Patent Publication Number: US-9403638-B2

Title: Rigid swing-open packet of cigarettes with a self-opening hinged lid, and relative production method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is the U.S. national phase of PCT/IB2012/052366, filed May 11, 2012. 
     TECHNICAL FIELD 
     The present invention relates to a rigid, swing-open packet of cigarettes, and relative production method. 
     BACKGROUND ART 
     Rigid, hinged-lid packets of cigarettes are currently the most widely marketed, by being easy to produce and easy and practical to use, and by effectively protecting the cigarettes inside. 
     In addition, rigid, slide- or swing-open packets of cigarettes have been proposed comprising two containers, one inserted inside and partly extractable from the other, i.e. an inner container containing a group of cigarettes and housed inside an outer container to move, with respect to the outer container, between a closed position inserted inside the outer container, and an open position extracted from the outer container. The movement of the inner container with respect to the outer container may be linear (slide-open) or rotary (swing-open) about a hinge connecting the two containers. 
     Embodiments of rigid, slide-open packets of cigarettes are described in FR2499947A3, U.S. Pat. No. 4,534,463A and U.S. Pat. No. 5,080,227A, and two embodiments of rigid, swing-open packets of cigarettes in WO03053818A1 and WO2006021581A1. 
     Patent EP2017198B1 describes a rigid, swing-open packet of cigarettes comprising: two inner packages, each containing a wrapped group of cigarettes; two inner containers, each housing a respective inner package and having a hinged lid; an outer container housing the two inner containers and having two opposite open lateral ends; and two hinges, each connecting an inner container to the outer container to allow the inner container to rotate between a closed position inserted inside the outer container, and an open position at least partly extracted from the outer container. The lid of each inner container has a control system, which connects the lid to the outer container to open the lid ‘automatically’ (i.e. without the user having to touch the lid) by exploiting the relative movement between the inner container and outer container. Each control system comprises a control tab extending inwards of the outer container from a top-wall edge of the outer container; and a slit formed through the top wall of the lid and engaged by the control tab. 
     The lid control system described in Patent EP2017198B1, however, has several drawbacks: when the inner container is in the closed position, the top wall of the lid must be kept well clear of the top wall of the outer container, thus preventing optimum use of the volume of the outer container, by having to leave a fairly large empty (i.e. unused) space at the top of the outer container. 
     DESCRIPTION OF THE INVENTION 
     It is an object of the present invention to provide a rigid, swing-open packet of cigarettes and relative production method, designed to eliminate the above drawbacks, and which, in particular, are cheap and easy to implement. 
     According to the present invention, there are provided a rigid, swing-open packet of cigarettes and relative production method, as claimed in the accompanying Claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A number of non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying drawings, in which: 
         FIG. 1  shows a view in perspective of a rigid, swing-open packet of cigarettes in accordance with the present invention and in the fully-closed position; 
         FIG. 2  shows a view in perspective of the  FIG. 1  packet of cigarettes in the fully-open position; 
         FIG. 3  shows a schematic front view of the  FIG. 1  packet of cigarettes in a partly open position; 
         FIGS. 4, 5 and 6  show schematic front views, with parts removed for clarity, of a top portion of the  FIG. 1  packet of cigarettes at successive stages in opening an inner container lid; 
         FIG. 7  shows a plan view of a blank from which to form an inner container of the  FIG. 1  packet of cigarettes; 
         FIG. 8  shows a plan view of a blank from which to form an outer container of the  FIG. 1  packet of cigarettes; 
         FIGS. 9, 10 and 11  show schematic front views, with parts removed for clarity, of a top portion of an alternative embodiment of the  FIG. 1  packet of cigarettes at successive stages in opening an inner container lid; 
         FIG. 12  shows a plan view of a blank from which to form an outer container of the  FIG. 9, 10, 11  packet of cigarettes; 
         FIGS. 13 and 14  show two production stages, in which a connecting tab is applied to the containers of the  FIG. 9, 10, 11  packet of cigarettes. 
     
    
    
     PREFERRED EMBODIMENTS OF THE INVENTION 
     Number  1  in  FIGS. 1-3  indicates as a whole a rigid, swing-open packet of cigarettes. 
