Patent Publication Number: US-7896225-B2

Title: Smoking article pack blank(s)

Description:
CROSS REFERENCE TO PRIOR APPLICATION 
     This application is a national stage filing (35 U.S.C. 371) of PCT/GB2004/000953, filed on Mar. 8, 2004, which claims priority to and benefit from Great Britain Patent Application No. 0305661.1, filed on Mar. 12, 2003. 
     The present invention relates to a smoking article pack blank(s), particularly but not exclusively for cigarettes. 
     Multi-compartment packs for cigarettes are already known in the art. For example, FR2614720 discloses a pack comprising a plurality of articulated compartments, which compartments are closed by means of a single interlocking lid. The patent does not disclose a blank from which the pack may be assembled, however, it is clear from the specification of FR2614720 that the pack is not of a form that could readily be assembled using conventional, or little modified, pack assembly machinery. 
     The present invention has as an aim the provision of smoking article pack blank(s) which blank is easy to assemble at the high manufacturing speeds required in the tobacco industry. 
     A further aim of the present invention is to provide a blank(s) which may be assembled using conventional pack assembly machinery, or at least a blank which may be assembled on machinery requiring little modification from conventional pack assembly machinery. 
     The present invention provides a smoking article pack blank, the blank comprising a lid portion and a base portion, the lid portion and the base portion being interconnected along a hinge line and the base portion comprising a first main panel, a second main panel and a bottom panel, each panel being defined by longitudinal side margins, the first and the second main panels each having side panels, which side panels depend from the longitudinal margins of the first and second main panels, at least one of the side panels having a side flap depending from a longitudinal margin thereof. 
     Preferably the side flap is connected to the adjacent side panel by a hinge line. 
     Preferably each panel has a top margin and a bottom margin. 
     It is much by preference that the bottom panel of the smoking article pack blank comprises at least two bottom panel sections. Advantageously the bottom panel comprises two bottom panel sections. 
     Preferably the bottom panel sections may be joined along a line of weakening. In an alternative arrangement the bottom panel sections may be integral with one another. 
     When the bottom panel sections are joined along a line of weakening, the line of weakening preferably extends between the longitudinal margins of the bottom panel. Advantageously the line of weakening extends between the opposing longitudinal margins of the bottom wall, the line of weakening extending up to but not through the longitudinal margins of the bottom wall. It is much by preference that the line of weakening in the bottom panel extends between the longitudinal margins of the bottom panel in parallel relation to the top margin and/or the bottom margin of the bottom panel. 
     Advantageously the line of weakening is a line of perforation. 
     In the alternative arrangement, wherein the bottom panel sections are integral with one another, it is much by preference that the bottom panel sections are separable from one another. Suitably the bottom panel sections are separable from one another by cutting along a line of integration between the two bottom panel sections. It is much by preference that the line of integration extends between the opposing longitudinal margins of the bottom panel. Even more preferably the line of integration extends between the opposing longitudinal margins of the bottom panel in parallel relation to the top margin and/or the bottom margin of the bottom panel. 
     Advantageously the bottom panel has a depth dimension and the side panels have width dimensions substantially equal to a multiple of the diameter of a smoking article. If the smoking articles are in nested arrangement within an erected pack, the depth dimension of the bottom panel and the width dimensions of the side panels of the smoking article pack blank may be slightly less than a multiple of the diameter of a smoking article. When referred to herein, multiple shall be taken as including one. Preferably the width dimension of each of the side panels depending from a main panel of the smoking article pack blank is substantially equal to the depth dimension of that bottom panel section adjacent to that main panel, which bottom panel section is delimited by the line of weakening or the line of integration in the bottom panel. Suitably the panels of the smoking article pack blank have a common longitudinal axis. 
     Advantageously the total depth dimension of the bottom panel is equal to the sum of the width of a side panel depending from a longitudinal margin of the first main panel and the width of a side panel depending from the longitudinal margin of the second main panel. 
     Preferably the hinge line connecting the side flap and the side panel is formed from the common longitudinal margin between the side flap and the side panel adjacent thereto. 
     Preferably the side flap depends from the outer longitudinal margin of the adjacent side panel. 
     Advantageously the side flap depends from the outer longitudinal margin of a side panel of the second main panel of the base portion of the smoking article pack blank. When the smoking article pack blank is erected, the side flap overlaps a side panel of the other main panel of the blank. Alternatively, the side panel of the other main panel may overlap the side flap when the blank is erected. 
