Abstract:
A cigarette carton comprising two half-cartons, each containing five cigarette packs, which may be sold as one standard 10-pack cigarette carton or may be separated and sold as individual half-cartons. The dual half-carton configuration permits the use of existing tax-stamping machines without significant modifications. Each half-carton is formed from a single blank and has a perforated extension tab extending from one side wall, and a top closure. Two half-cartons are joined together by positioning the walls from which the top closures are foldably attached remote from each other and by gluing each extension tab to the side wall of the other half-carton.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to cigarette packages. More particularly, this invention relates to detachable paperboard double half-cartons for cigarette packs in which two attached half-cartons are run through a standard tax-stamping machine and then may be separated for sale as separate, individual half-carton units. 
     Cigarettes are commonly sold in paperboard cartons of ten cigarette packs, each pack containing about twenty to twenty-five cigarettes. Due to the rising cost of standard cigarette cartons it has become desirable to make available to consumers half-cartons of five cigarette packs in addition to the standard 10-pack cartons. 
     Standard cigarette cartons contain two parallel rows of five packs in which the packs in each row are aligned side-by-side. In each row, the packs typically are positioned with the bottom of the pack facing upward and the sides adjacent to and touching each other. 
     Most states and some cities require that tax stamps be affixed to cigarette packs prior to sale. Because of this requirement, cigarette cartons are made without permanently sealing the lids of the cartons, so that they may be opened, run through a tax-stamping machine, re-closed, then shipped to retail stores for sale to consumers. Existing tax-stamping machines are geared for simultaneously stamping 10 cigarette packages in the standard 2×5-pack configuration. Accordingly, to use existing tax-stamping machines, half-cartons must be configured in parallel pairs such that two half-cartons may be sent through a standard tax-stamping machine in one 2×5-pack unit. However, the two half-cartons must be held together securely, without slipping, to ensure that the tax-stamping machine will function correctly. In addition, the two half-cartons must not be too thick to pass between the vertical rollers of the tax-stamping machine. 
     It would be desirable to be able to provide a half-carton for cigarette packs, of which two half-cartons can be temporarily attached for running through a tax-stamping machine without developing new technology or expensive retooling and modifications of existing carton fabrication machines and procedures. 
     SUMMARY OF THE INVENTION 
     It is an object of this invention to provide an improved way of packaging cigarette packs into detachable half-cartons for use in existing taxstamping machines and with minimal modifications to carton-fabrication machines and procedures. 
     It is another object of the present invention to make each half-carton from a single modified blank, preferably of paperboard. This has the advantage that only one half-carton design is required. 
     The blank is folded around a designated quantity of cigarette packs, preferably five, to form a half-carton with an interior wall, an exterior wall, a bottom wall, a first side wall, a second side wall containing a detachable extension tab, and a top closure. The top closure is attached horizontally to and at the top of the exterior wall. The detachable extension tab is attached vertically and centered along the edge of the side wall that is connected to the vertical edge of the interior wall. The extension tab will preferably be perforated along the edge connecting it to the side wall, and preferably will be semi-circular in shape with a radius of curvature less than the width of the side wall. However, many other shapes and sizes are possible for the extension tab. 
     During assembly, one half-carton is rotated 180° and attached to a second half-carton by abutting the interior walls of the half-cartons against each other and securing the extension tab on each half-carton to the first side wall of the other half-carton. The extension tabs may be secured with glue, tape or other adhesive. 
     Another object of the present invention is to provide a modified top closure that may be folded back to permit tax-stamping on existing equipment then later tucked into each half-carton. In this way, the double half-carton unit may be separated into two distinct, fully enclosed half-carton units of five cigarette packs for retail sale to consumers. Alternately, the half-cartons may be separated after tax stamping and the top closure of each folded over and secured to the outside of the interior wall of the half-carton. 
