, more preferably the pouch front wall, and allows a repeated opening and closing of the pocket. It is more preferred that the adhesive on the sticker is not applied to the whole part of the sticker which is not fixed to the cover flap and in particular not to the free end of this part. This allows the consumer an easy grip of the sticker for opening and closing and reopening the pocket.

In the closed position of the pocket, the inner surface of the extension flap will preferably cover from 15 to 95 percent, preferably from about 25 to about 75 percent and more preferably about 30 to about 60 percent of the inner surface of the cover flap.

In a preferred embodiment, if the cover flap is from about 70 to about 80 millimeters long, the length of the extension flap will be from about 40 to about 50 millimeters.

Preferably the cover flap is rectangular, the extension flap is rectangular and the heights and the widths of the extension flap and of the cover flap are essentially the same.

A further object of the invention is a method of preparing a pouch of the invention. A first rectangular sheet is provided. The first rectangular sheet is dimensioned to provide for the pocket rear wall, the cover flap and the extension flap. A second rectangular sheet is placed on the first sheet. The second rectangular sheet substantially has the width of the first sheet. However, the second sheet is dimensioned to provide for the pocket front panel and thus is essentially shorter than the first rectangular tube.

The method further comprises the step of permanently sealing along the mirror folding line and the side edges to form the first and the second pocket. The permanent seal preferably is a heat seal. The mirror folding line may then optionally be weakened. This allows for easier folding. Also text may be perforated in the area of the weakening line to allow for easier bending while conferring a message or any other type of information.

Then consumer goods are filled into the first and the second pocket, so that these consumer goods are within the first and the second pocket after the folding step.

Then, the access opening is permanently or reclosably sealed to close the first and second pocket

Then, the open end of the first rectangular sheet is folded twice by about 180 degrees to form the cover and the extension flap, such that the extension flap is arranged between pocket front wall and cover flap.

Then, the inner surface of the extension flap is adhered to the inner surface of the cover flap. Optionally, the cover panel may then be connected to the pocket by way of a connecting means.

Then, the first and the second pocket are folded about a mirror folding line. The mirror folding line corresponds to the horizontal symmetry axis of the two pocket pouch of the invention.

Optionally, the two pockets are then connected by way of a connecting means.

In the case of heat sealing, the step order of the manufacturing process may be as follows. The adhesive is applied either online during the manufacturing of the pouch or preapplied to the sheet by the sheet supplier. Then the sheet is folded to form the pouch as described above. Finally, the adhesive is heat activated to provide for the permanent and peelable seal.

Where connecting of different walls or parts of the pocket is necessary, for example of the edges of the pocket front wall and the pocket rear wall, this can be done by heat-sealing, ultrasonic welding, adhesive, cold sealing or other suitable connecting techniques that preferably create a substantially gas or moisture tight connection between the walls. Either before that connecting step or thereafter consumer goods, such as loose or cut tobacco, can be introduced into the pocket formed by the pocket front wall and the pocket rear wall. Thereafter the cover flap and the extension flap is folded at least twice and each time by about 180 degrees around first and second folding lines as described above. Thereinafter the inner surface of the extension flap is adhered, preferably peelably sealed to the inner surface of the cover flap. An adhesive or a sticker may be applied to the pocket and the pocket of the invention is closed, yielding the pocket of the invention in closed position. Optionally, the rectangular sheet wherefrom the pouch is made includes a second and further optionally a third extension flap. In that case the second extension flap depends from the first extension flap and a third folding line is provided between first and second extension flaps and the third extension flap depends from the second extension flap and a fourth folding line is provided between second and third extension flaps. If present, the second extension flap is folded by about 180 degrees around the third folding line and the third extension flap is folded by about 180 degrees around the fourth folding line.

A further object of the invention is preparing a pouch comprising the steps of

providing a first rectangular sheet,

placing a second rectangular sheet on the first rectangular sheet, the second rectangular sheet having essentially the same width and being shorter than the first rectangular sheet,

permanently sealing along a mirror folding line and along the side edges to form a first pocket with an access opening and a second pocket with an access opening,

optionally weakening the mirror folding line,

filling consumer goods into the first and the second pocket,

permanently or reclosably sealing the access openings to close the first and second pocket,

folding both ends of the first rectangular sheet each twice by about 180 degrees to each form a cover flap and an extension flap, such that each extension flap is arranged between a pocket front wall and a cover flap,

adhering the inner surface of one or both of the extension flaps to the inner surfaces of their respective cover flaps,

optionally connecting one or both of the cover flaps to the front walls of their respective pockets by way of a connecting means,

folding the first and the second pocket about the mirror folding line,

optionally connecting the two pockets by way of a connecting means, and

optionally closing the pouch by a sticker, wherein the sticker is permanently attached to part of the cover flap or to part of the pocket rear wall.

