Packs for smoking articles such as cigars

Abstract: There is provided a pack (10) for smoking articles such as cigars (11) comprising an inner portion (13) retained within an outer portion (12). The outer portion (12) has two portions (14,15) connected by a hinge line (16), the inner portion (13) spanning the junction between the two portions (14,15) when the pack is closed. The inner and outer portions (12,13) are formed initially as open ended hulls, the open ends of the pack being closed off after the smoking articles (11) have been inserted.

Description: This invention relates to packs for smoking articles and also to methods of making such packs. EP-A-0 346 026 represents the relevant background art. According to a first aspect of the present invention there is provided a paperboard pack for smoking articles comprising an outer hull and an inner hull retained within said outer hull in a predetermined position, the ends of the pack being closed by closure panels, said outer hull having a hinge fold and at least one cut extending from said fold such that, in use, one portion of the outer hull can be hinged relative to the other portion of the outer hull, a part of the inner hull spanning said at least one cut at at least one location, and at one end of the pack the ends of the inner and outer hulls coincide the inner hull at said one end incorporating a hinged end flap which flap has lateral protrusions adjacent the hinge line for abutting the outer hull to prevent the inner hull being moved too far inwards. In a preferred arrangement the protrusions do not project beyond the outer hull. In one embodiment the outer hull at said one end incorporates a hinged end flap which is adhesively secured to the end flap on the inner hull. Another preferred feature is that the inner hull has projecting ears which interfere with the outer hull to resist relative movement between the two hulls. Adhesive may also be used to secure the inner and outer hulls. A further feature is that the part of the inner hull projecting into said one portion of the outer hull is provided with retaining ears which project from the inner hull to assist in the retention of the pack in its closed position by friction. In addition the uppermost part of the inner hull opposite the hinge is positioned so as to interfere with the outer hull during opening and closing so as to ensure positive action. Preferably said at least one cut is not continuous before the initial opening of the pack, such that a number of nibs, as well as the hinge, still connect the two portions of the outer hull. Conveniently two nibs are provided opposite the hinge. In most configurations the inner and outer hulls have rectangular panels whereby the pack is generally cuboid and the hulls have two relatively broad panels and two relatively narrow panels with the hinge being formed on one of the narrow panels of the outer hull. According to a second aspect of the present invention there is provided a method of manufacturing a paperboard pack for smoking articles, comprising the steps of: (i) forming an open ended outer hull, (ii) making a cut or cuts in the outer hull to define two portions which, in use of the pack, are hingedly connected to each other, (iii) forming an open ended inner hull, (iv) inserting the inner hull via one end of the outer hull into the outer hull into a predetermined location and retaining the inner hull in said location, said predetermined location of the inner hull within the outer hull being defined by the abutment with the outer hull of protrusions formed on an end flap adjacent a hinge connection with the inner hull, (v) inserting said smoking articles into the inner hull, and (vi) closing the ends of the pack. In one method the smoking articles are inserted after the inner hull has been inserted in the outer hull. It is a preferred feature that the closing of said one end of the pack involves the step of folding said end flap of the inner hull so as to close the end at least partially and to fold over and adhesively secure to it an end panel hingedly connected to the outer hull. Conveniently the closing of the other end involves the folding and adhering of two further end panels hingedly connected to the outer hull. Ideally the pack is cuboid and the four main panels of each hull are generally rectangular and the forming of the cut is such that no cut is made in one panel of the outer hull thereby constituting the hinge. Also it is desirable if the cut is formed such that opposite the hinge, two nibs are retained connecting the two portions of the outer hull. Embodiments of the invention will now be described in more detail. The description refers to the accompanying drawings in which: Figure 1 is a front view of a pack according to the present invention in a closed position, Figure 2 is a front view of the pack of figure 1 in an open position, Figure 3 is a view of a blank used to form an outer hull of the figure 1 pack, Figure 4 is a view of a blank used to form an inner hull of the figure 1 pack, Figure 5 is a front perspective view from below of the figure 3 blank assembled ready for final assembly, and Figure 6 is a front perspective view from below of the figure 4 blank assembled ready for final assembly. Figures 1 and 2 show a pack 10 for smoking articles 11 such as cigars. The pack 10 has an outer section 12 and an inner section 13. The outer section 12 has an upper portion 14 and a lower portion 15 which are hingedly connected together at 16 such that the pack 10 can be opened and closed. Referring now to all the figures, the outer section 12 is formed from a paperboard blank 20 having rectangular front and rear panels 21, 22, side panels 23, 24, top end panels 25 and bottom end panel 26. A hinge fold 27 is formed by indentation in the two side panels 23 and a cut line 31 extends across the front and rear panels 21, 22 and the side panel 24 except for two small