     It is much by preference that the side flap overlaps a side panel of the first main panel of the base portion of the smoking article pack blank. Advantageously, the side panel and the overlapping side flap are of substantially equal width dimensions. When the smoking article pack blank is erected it is much by preference that the longitudinal margin of the side panel from which margin the side flap depends forms a longitudinally extending hinge line in a side wall of the erected blank. The longitudinal margin of the overlapping side panel adjacent the longitudinally extending hinge line allows the erected blank to-hinge thereabout. 
     Preferably the smoking article pack blank is an outer blank. As referred to herein an ‘outer blank’ is a blank which may be assembled about an erected inner blank or a plurality of inner blanks or, alternatively may be assembled about an assemblage of smoking articles which assemblage is wrapped in a wrapping material. 
     In a second embodiment of the present invention, the smoking article pack blank base portion comprises two side flaps, which side flaps depend respectively from the longitudinal margins of the first and second side panels of one of the main panels of the blank. Preferably the side flaps depend from the outer longitudinal margins of the first and second side panels of the second main panel of the blank. 
     When the smoking article pack blank is erected it is much by preference that the longitudinal margins of the side panels from which margins the side flaps depend form longitudinally extending hinge lines in each of the side walls of the erected blank. The longitudinal margins of the overlapping side panels adjacent the longitudinally extending hinge lines allow the erected blank to hinge thereabout. 
     In the second embodiment of the present invention the smoking article pack blank base portion further comprises a second line of weakening, which second line of weakening extends longitudinally from the top margin of the second main panel to the bottom margin of the second main panel. 
     Preferably the second line of weakening extends longitudinally in substantially parallel relation to the longitudinal side margins of the second main panel of the smoking article pack blank. In addition, the second line of weakening extends across the bottom margin of the second main panel, into the bottom panel of the smoking article pack blank. Preferably the bottom margin of the second main panel has a line of weakening thereacross. It is much by preference that the second line of weakening extends up to but does not intersect with, or extend beyond, the line of weakening extending transversely across the bottom panel of the bottom panel. Preferably the second line of weakening is located along the central longitudinal axis of the second main panel and the bottom panel of the blank. 
     Preferably the second line of weakening is a line of perforation. 
     It will be understood that in an alternative arrangement of the second embodiment of the present invention, the second line of weakening could alternatively be a line of integration. 
     It will be apparent to the skilled artisan that the second embodiment of the present invention may equally comprise a line of weakening and a line of integration in combination. For example, the second line of weakening may be replaced by a line of integration whilst there remains a line of weakening in the bottom panel of the smoking article pack blank. Likewise the line of weakening in the bottom panel of the smoking article pack blank may be replaced by a line of integration whilst the pack blank further comprises a second line of weakening. 
     In the alternative arrangement of the second embodiment of the present invention the second line of integration separates the second main panel of the smoking article pack blank into two second main panel sections. Preferably the two second main panel sections are separable from one another line the line of integration. It will be understood the separation of the two second main panel sections along the line of integration may be by cutting, for example, along the line of integration. 
     The present invention may further provide a smoking article pack assembly comprising plurality of inner blanks, which inner blanks may be used in combination with a smoking article pack blank of the present invention. When erected, each inner blank is capable of enwrapping a bundle of smoking articles. 
     Preferably the inner blanks are formed separately from the smoking article pack blank of the present invention. Alternatively, the inner blanks may be formed as an integral part with the smoking article pack blank. 
     It is much by preference that an inner blank comprises at least one main panel. More preferably the inner blank comprises two main panels. Advantageously the two main panels of the inner blank are interconnected by a bottom panel. 
     It is much by preference that at least one of the main panels of the inner blank has a cut-out portion in a top margin thereof. Preferably the cut-out portion is of a depth which allows access to, and easy removal of, smoking articles held within the inner blank when the inner blank is erected. 
     When the smoking article pack blank is assembled about a plurality of inner blanks, one main panel of each of the inner blanks is fixed to a main panel of the smoking article pack blank, the other main panel of each of the inner blanks is exposed when the line(s) of weakening and/or the line of integration of the smoking article pack blank is broken and/or cut and the smoking article pack blank is opened about a hinge line in the side wall thereof. 
     The assembled smoking article pack is retained in a closed position until first opening by the consumer by means of the lid portion and the unbroken line(s) of weakening of the assembled smoking article pack blank. Once the consumer has broken the line(s) of weakening on first opening of the assembled pack, the pack may be re-closed by means of the lid portion of the assembled smoking article pack blank. 
     Alternatively the line of weakening and/or line of integration may be broken or cut before the erected pack has reached the consumer. 