     The packet  1  of cigarettes in  FIGS. 1-3  comprises two inner packages  2  ( FIG. 2 ); two rigid, parallelepiped-shaped inner containers  3 , each housing an inner package  2 ; and a rigid, parallelepiped-shaped outer container  4  housing inner containers  3 . Each inner package  2  comprises a group of cigarettes arranged in a number of rows; and a sheet of foil wrap wrapped about and fully enclosing the group of cigarettes. Each inner container  3  is hinged to outer container  4  to rotate, with respect to outer container  4 , between a closed position ( FIG. 1 ) fully inserted inside outer container  4 , and an open position ( FIG. 2 ) partly extracted from outer container  4  for access to inner package  2 . 
     Each inner container  3  is in the form of a cup-shaped parallelepiped, and comprises an open top end  5  for access to inner package  2 ; a bottom wall  6  opposite open top end  5 ; a front wall  7 ; a rear wall  8  opposite and parallel to front wall  7 ; and two opposite parallel lateral walls  9 . 
     Outer container  4  is also parallelepiped-shaped, and comprises a top wall  10 ; a bottom wall  11  opposite and parallel to top wall  10 ; two opposite parallel lateral walls  12 ; and two opposite open lateral ends  13 , through which respective inner containers  3  are extracted/inserted from/into outer container  4  into the open/closed position. 
     Each inner container  3  is hinged to outer container  4  by a hinge  14  located close to an edge of bottom wall  6  of inner container  3  and an edge of bottom wall  11  of outer container  4 , at an open lateral end  13  of outer container  4 . More specifically, each hinge  14  is located a given distance from an edge of bottom wall  6  of inner container  3  and an edge of bottom wall  11  of outer container  4 , at an open lateral end  13  of outer container  4 , i.e. is located a given distance from a bottom transverse edge of inner container  3  and a bottom transverse edge of outer container  4 . 
     In a preferred embodiment, rear wall  8  of each inner container  3  is lower than front wall  7 , so that, in the closed position, front wall  7  closes the respective open lateral end  13  of outer container  4  completely, and rear wall  8  does not impede rotation about hinge  14  of inner container  3  with respect to outer container  4  by interfering with top wall  10  of outer container  4 . Also, the top portions of lateral walls  9  of each inner container  3  are shaped to connect front wall  7  to rear wall  8  smoothly and compensate for the difference in height. 
     Packet  1  of cigarettes has stops for limiting withdrawal, and preventing detachment, of each inner container  3  from outer container  4 , and which, for each inner container  3 , comprise two retaining tabs  15  projecting outwards of inner container  3  from lateral walls  9  and located close to rear wall  8  of inner container  3 ; and two retaining pockets  16  projecting inwards of outer container  4  from lateral walls  12  and located close to open lateral end  13  of outer container  4 . In actual use, when inner container  3  is rotated with respect to outer container  4  about hinge  14  into the open position, each retaining tab  15  slides inside a respective retaining pocket  16  to arrest withdrawal of inner container  3 . 
     To extract an inner container  3 , the user of packet  1  of cigarettes must move inner container  3  with respect to outer container  4  by gripping outer container  4  with one hand, and inner container  3  with the other. As shown in  FIGS. 1 and 2 , for easy grip of inner containers  3 , each lateral wall  12  of outer container  4  has a recess close to each open lateral end  13 , to allow the user to grip and exert pull on lateral walls  9  of each inner container  3 . 
     In the  FIG. 1-3  embodiment, packet  1  of cigarettes comprises two inner containers  3 , each housed inside and hinged to outer container  4  by a hinge  14  to rotate between the Open and closed positions. In a different embodiment not shown, packet  1  of cigarettes comprises one inner container  3  housed inside and hinged to outer container  4  by a hinge  14  to rotate between the open and closed positions. In this case, outer container  4  is half the size of outer container  4  in the  FIG. 1-3  embodiment, and one of the two open lateral ends  13  of the  FIG. 1-3  outer container  4  is closed by a further lateral wall. 
     As shown in  FIGS. 2 and 3 , each inner container  3  comprises a lid  29  hinged to inner container  3  by a hinge  30  to rotate with respect to inner container  3  between an open position opening open top end  5 , and a closed position closing open top end  5 . 
     Each lid  29  comprises a rectangular top wall  31 , which is opposite and parallel to bottom wall  6  of inner container  3  when lid  29  is closed; a rectangular rear wall  32 , which forms an extension of rear wall  8  of inner container  3  when lid  29  is closed; and two triangular lateral walls  33 , which form extensions of lateral walls  9  of inner container  3  when lid  29  is closed. Hinge  30  of each lid  29  connects a top edge of rear wall  8  of inner container  3  to a bottom edge of rear wall  32  of lid  29 . 