nib portions 28 at the junction of the side panel 24 and the front and rear panels 21, 22. All the panels are hingedly connected by fold lines 29 and the blank 20 is folded to form a hull or encircling sleeve 30 and the side panels 23 are adhesively secured to each other in order to retain this hull 30. In such a form the hull 30 can be folded flat for ease of transport and opened up so as to have a rectangular section through opening during pack assembly. The inner section 13 is formed from a paperboard blank 40 having generally rectangular front and rear panels 41, 42, side panels 43, 44 and a bottom end panel 45. The panels are linked by combinations of scored fold lines and plain fold lines supplemented by cuts 46, 47 which form ears 48, 49, the purpose of which will be explained later. In the particular embodiment shown the fold lines between panels 44 and 41, 42 above the ears 49 are plain fold lines as are the fold lines below the lowermost ears 48. The fold lines in between are scored fold lines. This variety of fold types assists in the retention of the hull in a square form during manufacture and use, i.e. all panels being perpendicular to each other. If this square form is not present then the pack can be difficult to manufacture and can also result in difficulties in use by the consumer. Also the fold lines between panels 43 and 41; and 42 and 43 are scored except for the very top portion which is a plain fold line. This top portion may be up to 5 mm long, but is preferably about 1.5 mm. The section of plain fold line primarily prevents possible delamination of the paperboard when the lid of the pack is closed. If the top portion is a scored fold line then the edge of the lid can interfere with and act to separate the paperboard of the side panels 41, 42. It will be understood of course that although the fold line combinations as discussed are preferred, other variations are possible. For example, all plain folds or all scored folds could be used if desired. Also the end panel 45 is formed with laterally projecting tabs 50. The blank 40 is folded to form a hull or sleeve 51 and the side panels 43 are adhesively secured to each other in order to retain the hull 51 shape. Again the hull 51 can be folded flat and opened up during pack assembly. The actual assembly of the two hulls, together with the smoking articles is variable. One assembly will be described in detail below and examples of variations will also be discussed. Firstly the hulls 30, 51 are opened up so as to take up the forms shown in figures 5 and 6. The upper end panels 25 of the hull 30 are then folded down and adhesively secured together. The inner hull 51 is then inserted through the open bottom of the hull 30. The tightness of this fit is determined by the dimensions of the hulls and in particular the dimensions of the ears 48, 49 which frictionally engage the inside of the outer hull 30. Insertion is complete when the tabs 50 on the inner hull 51 abut the side panels 23, 24 of the outer hull 30. It will be apparent, however, that the provision of the ears 48, 49 is optional and that any number of ears could be provided. The ears could also have different shapes and sizes. This abutment is very important because it ensures accurate positioning of the inner hull 51 within the outer hull 30. It will be appreciated that it is the interference of the side panel 24 of the upper portion 14 with the inner hull 51 which has a principal bearing on the closing and opening action of the pack 10. It is desirable that a positive closing action is obtained, but if there is insufficient interference then this will not be obtained. Conversely, too much interference makes the pack difficult or even impossible to open. The ears 49 also assist the opening and closing action by frictional engagement with the upper portion 14, but this may not be sufficient on their own to provide a good closing action repeatedly. The ears 49 are an optional feature. After abutment, the smoking articles 11 can be inserted through the open bottom of the pack. The end panel 45 is then folded up, the tabs 50 still abutting the side panels 23, 24 of the outer hull 30 to prevent further movement of the inner hull 51 inwards. The bottom end panel 26 of the outer hull 30 is then folded down and adhesively secured to the end panel 45 of the inner hull 51. It will be understood that to avoid the tabs 50 from showing excessively in the finished pack, they do not project significantly beyond the side walls 23, 24 of the outer hull 30 and preferably not at all although manufacturing tolerances make this latter situation difficult. The resulting pack 10 has a hinge lid, i.e. upper portion 14, which is still secured, until use, to the lower portion 15 of the pack 10. The user then has the satisfying step of initially breaking open the pack 10 in such a way as to break the nibs 28. Furthermore, subsequent closing and opening of the pack remains positive in view primarily of the accurate positioning of the inner hull within the outer hull. The pack 10 is also particularly rigid thereby affording considerable protection to the relatively fragile smoking articles contained within the pack. Clearly the precise form of the cut 31 is a matter of design choice. Also the hinge could be provided on one of the wider front or rear panels 21, 22 if such a pack was desired. Also, there is no necessity for the pack to be cuboid as shown, but may have contoured panels or any suitable cross-sectional shape such as hexagonal. Turning to the matter of method of assembly, the top end could be closed off at any suitable time before, after or during insertion of the inner hull. Also the smoking articles could be inserted at any suitable time before, during or after insertion of the inner hull, either through the top end or the bottom end of the pack. During insertion of the smoking articles either or both ends of the pack could be open.