     During the initial assembly process, after the two half-cartons are attached to form one 2×5-pack unit, the top closures are temporarily closed by folding one top closure over the top of both half-cartons, then folding the other top closure over the top of the first one. The top closures may be secured closed by a releasable glue, tape or other adhesive. The double half-carton unit is then ready for shipping and later tax stamping. 
     Immediately prior to tax stamping, the temporarily closed top closures are opened and folded back to expose the bottoms of the cigarette packs. Each pack is then stamped. Once stamped, the top closures may be closed by tucking the tuck portion inside the half-carton along the top of the interior side of the interior wall. Alternatively, the top closure may be secured by gluing the tuck portion to the exterior side of the top portion of the interior wall. 
     It is a further object of the present invention to ship such enclosed double half-cartons to retailers for sale to consumers either in a double half-carton unit, or by breaking the perforated edges of the extension tabs and thereby separating it into two half-carton units. The cigarette packs in each half-carton are preferably positioned such that the label or logo on the bottom of the packs may be read by a consumer who opens the top closure with the interior wall of the half-carton facing the consumer. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed descriptions, taken in conjunction with the accompanying drawings, in which the reference characters refer to the parts throughout and in which: 
     FIG. 1 shows a single blank of paperboard that when folded forms a half-carton; 
     FIG. 2 shows two assembled half-cartons positioned in parallel for attachment; 
     FIG. 3 shows the two half-cartons after being attached; 
     FIG. 4 shows the process of temporarily closing the top closures for shipment to be later reopened for tax stamping; 
     FIG. 5 is a side view of a double half-carton unit with the top closures in the temporarily closed position; 
     FIG. 6 is a side view showing the top closures of the double half-carton unit being tucked into each half-carton after having been tax stamped; and 
     FIG. 7 shows the double half-carton unit after separation into two fully enclosed half-cartons of five cigarette packs. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the preferred embodiment of the present invention, a blank of paperboard is fabricated as shown in FIG. 1, which will ultimately form one half-carton. The dashed lines containing alternating long and short dashes are fold lines or perforated scores along which the walls of the half-carton are folded to form the half-carton configuration. Dashed line 200, which separates side wall 25 and extension tab 30, is perforated to allow for later separation of the extension tab and the two half-cartons. 
     The blank is folded along the fold lines or perforated scores to encase five cigarette packs aligned side-by-side. The top of the cigarette packs will rest along bottom wall 40. Interior wall 55 is folded up such that it rests against the interior walls of the five cigarette packs. Dust flaps 45 and 50 and box insert side walls 60 and 65 are folded up to rest along the side walls of the two cigarette pack positioned farthest from each other. Exterior wall 20 is then folded up to rest against the exterior walls of the five cigarette packs, and side walls 25 and 35 are folded in and glued to box insert side walls 60 and 65, respectively. 
     The extension tab 30 is preferably semi-circular in shape and has a radius of curvature that is less than the width of side wall 35, that is, less than the shortest distance between exterior wall 20 and interior wall 55 when the half-carton is assembled. Of course, any shape of extension tab may be provided, so long as it does not extend out more than the width of side wall 35. 
     Those skilled in the art will understand that the half-carton does not need to be formed around five cigarette packs but instead may be formed hollow, so that the cigarette packs may later be inserted into the half-carton. 
     The cigarette packs are preferably positioned in each half-carton with the bottom of the pack next to the top closure and with the logo or brand name readable when the top closure is opened away from the consumer. In other words, the bottom of the logo or brand name on the exposed side of the cigarette pack is adjacent to the interior wall and the top is adjacent to the exterior wall. 
     In addition, those skilled in the art will recognize that the blank may be folded into a half-carton in any position. For example, the blank may be folded with bottom wall 40 positioned vertically. 
     Finally, those skilled in the art will appreciate that many types of glue, tape or adhesive may be used to attached side walls 25 and 35 to box insert side walls 60 and 65, respectively, and extension tab 30 may be detachably attached to side wall 25 by other means than perforation line 200. Also, many shapes and sizes of box insert side walls 60 and 65 may be used, and dust flaps 45 and 50 may also be of any size, or omitted altogether. However, the preferred embodiment includes dust flaps and uses large box insert side walls to provide greater stability to the half-carton. 
