Cigarette carton assembly

A cigarette carton assembly for 10 packages of cigarettes can be tax stamped using automated tax stamping machinery; and later divided into 2 half carton assemblies, each containing 5 packages of cigarettes. Each of the half carton assemblies have cigarette packages positioned therein in a 1 by 5 configuration. The carton assembly includes a collar which acts as a top portion of the carton assembly, and allows the carton assembly to be taxed stamped using automated tax stamping machinery. Then, the collar can be removed from the carton assembly, and the remaining carton assembly can be subdivided into two half carton assemblies.

BACKGROUND OF THE INVENTION 
The present invention relates to the packaging of smoking articles such as 
cigarettes into cartons, and in particular, to the packing of packages of 
cigarettes into cartons such that the individual packages can be readily 
tax stamped. 
It is common practice to ship and store cigarette packages in cartons. 
Conventional or standard cigarette cartons ordinarily hold ten packages, 
each package containing about 20 cigarettes. The packages are usually 
arranged in two relatively superposed rows of 5 packages each. Such 
standard cartons completely encase the cigarette packages and are provided 
with glued flaps. Examples of cartons for ten packages of cigarettes are 
provided in U.S. Pat. Nos. 3,752,308 to Begemann; 4,738,359 to Phillips, 
Jr.; and 4,903,844 to Oglesby. 
Individual jurisdictions require the application of a tax stamp to each 
package of cigarettes sold in the respective jurisdiction. Typically, the 
distributor or jobber in the jurisdiction receives the cartons from the 
manufacturer, unseals the flap of carton which is sealed with a fugitive 
adhesive, applies the tax stamp to each package of cigarettes, and then 
recloses and reseals the carton. In order to minimize the time, labor and 
expense associated with tax stamping of the packages within the carton, 
various automated tax marking or stamping machines have been developed. 
Such tax marking machines automatically print or otherwise affix tax 
stamps to packages within the carton. Tax stamping machines which are most 
commonly employed by distributors and jobbers include ADCO Automatic Heat 
Transfer Decalomanic Stamping Machine which is available from American 
Decal & Mfg. Co., Chicago, Ill.; Cigarette Tax Stamp Applying Machine 
which is available from Meyercord, Carol Stream, Ill.; and Cigarette Tax 
Machine which is available from Pitney Bowes, Stamford, Conn. Accordingly, 
the dimensions and construction of the standard cigarette carton have been 
established by the tax stamping machinery customarily employed by the 
distributors, wholesalers and jobbers who tax mark the cigarette packages 
prior to retail sale. 
A manufacturer desiring to provide cigarette packages in non-standard size 
or shape cartons is forced to pay to have the individual packages hand tax 
stamped. Alternatively, the manufacturer can package cigarette packages in 
standard cartons for tax stamping and handling, and then manually load the 
tax stamped packages into non-standard size or shape cartons. However, a 
manual method for providing non-standard size or shape cartons of packaged 
cigarettes is time consuming, laborious and expensive. 
As disclosed in Modern Packaging, (1947) half carton packs are provided 
using a three sided paperboard collar and cellophane wrap such that the 
bottom of the cigarette packages are exposed for tax stamping. As 
disclosed in U.S. Pat. No. 4,738,359 to Phillips, Jr., cigarette packages 
can be contained in half cartons which can be tax stamped while in a 
master carton and later removed from the master carton for sale. Other 
methods for packaging cigarette packages into cartons which are divisible 
into smaller units are proposed in U.S. Pat. Nos. 3,809,227 to Begemann; 
4,631,900 to Mattei, et al.,; 4,938,817 to Focke; and 4,932,534 to Focke, 
et al. 
Occasionally, manufacturers desire to market cartons containing five 
packages of cigarettes. Such cartons are similar in design to the standard 
cartons, but only contain 1 row of 5 packages. However, such cartons have 
not achieved any appreciable commercial success. In particular, five 
package cartons having configuration comparable to standard cigarette 
cartons have had a top flap configuration. The particular top flap has 
required that the packages of such cartons be tax stamped by hand or that 
the tax stamped packages be manually loaded in the cartons. 