     It will be readily understood by a person skilled in the art that in the second embodiment of the present invention, the erected smoking article pack blank comprises two longitudinally extending hinge lines in the side walls thereof. It will be further understood that the second embodiment of the present invention provides a smoking article pack blank comprising two lines of weakening, one of which lines of weakening extends transversely across the bottom panel of the smoking article pack blank between the longitudinal margins thereof, the other line of weakening extends longitudinally between the top margin of the second main panel of the smoking article pack blank and the first line of weakening in the bottom panel of the smoking article pack blank. 
     The blank of the present invention may be utilised in forming packs of varying dimensions and shapes. The present invention may, for example, provide blanks with square, round or bevelled longitudinal margins. Furthermore the present invention may be utilised, for example, in forming packs having the dimensions known in the art as International, King Size, SuperKing or Jumbo Carton. Preferably the smoking article pack blank of the present invention may be erected to form a hinged-lid pack. The present invention may also be used in combination with the inventive concept disclosed in our co-pending patent application WO 03/078724. 
     A smoking article pack assembled from the outer and inner blanks of the present invention may be overwrapped with, for example, a cellophane wrapper. It is much by preference that the cellophane wrapper has a tear strip for easy removal thereof by the consumer. Advantageously the tear strip is located such that the consumer must remove the entire cellophane wrapper in order to gain access to the pack and the smoking articles contained therein. The tear strip may, for example, be located about the lid portion of the assembled pack. Alternatively the tear strip may be located in longitudinal orientation about the assembled pack. 
     The present invention further provides a method of assembly of a smoking article pack, which smoking article pack is assembled from an outer smoking article pack blank of the present invention and a plurality of inner blanks, the method of assembly comprising wrapping a bundle of smoking articles in a wrapper, feeding an inner blank to a pack assembly machine, partially erecting the inner blank, plunging the wrapped bundle of smoking articles into the partially erected inner blank, completely erecting the inner blank about the wrapped bundle of smoking articles, feeding an outer blank to the pack assembly machine, which outer blank is partially erected before two or more erected inner blanks are plunged into the outer blank, and completely erecting the outer blank about the inner blanks. 
     Preferably the method of assembly may be performed using one or more pack assembly machines. Most preferably the method of assembly requires one pack assembly machine. 
     Preferably the smoking article pack is assembled from an outer smoking article pack blank of the present invention in combination with inner blanks of the present invention. 
    
    
     
       In order that the present invention be easily understood and readily carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which: 
         FIG. 1  shows a smoking article pack outer blank according to one embodiment of the present invention; 
         FIG. 2  shows an inner blank to be used in combination with the outer blank of  FIG. 1 ; 
         FIG. 3  shows a second inner blank to be used in combination with the outer blank of  FIG. 1  and the inner blank of  FIG. 2 ; 
         FIG. 4  shows an outer smoking article pack blank according to a second embodiment of the present invention; 
         FIG. 5  shows an inner blank to be used in combination with the outer blank of  FIG. 4 ; 
         FIG. 6  shows a second inner blank to be used in combination with the outer blank of  FIG. 4  and the inner blank of  FIG. 5 ; 
         FIG. 7  shows a further inner blank to be used in combination with the outer blank of  FIG. 4  and the inner blanks of  FIG. 5 and 6 ; 
         FIG. 8  shows an alternative arrangement of the inner blank of  FIG. 2 ; 
     
    
    
     Features common to more than one Figure will be denoted by the same reference numeral. 
       FIG. 1  shows an outer blank  1  according to one embodiment of the present invention. Outer blank  1  has a lid portion  2  and a base portion  3 . The lid portion  2 , comprises a front panel  4 , a back panel  5 , a top panel  6  and a front inner panel  7 . Each of the panels  4 ,  5 ,  6  and  7  has a top margin  8 ,  9 ,  10 ,  11  respectively. In the embodiment of the present invention shown in  FIG. 1 , top margins  8 ,  9 , and  10  also form the bottom margins of the front inner panel  7 , the top panel  6  and the front panel  4  respectively. 
     The lid portion  2  further comprises longitudinal margins  12  and  13  from which margins depend side panels  14  and  15  respectively. Back panel  5  has longitudinal margins  16  and  17 . Inner side panels  18  and  19  depend from the back panel longitudinal margins  16  and  17 . The inner side panels  18  and  19  have top margins  20  and  21  respectively, which top margins form the bottom margins of inner top panels  22  and  23 . 