     FIG. 2 shows two assembled half-cartons, labeled 300A and 300B, positioned for attachment. Each half-carton contains five cigarette packs 101-105, the numbers in incremental order starting at side wall 25 and ending at side wall 35. The cigarette packs in half-carton 300A are labeled 101a-105a, and those in half-carton 300B are labeled 101b-105b. This parallel numbering system--in which each part is designated with the number used in FIG. 1 followed by the letter &#34;a&#34; or &#34;b&#34; to indicate the half-carton being referred to--is used throughout FIGS. 2-7. 
     One half-carton has been rotated 180° such that interior walls 55a and 55b face each other. This configuration allows extension tab 30a to be attached to side wall 35b, and extension tab 30b to be attached to side wall 35a. Top closures 15a and 15b are positioned opposite each other such that when the half-cartons are moved together, as shown by the two arrows in FIG. 2, and attached, the top closures are on opposite sides of the top of the double half-carton unit. This configuration is important so that the top closures may later be bent back to allow for tax stamping. Thus, it is important that extension tabs 30a and 30b extend from the side remote from the side to which top closures 15a and 15b, respectively, are hinged. 
     FIG. 3 shows the half-cartons of FIG. 2 attached to each other. In the preferred embodiment, extension tab 30a is secured to side wall 35b with glue; however, tape or any other adhesive may be used. On the opposite side of the double half-carton unit, which is not visible in FIG. 3, extension tab 30b is similarly glued or otherwise secured to side wall 35a. The glue, tape or other adhesive used must withstand greater force than that required to tear perforation lines 200a and 200b. It must also withstand the force of the tax-stamping machine. 
     Because one half-carton is rotated 180°, cigarette pack 101a is adjacent to cigarette pack 105b, cigarette pack 102a is adjacent to cigarette pack 104b, cigarette pack 103a is adjacent to cigarette pack 103b, cigarette pack 104a is adjacent to cigarette pack 102b, and cigarette pack 105a is adjacent to cigarette pack 101b, as shown in FIG. 3. 
     The cigarette packs 101a-105a and 101b-105b are preferably positioned such that the brand name or logo is readable when top closure 15a or 15b is opened and pivoted away from the consumer. Thus, the orientation of the logos and brand names on the cigarette packs in one half-carton are inverted relative to the orientation of those in the adjoining half-carton. This orientation is illustrated by the letter &#34;C&#34; on each cigarette pack shown in FIGS. 2-3. 
     When the half-cartons are attached, interior walls 55a and 55b abut against each other, forming a centerline that divides the two rows of cigarette packs. Exterior walls 20a and 20b form the exterior walls of the double half-carton unit. Perforation lines 200a and 200b form a vertical centerline between half-cartons 300A and 300B, and function as the only direct connection between and attaching the half-cartons However, the half-cartons may be further secured by other detachable adhesive means at other locations. 
     Top closures 15a and 15b are then temporarily closed, as shown in FIGS. 4-5. Top closure 15b is first folded across the open top of the two rows of cigarette packs. The tuck portion 5b of top closure 15b will lay on top of half-carton 300A in a non-tucked position, directly above cigarette packs 101a-105a. The top wall portion 10b of top closure 15b will lay on top of half-carton 300B, directly above cigarette packs 101b-105b. 
     Top closure 15a is then folded across the top of temporarily closed top closure 15b. When closed, tuck portion 5a of top closure 15a will lay directly on top of top wall portion 10b of top closure 15b, and top wall portion 10a of top closure 15a will lay directly on top of tuck portion 5b of top closure 15b. 
     Top closures 15a and 15b are preferably secured by glue points 70 that are strong enough to keep the unit closed during shipment, but weak enough to be torn open without significantly damaging the paperboard on the top closures. The glue may be placed at one or more places along top wall 10b. Three equal spaced glue points 70 are shown in FIG. 4. 