It would be desirable to provide a manner or method for efficiently and 
effectively packaging cigarettes in divisible cartons (e.g., half cartons) 
which in turn are provided from standard size cartons of conventional 
shape or configuration. In particular, it would be desirable for the 
cigarette manufacturer to efficiently and effectively provide cigarette 
packages contained within standard cartons for tax stamping using 
conventional automatic or semi-automatic tax stamping machinery, which 
standard cartons have the capability of being divisible into half cartons. 
SUMMARY OF THE INVENTION 
The present invention relates to carton assemblies for packaged smoking 
articles (e.g., cigarettes). In particular, the invention relates to a 
carton assembly for 10 packages of cigarettes which are arranged therein 
(i.e., in a 2 by 5 configuration) for transport through and tax marking 
using a tax marking apparatus designed for tax marking the packages within 
a standard carton of conventional size and shape. The preferred carton has 
a top portion, a bottom portion, two end portions and two side portions. A 
"standard carton" assembly for 10 packages of cigarettes arranged in a 2 
by 5 configuration is capable of being divided into smaller size cartons. 
Preferably, the standard carton assembly is capable of being divisible 
into 2 "half carton" assemblies each containing 5 packages preferably 
arranged in a 1 by 5 configuration. 
In one aspect, the present invention relates to a standard carton assembly 
which includes 2 half carton assemblies which are attached together. In 
particular, a standard carton assembly for 10 packages of cigarettes is 
provided by combining two half carton assemblies for 5 packages of 
cigarettes using material which provides a portion of the standard carton 
assemblies as well as the half carton assemblies. Each of the half carton 
assemblies preferably have cigarette packages positioned therein in a 1 by 
5 configuration. A collar means provides the top portion of the carton 
assembly or a portion of the top portion of the carton assembly. The 
collar means extends around the horizontal perimeter of the combined half 
carton assemblies, and provides a top portion to the carton assembly. 
The collar means is removable, such that the half carton assemblies can be 
separated for further sales, distribution or use. 
The present invention provides the manufacturer of smoking articles, such 
as cigarettes, with a method for packaging its product in carton 
assemblies which can be tax marked (e.g., using prints, decals, or the 
like) using conventional tax marking apparatus. Of particular interest is 
the fact that the divisible carton assemblies containing cigarettes can be 
assembled by the manufacturer, passed through tax stamping operations, and 
delivered to the retailer or consumer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring to FIG. 1, blank assembly 10 includes two blank portions 12 and 
14. Blank portions 12 and 14 are designed to form an assembled "standard" 
carton for 10 cigarette packages which can be separated into 2 "half 
carton" assemblies each containing 5 cigarette packages. Such blank 
portions are representative of blanks useful for constructing half carton 
assemblies, but other blanks and other half carton assembly configurations 
can be employed. 
The blank portions 12 and 14 most preferably are provided from paperboard 
sheet, and include a plurality of fold lines, creases or score lines 
(shown as solid lines in FIG. 1); or perforations, cuts or slits (shown as 
dotted lines in FIG. 1). The degree of perforation can vary, and can be 
provided as to provide as desired. However, the degree of perforation is 
such that the joined half carton assemblies do not easily tear, and that 
the standard size carton can be handled as such. The cuts conveniently are 
made by slitting the blanks without necessarily removing material 
therefrom. The folds, perforations and cuts of the blank portions define 
panels which correspond to walls, portions, sides and flaps of the carton 
assemblies which ultimately are constructed from those blank portions. 