Claims: A paperboard pack (10) for smoking articles comprising an outer hull (12) and an inner hull (13) retained within said outer hull in a predetermined position, the ends of the pack being closed by closure panels (25, 26), said outer hull having a hinge fold (27) and at least one cut (31) extending from said fold such that, in use, one portion (14) of the outer wall can be hinged relative to the other portion (15) of the outer hull, a part of the inner hull spanning said at least one cut at at least one location and at one end of the pack the ends of the inner and outer hulls coincide, the inner hull at said one end incorporating a hinged end flap (45) which flap has lateral protrusions (50) adjacent the hinge line for abutting the outer hull to prevent the inner hull being moved too far inwards. A pack as claimed in claim 1 wherein the protrusions do not project beyond the outer hull. A pack as claimed in claim 2 wherein the outer hull at said one end incorporates a hinged end flap (26) which is adhesively secured to the end flap (45) on the inner hull. A pack as claimed in claims 2 or 3 wherein the inner hull has projecting ears (48, 49) which interfere with the outer hull to resist relative movement between the two hulls. A pack as claimed in any one of claims 1 to 4 wherein the part of the inner hull projecting into said one portion of the outer hull is provided with retaining ears (49) which project from the inner hull to assist in the retention of the pack in its closed position by friction. A pack as claimed in any one of claims 1 to 5 wherein the uppermost part of the inner hull opposite the hinge is positioned so as to interfere with the outer hull during opening and closing so as to ensure positive action. A pack as claimed in any one of claims 1 to 6 wherein said at least one cut is not continuous before the initial opening of the pack, such that a number of nibs, as well as the hinge, still connect the two portions of the outer hull. A pack as claimed in any one of claims 1 to 7 wherein the inner and outer hulls have rectangular panels whereby the pack is cuboid and the hulls have two relatively broad panels and two relatively narrow panels with the hinge being formed on one of the narrow panels of the outer hull. A method of manufacturing a paperboard pack (10) for smoking articles, comprising the steps of: (i) forming an open ended outer hull (12), (ii) making a cut or cuts (31) in the outer hull to define two portions (14, 15) which, in use of the pack, are hingedly connected to each other, (iii) forming an open ended inner hull (13), (iv) inserting the inner hull via one end of the outer hull into the outer hull into a predetermined location and retaining the inner hull in said location, said predetermined location of the inner hull within the outer hull being defined by the abutment with the outer hull of protrusions (50) formed on an end flap (45) adjacent a hinge connection with the inner hull, (v) inserting said smoking articles into the inner hull, and (vi) closing the ends of the pack. A method as claimed in claim 9 wherein the smoking articles are inserted after the inner hull has been inserted in the outer hull. A method as claimed in claim 10 wherein the closing of said one end of the pack involves the step of folding said end flap (45) of the inner hull so as to close the end at least partially and to fold over and adhesively secure to it an end panel (26) hingedly connected to the outer hull. A method as claimed in claim 11 wherein the closing of the other end involves the folding and adhering of two further end panels (25) hingedly connected to the outer hull. A method as claimed in claim 12 wherein the pack is cuboid and the four main panels of each hull are generally rectangular and the forming of the cut is such that no cut is made in one panel of the outer hull thereby constituting the hinge.

Inventors: LUTON COLIN DENNIS, WRIGHT CLIVE GRAHAM, LUTON, COLIN DENNIS, WRIGHT, CLIVE GRAHAM
Applicants: IMP TOBACCO CO LTD, IMPERIAL TOBACCO LIMITED
Application year: 1995
Main classification: B65D85
IPC codes: B65D85, B65D5