     Outer blank base portion  3  has a first main panel  24 , a second main panel  25  and a bottom panel  26   a ,  26   b . The base first main panel  24  is interconnected with lid back panel  5  along hinge line  27 . The first main panel of the base portion is connected to the bottom panel  26   a ,  26   b  along margin  28  and the bottom panel  26   a ,  26   b  is further connected to the second main panel along margin  29 . 
     The outer blank second main panel  25  has longitudinal margins  30  and  31  from which margins depend side panels  32  and  33  respectively. Side flap  35  depends from the outer longitudinal margin  34  of side panel  33 . In an alternative arrangement, side flap  35  may depend from the outer longitudinal margin  41  of side panel  32 . 
     The first main panel  24  has longitudinal margins  36  and  37 . Side panels  38  and  39  depend from longitudinal margins  36  and  37  respectively. 
     Bottom panel  26  has a line of perforation  40  extending between longitudinal margins  42  and  43  thereof. 
     When the outer blank  1  is erected, side flap  35  lies against the inner face of side panel  39 . Alternatively, side flap  35  may lie against the outer face of side panel  39 . Side flap  35  is then fixed in position, for example by gluing, to side panel  39 . Longitudinal margin  34  then forms a hinge line thus allowing the erected outer blank  1  to hinge about that hinge line. The sum of the widths of side panels  32  and  38 , including scoring (if present), is equal to the depth of the erected outer blank. The sum of the widths of side panels  32  and  38 , including scoring (if present), is equal to the length of each of the bottom panel longitudinal margins  42  and  43 . The length of longitudinal margins  42  and  43  is equal to a multiple of the diameter of a smoking article, unless the smoking articles are in nested arrangement when the length of each of the longitudinal margins  42  and  43  will be slightly less than a multiple of the diameter of a smoking article. 
     The width of each of side panels  32  and  33 , including scoring (if present), is equal to the length of the longitudinal margin of bottom panel portion  26   a . The width of each of side panels  38  and  39 , including scoring (if present), is equal to the length of the longitudinal margin of bottom panel portion  26   b.    
       FIG. 1  shows an outer blank  1  having round longitudinal margins. Outer blank  1  may alternatively have square or bevelled longitudinal margins. 
     The outer blank  1  shown in  FIG. 1  may be used in combination with the inner blanks shown in  FIGS. 2 and 3 . In  FIG. 2 , inner blank  44  comprises main panels  45  and  46  and a bottom panel  47 . Main panel  45  is connected to bottom panel  47  along margin  48 . Main panel  46  is connected to bottom panel  47  along margin  49 . The inner blank  44  further comprises side panels  50 ,  51 ,  52  and  53 , the side panels depending from the longitudinal margins  54 ,  55 ,  56  and  57  of the main panels  45  and  46  respectively. The inner blank has lugs  58  and  59 , which lugs retain the lid portion  2  of outer blank lin a closed position when the pack is fully erected. Inner blank  44  has cut-out sections  60  and  61 . Cut-out section  60  allows the consumer access to the smoking articles retained by the erected inner blank. 
     Inner blank  44  is positioned within outer blank  1  such that the main panel  45  of inner blank  44  lies against the inner surface of the second main panel  25  of the outer blank  1 . The inner blank  44  may then be fixed in place, for example, by gluing. It is preferable that inner blank  44  should be erected and filled with smoking articles before being fixed to outer blank  1 . 
       FIG. 3  shows a second inner blank  62  for use in combination with the outer blank  1  of  FIG. 1  and the inner blank  44  of  FIG. 2 . Second inner blank  62  has main panels  63  and  64 , and a bottom panel  65 . Main panels  63  and  64  have side panels  66 ,  67 ,  68  and  69 , which side panels depend from longitudinal margins  70 ,  71 ,  72  and  73  respectively. Main panel  64  is connected to bottom panel  65  along margin  74  and main panel  63  is connected to bottom panel  65  along margin  75 . 
     Cut-out sections  76  and  77  are provided in the top margins  78  and  79  of main panels  64  and  63 . 
     When erected, inner blank  62  enwraps a bundle of smoking articles, inner blank  62  is then placed onto outer blank  1  such that main panel  64  lies against the inner surface of the outer blank first main panel  24 . Outer blank  1  is then erected about inner blanks  44  and  62 . 
     The smoking article pack formed when the outer and inner blanks are erected may then be wrapped in an outer wrapper, for example cellophane. A tear-strip is then provided to allow the consumer to remove the outer wrapper from the assembled pack. The line of perforation  40  is then broken there along and the lid hinged along hinge line  27 , therefore providing access to the outer surfaces of panels  46  and  63 . Panels  46  and  63  may be used to provide information to the consumer. Alternatively, panels  46  and  63  may be printed with graphics and/or indicia, the surfaces being visible to the consumer when the erected pack is in an open position. 