Blank portion 12 includes bottom portion 20 corresponding to the bottom of 
the carton assembly, a right side wall part 22, a left side wall part 24, 
and a first end wall part 26 positioned integral with and at one end of 
left side wall part 24. The length of left side wall part 24 is 
essentially equal to the width of five cigarette packages, the length of 
right side wall part 22 also is essentially equal to the width of five 
cigarette packages, the width of each of side wall parts 22 and 24 is 
equal to the height of a cigarette package, and the width of bottom 
portion 20 is essentially equal to the depth of one cigarette package. The 
blank portion 12 also includes a first end flap 28 integral with and at 
one end of right side wall part 24, and optional reinforcing tab or "dust 
flap" 30 integral with and at one end of bottom portion 20. The blank 
portion 12 includes a second end wall part 34 positioned integral with and 
at one end of left side wall part 24, a second end flap 36 integral with 
and at one end of right side wall part 22, and optional reinforcing tab 38 
integral with and at one end of bottom portion 20. The blank portion 12 
also includes top "tuck flap" 42 integral with and to one side of left 
side wall part 24. The tuck flap acts as the top portion of an assembled 
half carton. The tuck flap 42 shown in FIG. 1 does not extend along the 
entire length of the left side wall part; however, the tuck flap can 
extend along the entire length of that side wall part (as shown in FIG. 
2). The tuck flap 42 includes an inner portion 43 having a width 
essentially equal to that of the depth of one cigarette package, and acts 
as a top wall of an assembled half carton; and outer portion 44 having a 
width essentially equal to that of the depth of one cigarette package, 
which acts as a tuck tab to maintain the assembled half carton in a closed 
position. The blank portion 12 also includes optional tear tabs 46, 47, 48 
and 49, formed in right side wall part 22 by perforating, nicking or 
slitting selected regions of that side wall part. 
Blank portion 14 is similar in many respects to the previously described 
blank portion 12, but is a mirror image of blank portion 12. Blank portion 
14 includes bottom portion 60 corresponding to the bottom of the carton 
assembly, a right side wall part 62, a left side wall part 64, and a first 
end wall part 66 positioned integral with and at one end of right side 
wall part 62. The blank portion 14 also includes first end flap 68 
integral with and at one end of left side wall part 64, and optional 
reinforcing tab or "dust flap" 70 integral with and at one end of bottom 
portion 60. The blank portion 14 also includes top "tuck flap" 75 integral 
with and to one side of right side wall part 62. Tuck flap 75 includes 
inner portion 77 and outer portion 78. The blank portion 14 also includes 
a second end part 80 integral with and at one end of right side wall part 
62, a second end flap 82 integral with and at one end of left side wall 
part 64, and optional reinforcing tab 84 integral with and at one end of 
bottom portion 60. The blank portion 14 also includes optional tear tabs 
90, 91, 92 and 93 formed in left side wall part 64 by perforating, nicking 
or slitting selected regions of that side wall part. 
Blank portions 12 and 14 of FIG. 1 are designed to be assembled into half 
cartons for five packages of cigarettes each using known techniques; and 
to fit together and to be attached or secured together by applying 
adhesive to the outer surfaces of the tear tabs of the respective blank 
portions. As such, blanks 12 and 14 are erected into portions of the 
ultimate carton assembly by folding the blanks along the various fold 
lines; and the resulting half cartons are secured together into a standard 
carton assembly by adhesive at the regions where the tear tabs of the half 
cartons touch. 
Referring to FIG. 2, alternate blank assembly 10 includes two blank 
portions 12 and 14, which are generally similar to those blank portions 
described with reference to FIG. 1. However, the blank portions shown in 
FIG. 2 do not require the tear tabs in the side wall parts 22 and 64 of 
the blank portions; but rather, blank portion 14 includes outer tab 
portions 120 and 122 integral with and at the ends of first end wall part 
66 and second end wall part 80, respectively. 
Blank portions 12 and 14 of FIG. 2 are designed to be assembled into half 
cartons for five packages of cigarettes each; and to fit together and to 
be secured together by applying adhesive to the inner surfaces of outer 
tab portions 120 and 122 of blank portion 14 and the outer surfaces of end 
wall parts 26 and 34, respectively, of blank portion 12. 
Referring to FIG. 3, there is shown blank portion 140 which is designed to 
form a collar for a standard carton for 10 cigarette packages. Blank 
portion 140 includes two side wall parts 142, 144 and two end wall parts 
148, 150. The lengths of each of the side wall parts are essentially equal 
to the width of 5 cigarette packages, and the lengths of each of the end 
wall parts are essentially equal to the depth of two cigarette packages. 