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

Figure 1 shows a front view of a pouch 10 of the invention in opened position;

Figure 2 shows a front view of the pouch 10 of the invention open position;

Figure 3 shows a front view of the pouch 10 of the invention in closed position and Figure 4 shows the setting of the peel force test for pouches.

The reference numerals in Figure 1 , Figure 2, Figure 3 and Figure 4 have the following meanings: 10 Pouch

12 Cover flap

14 Extension flap

16 Mirror folding line

17 Pocket opening

18 First pocket

20 Second pocket

22 Front wall or panel of the pocket

24 Rear wall or panel of the pocket

26 First folding line

28 Second folding line

32 Sticker

34 Adherence zone

36 Side edge

38 Clamp

40 Roll

42 Tensile measurement equipment

44 Wire Figure 1 is a front view of a pouch 10 of the invention. The first pocket 18 and the second pocket 20 are two implementations of the pouch of Figure 2 that are symmetric about the mirror folding line 16. The mirror folding line 16 may be perforated for easy separation of the first pocket 18 and the second pocket 20. In another embodiment the mirror folding line 16 is a bent line. The cover flap 12 can be seen just as part of the pocket front wall 22 and a sticker 32 for closing the pouch 10 which means for connecting the cover flap 12 and extension flap 14 to front wall of the pocket. The inner surface of the extension flap 14 is adhered to the inner surface of the cover flap 12.

In Figure 2 one half of the non-wrapped-around pouch 10 of the invention as separated by mirror folding line 16 is seen in a side view and in open position with pocket front wall 22 and pocket rear wall 24. The side edges 36 of the pocket front wall and the pocket back wall are permanently sealed. The pocket opening 17 is given at the top of the open pouch 10, and it can be seen that the consumer goods, for example loose tobacco inside the pouch, can easily be accessed by the consumer. Pocket front wall 22 and pocket rear wall 24 do have the same height. In the upper third of pocket rear wall 24 a first folding line 26 is given. A cover flap 12 extends between the upper end of the pocket rear wall 24 and second folding line 28, whereas the extension flap 14 depends from flap 12. The extension flap 14 is folded inwardly around second folding line 28 and is eventually arranged essentially parallel to pocket front wall 22 and cover flap 12. The inner surface of the extension flap 14 adheres to the inner surface of the cover flap 12. The inner surface of the extension flap 14 adheres to the inner surface of the cover flap 12 along the adherence zones 34. The sticker 32 (not shown) connects the cover flap 12 to the pocket.

In Figure 3 the non-wrapped-around pouch 10, half of which is sketched in Figure 2, is seen in a side view and in closed position. In Figure 3 the cover flap 12 and the extension flap 14 are folded downwards around second first folding line 26. The extension flap 14 is folded inwardly around second folding line 28 and is eventually arranged essentially parallel to pocket front wall 22 and cover flap 12. The inner surface of the extension flap 14 adheres to the inner surface of the cover flap 12 along the adherence zones 34. The adherence zones cover the side edges of the inner surfaces of the cover flap 12 and the extension flap 14.

The pouch 10 in Figure 3 is closed by sticker 32. Part but not all of sticker 32 is fixed to part of the cover flap 12 in a permanent and under normal handling conditions of the pouch 10 non-removable way. The remaining part of sticker 32 is partially applied with an adhesive which allows a repeated opening and closing of the pouch. However, only part of the sticker 32 is applied with such an adhesive meaning that a free end of sticker 32 results. This free end can be used by the consumer as a grip to open and close the pouch 10.

Figure 4 shows the peel force test for pouches. A pouch sample 10 is laid down horizontally and two clamps 38 are set at the free edge of the extension flap 14 in equal distance from the middle of the free, that means non-adhered, edge of the extension flap14. Wires 44 lead the opening force from the clamps 38 to the Tensile testing equipment 42 over the direction roller 40. The force necessary to pull the extension flap and cover flap apart is measured.