     Alternately, one or more glue points may be applied to the bottom of tuck portion 5a. In either case, the glue will temporarily affix top wall 10b to tuck portion 5a as shown by glue point 70 in FIG. 5. 
     Tape or another adhesive may be used instead of glue, and the glue or other adhesive means may be located at other positions on the dual half-carton configuration. Such adhesive means are common in the industry and obvious to implement by one ordinarily skilled in the art. 
     Alternately, top closure 15a may be closed before tuck flap 15b. Because the half-cartons are identical, the double half-carton unit has rotational symmetry along the vertical major axis positioned between and at the center of interior walls 55a and 55b. Thus, regardless of which top closure is closed first, the temporarily closed, double half-carton is the same. 
     The temporarily closed, double half-carton unit is then shipped either directly or indirectly via a warehouse to a tax-stamping facility. Once there, the temporarily closed top closures 15a and 15b are opened, using machinery and techniques that will be obvious to those skilled in the art. Once opened, the double half-carton unit will be the same as it was prior to closing the top closures, as shown in FIG. 3. 
     Top closures 15a and 15b are then folded back along exterior walls 20a and 20b, respectively, and run through an existing tax-stamping machine. Top closures 15a and 15b are then tucked into each respective half-carton as shown in FIG. 6. Tuck portion 5a of top closure 15a is inserted between the cigarette packs 101a-105a and the inside of interior wall 55a. Top portion 10a of tuck flap 15a forms the top wall of half-carton 300A. 
     Similarly, tuck portion 5b is inserted between cigarette packs 101b-105b and interior wall 55b, and top portion 10b forms the top wall of half-carton 300B. 
     The closed, double half-carton unit is then ready for final shipment to retailers for sale to consumers. A retailer may sell the double half-carton unit as one carton of ten cigarette packs, or the retailer may separate and sell individual half-cartons of five cigarette packs. 
     The double half-carton unit may be separated by applying force to each half-carton in the direction indicated by the arrows in FIG. 7. This action will tear perforated lines 200a and 200b and separate the unit into individual half-cartons. When separated, extension tab 30a is attached to side wall 35b, and extension tab 30b is attached to side wall 35a. Thus each extension tab remains on the opposite half-carton from which it originated. 
     It will be apparent that minor modifications to the manner in which the half-cartons are fabricated, temporarily closed, opened for tax stamping, closed for shipment to retailers, or separated into half-cartons for sale to consumers, may be made. For example, the half-carton fabrication process may include two identical machines that make half-cartons from blanks configured to produce pairs of half-cartons with the interior walls facing each other for attachment. This would alleviate the need to rotate one half-carton 180° prior to attachment. 
     The top closures need not be tucked into the half-cartons after tax stamping. Instead, they may be tucked into the space between interior walls 55a and 55b such that tuck portion 5a is glued, taped or otherwise secured to interior wall 55a, and tuck portion 5b is glued, taped or otherwise secured to interior wall 55b. 
     In addition, the shape and size of the extension tabs may be modified. The extension tab may be located on the opposite side wall (i.e., attached to side wall 30). Or both extension tabs may be located on one half-carton, on each of its two side walls. 
     Alternately, the size and shape of the dust flaps and insert side walls may be changed, or either or both may be eliminated. 
     Finally, sticky glue points, tape or other adhesive may be added to the interior walls of the half-cartons, or across the centerline of the two half-cartons to provide greater adhesion of the double half-carton unit during tax stamping. 
     For purposes of clarity, terms used in this specification and in the following claims, such as top, bottom, interior, exterior and side, are used solely to provide the reader with a reference for relative positions of the various half-carton walls and in no way limit the use of the invention nor the scope of the claims. For example, the &#34;bottom wall&#34; of the half-carton need not be used as the bottom of the box. 
     One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims that follow.