The widths of the end wall parts 148, 150 are essentially equal to the 
height of one cigarette package. The widths of the side wall parts 142, 
144 can vary, but are about 1/2 the width of the end wall parts 148, 150. 
Large top flap portion 155 is positioned integral with and at one side of 
side wall part 142; and small top flap portion 157 is positioned integral 
with and at one side of side wall part 144. The top flaps portions 155 and 
157 provide for a configuration comparable to that of the top of a 
standard cigarette carton assembly known in the art (i.e., the width of 
top flap portion 155 is essentially equal to the depth of 2 cigarette 
packages, and the width of top flap portion 157 is less than that of top 
flap 155). Tab 159 is positioned integral with and at one end of side wall 
part 142. The collar is assembled in a rectangular shape by applying 
adhesive to the outer surface of tab 159 and securing that tab to inner 
surface of end wall part 150. 
Referring to FIG. 4, alternate blank portion 140 is generally similar to 
the blank portion described with reference to FIG. 3. However, the blank 
portion shown in FIG. 4 does not include a large top flap positioned at 
one side of side wall part 142. Such a blank portion 140 is designed to 
form a collar to be employed with a standard carton assembly having a tuck 
flap (i) which extends along the entire length of the carton assembly, and 
(ii) which is comparable in size and shape to that of large top flap of a 
standard carton assembly. As such, the collar provides a portion of the 
top portion of the ultimate carton assembly. 
Referring to FIG. 5, a 10 package cigarette carton assembly 180 is provided 
in a form in which cigarette packages therein (not shown) are arranged or 
positioned in a standard 2 by 5 configuration. That is, 5 packages are 
positioned side-by-side in a row on the right side of the standard carton 
assembly, and 5 packages are positioned side-by-side on the left side of 
the standard carton assembly. The carton assembly 180 includes 2 half 
carton assemblies of the type described with reference to FIG. 1, which 
are attached together. Collar means 184 is assembled from the blank 
described with reference to FIG. 3, and is positioned over the top of the 
carton assembly 180 and extends around the horizontal perimeter of the 2 
half carton assemblies which are attached together. As such, the carton 
assembly 190 shown in FIG. 6 is provided. The top tuck flaps of the half 
carton assemblies are folded back so as to lie along the respective outer 
sides of the respective carton assemblies and are covered by the side 
walls of the collar means. The collar means is open at its bottom region. 
If desired, fugitive adhesive can be applied to the inner surfaces of the 
end wall parts of the collar means so as to maintain that collar means in 
place relative to the remaining portion of the carton assembly. The end 
wall parts of the collar means provide stabilization and support so that 
the collar means does not fall down over the remaining portion of the 
carton assembly. The side wall parts of the collar means extend over a 
portion of the height of the side walls of the remaining portion of the 
carton assembly so as to (i) require the use of a minimal amount of 
material by not requiring materials for significant portions of the side 
wall portions as well as a bottom portion, and (ii) completely cover the 
folded back tuck flaps of the half cartons. The top flaps 155 and 157 of 
the collar means can be sealed using fugitive glue as is common in the 
industry. Then, the cigarette packages contained in the carton assembly 
can be readily tax stamped using conventional automated techniques and 
equipment. The carton assembly then can be sealed for further shipping and 
handling. The carton assembly can be marketed as such (as shown in FIG. 6) 
or can be readily divided into two cigarette carton assemblies (each 
containing 5 packages), by removing the collar, discarding the collar, and 
breaking apart the two half carton assemblies (as shown in FIG. 7). That 
is, the standard carton assembly includes means for dividing that assembly 
into two half carton assemblies. 