       FIG. 4  shows an alternative outer blank  81  according to a second embodiment of the present invention. The outer blank  81  of the second embodiment has all the features of the outer blank  1  of  FIG. 1 . The outer blank  81  of  FIG. 4  has an additional side flap  80  depending from longitudinal margin  41  of side panel  32 . Thus the outer blank  81  of  FIG. 4  has two side flaps depending from the longitudinal margins of side panels  32  and  33 . A line of perforation  82  extends longitudinally from the top margin  83  of second main panel  25 , across margin  29  into bottom panel  26 . The line of perforation  82  extends to, but not beyond, line of perforation  40 . 
     When the outer blank  81  is erected, side flaps  80  and  35  lie against the inner surface of side panels  38  and  39  and are fixed thereto, for example by gluing. When lines of perforation  82  and  40  are broken, the outer blank is free to hinge about the two side hinge lines formed along longitudinal margins  34  and  41 . In an alternative arrangement, side flaps  80  and  35  may lie against the outer surface of side panels  38  and  39  when outer blank  81  is erected. 
       FIGS. 5 ,  6  and  7  show inner blanks suitable for use in combination with the outer blank  1  of  FIG. 4 . 
       FIG. 5  shows an inner blank  84 , comprising main panels  85  and  86 , and a bottom panel  87 . Main panel  85  has side panels  88  and  89 , which side panels ( 88 ,  89 ) depend from longitudinal margins  90  and  91  respectively. 
     Main panel  86  has side panels  92  and  93 , which side panels ( 92 ,  93 ) depend from longitudinal margins  94  and  95 . 
       FIG. 6  shows a further inner blank  96 , comprising main panels  97  and  98 , and a bottom panel  99 . Main panel  97  has side panels  100  and  101  depending from longitudinal margins  102  and  103  respectively. 
     Main panel  98  has side panels  104  and  105 , which side panels have longitudinal margins  106  and  107  from which margins side panels  104  and  105  depend. 
       FIG. 7  shows a further inner blank  108 , comprising main panels  109  and  110 , and bottom panel  111 . Main panel  109  has side panels  112  and  113  depending from longitudinal margins  114  and  115 . 
     Main panel  110  has side panels  116  and  117 , depending from longitudinal margins  118  and  119  respectively. 
     When assembling a smoking article pack from the outer blank  81  of  FIG. 4  and the inner blanks of  FIG. 5 ,  6  and  7 , main panel  109  of inner blank  108  is fixed, for example by gluing, to first main panel  24  of outer blank  81 . Side panels  112  and  113  are secured by gluing to the inner surfaces of side panels  38  and  39  of outer blank  81 . 
     Main panel  98  of inner blank  96  is secured to the inner surface of a first portion  25   a  of the second main panel of outer blank  81 . Side panel  104  of inner blank  96  is secured to the inner surface of side panel  32  of outer blank  81 . 
     Main panel  86  of inner blank  84 , is secured to the inner surface of a second portion  25   b  of the second main panel of outer blank  81 . Side panel  93  of inner blank  84  is secured to the inner surface of side panel  35  of outer blank  81 . 
     The outer blank  81  and inner blanks  84 ,  96  and  108  may then be fully assembled to form a smoking article pack. The smoking article pack may then be overwrapped, for example, by cellophane. 
     It is much by preference that the inner blanks are assembled about bundles of smoking articles before assembly of the outer blank about the inner blanks. 
       FIG. 8  shows an alternative arrangement of the inner blank of  FIG. 2 . Cut-out portion  60  is of a lesser depth dimension than the corresponding cut-out portion  60  of the inner blank of  FIG. 2 . It will be apparent to a person skilled in the art that when the outer blank  1  of  FIG. 1  is assembled about the inner blanks shown in  FIGS. 3 and 8 , access to the smoking articles within the assembled pack is initially restricted until the line of perforation  40  of the outer blank  1  is broken and the pack assembly is hinged open about line  34 . 
     The outer and inner blanks represented in the aforegoing Figures may have round, square or bevelled longitudinal margins. The blanks may also be of dimensions suitable for any size of smoking article pack or carton. The outer and inner blanks of the present invention, when used in combination in assembling a smoking article pack, should be suitably dimensioned such that the outer blank may be assembled about a plurality of inner blanks.