Cigarette packages can be inserted into the previously described assembled 
half carton assemblies, and the half carton assemblies containing 
cigarette packages then can be combined together into a standard carton 
assembly of conventional size and shape for tax stamping operations and 
commercial sale. Cigarette packages also can be inserted into a standard 
size assembly provided from two combined half carton assemblies, and then 
the carton assembly containing cigarettes can be subjected to tax stamping 
operations prior to commercial sale. The standard size carton assembly of 
the present invention behaves like a standard carton during tax stamping 
operations. The use of the collar means, which provides for a portion of 
the carton assembly, allows for the production of a useful standard size 
carton assembly while making efficient use of packaging materials. That 
is, as the collar may be discarded when two half carton assemblies are 
produced, the present invention does not require a collar having what 
would correspond to the bottom and significant amount of the side walls of 
a standard carton assembly. When the collar is removed from the remaining 
portion of the carton assembly, the tuck flaps of the half carton 
assemblies which were maintained in a folded back position by the collar, 
can be positioned over the top region of each respective half carton 
assembly to close each half carton assembly. 
Referring to FIG. 7, two half carton assemblies 12 and 14 are shown as 
separated after the collar (not shown) has been removed from carton 
assembly and discarded or otherwise disposed of. That is, the adhesive 
seals at each of the tear tabs of the half carton assemblies are broken. 
The tuck flaps 42 and 75 are folded from along the respective sides of the 
carton assemblies to be positioned over the top region of each respective 
half carton assembly. As such, the half carton assemblies can be closed 
and opened in a known manner. It is also possible to seal the half carton 
assemblies using the tuck flaps prior to dividing the carton assembly into 
half cartons. 
As used herein, the term "package" means a package comparable in size and 
shape to a conventional cigarette package which normally contains 20 
cigarettes. See, for example, U.S. Pat. No. 4,852,734 to Allen, et al., 
and U.S. Pat. Application Ser. Nos. 525,737, filed May 17, 1990 and 
717,456, filed Jun. 19, 1991. The package can be a soft package or a crush 
proof box. Generally, a package has a height of about 70 mm to about 100 
mm, and most frequently 20 rod-shaped smoking articles each having a 
circumference of about 22 mm to about 25 mm are arranged therein in a so 
called "7-6-7" or "7-7-6" configuration. 
As used herein, the term "standard carton assembly" means a conventional 
carton assembly which is capable of containing 2 rows of 5 cigarette 
packages, and which most preferably is capable of being passed through 
commonly employed automated tax stamping apparatus. Generally, the length 
of a standard carton assembly is a minimum of about 266 mm and a maximum 
of about 286 mm. Generally, the width of a standard carton assembly ranges 
from about 40 mm to about 50 mm. Generally, the height of a standard 
carton assembly (when the top flaps are positioned such that the carton 
assembly is in a closed configuration) ranges from about 70 mm to about 
100 mm. 
An example of a preferred embodiment of this invention is as follows. A 
standard carton assembly has a length of about 270 mm, height of about 101 
mm, width of 45 mm; and contains 10 packages of 20 cigarettes. The 
packages are arranged in 2 rows in a 1 by 5 fashion within the standard 
assembly carton. The carton assembly is manufactured from paperboard 
having a thickness of about 0.25 mm to about 0.30 mm. The carton assembly 
is provided from blank portions of the type shown in FIGS. 1 and 3. 
The cigarette packages within the carton assembly of the present invention 
can be tax stamped using conventional tax stamping apparatus. The flaps of 
the carton assembly can be opened, the top (i.e., exposed) side of each of 
the cigarette packages therein can be stamped, and the carton assembly 
sealed, all without the necessity of removing or rearranging the cigarette 
packages. Thus, the half cartons (i.e., cartons which contain 5 packages 
of smoking articles) can be handled and processed by the jobber or 
wholesaler as are conventional or standard cartons containing 10 packages 
of cigarettes. When the carton assembly is available for retail sale, two 
half carton assemblies can be provided from the standard carton and 
handled as such. Thus, the cigarette manufacturer can efficiently and 
effectively provide an inexpensive multi-pack unit of smoking articles for 
sale. Additionally, the manufacturer can easily provide a means for 
displaying and merchandising unique multi-pack units of its products.