     As shown in  FIGS. 4, 5 and 6 , each lid  29  has a control tab  34  connecting it to outer container  4  so that the movement of inner container  3  with respect to outer container  4  also moves lid  29 , without the user having to act directly on lid  29 . By virtue of respective control (or connecting) tab  34 , each lid  29  therefore opens ‘automatically’, when respective inner container  3  is extracted, without the user having to act directly on lid  29 . 
     Each control tab  34  has a top end  35  permanently integral with top wall  10  of outer container  4 ; and a bottom end  36  opposite top end  35  and permanently integral with top wall  31  of lid  29  of corresponding inner container  3 . Each control tab  34  folds up (as shown in  FIG. 4 ) when the corresponding inner container  3  is in the closed position inserted inside outer container  4 , and unfolds (as shown in  FIG. 6 ) when the corresponding inner container  3  is in the open position, partly extracted from outer container  4 . In a preferred embodiment, the bottom end  36  of each control tab  34  is glued to top wall  31  of lid  29 , whereas the top end  35  of each control tab  34  may be connected to top wall  10  of outer container  4  along a fold line  37  (as shown in  FIGS. 4, 5 and 6 ) or glued to top wall  10  of outer container  4  (as shown in  FIGS. 9, 10 and 11 ). 
     In the  FIGS. 4, 5 and 6  embodiment, the top end  35  of each control tab  34  is connected to top wall  10  of outer container  4  along fold line  37 . More specifically, the top end  35  of each control tab  34  is connected along fold line  37  to a corresponding reinforcing tab  27  for reinforcing top wall  10  of outer container  4  (as explained in detail below, top wall  10  of outer container  4  comprises a panel  10 ′, and two reinforcing tabs  27  glued to the inside of panel  10 ′). 
     In the  FIGS. 4, 5 and 6  embodiment, each control tab  34  has two fold lines  38  and  39  located a given distance apart, between top end  35  and bottom end  36 , to allow control tab  34  to fold into an ‘L’ about top wall  31  and rear wall  32  of lid  29  when the corresponding inner container  3  is in the closed position ( FIG. 4 ) inserted inside outer container  4 . 
     As shown in  FIG. 7 , each inner container  3  is formed by folding a flat, substantially elongated rectangular inner blank  17 , the parts of which are indicated, where possible, using the same reference numbers, with superscripts, as for the corresponding parts of inner container  3 . 
     Inner blank  17  has two longitudinal fold lines  18 , and a number of transverse fold lines  19  which define, between longitudinal fold lines  18 , a panel  8 ′ forming rear wall  8 ; a panel  6 ′ forming bottom wall  6 ; and a panel  7 ′ forming front wall  7 . 
     Panel  7 ′ has a reinforcing flap  20  connected to panel  7 ′ along a transverse fold line  19 , and which is folded 180° onto panel  7 ′ to reinforce the top of front wall  7 . 
     Panel  8 ′ has two lateral wings  9 ′, which form respective inner portions of lateral walls  9 , are located on opposite sides of panel  8 ′, and are separated from panel  8 ′ by longitudinal fold lines  18 . Panel  7 ′ has two lateral wings  9 ″, which form respective outer portions of lateral walls  9 , are located on opposite sides of panel  7 ′, and are separated from panel  7 ′ by longitudinal fold lines  18 . Each lateral wing  9 ′ of panel  8 ′ has a tab  21  separated from lateral wing  9 ′ by a transverse fold line  19 , and which is folded 90° with respect to lateral wing  9 ′ and fixed to an inner surface of panel  6 ′. A window  22 , containing a respective retaining tab  15 , is formed in each lateral wing  9 ′; and each lateral wing  9 ″ has a recess  23  designed to overlap a respective retaining tab  15 . 
     Inner blank  17  also comprises a panel  32 ′, which forms rear wall  32  of lid  29  and is connected to panel  8 ′ along hinge  30 ; a panel  31 ′, which forms top wall  31  of lid  29 ; and two lateral wings  33 ′ forming lateral walls  33  of lid  29 , and each of which has a tab  31 ″, which is folded 90° with respect to lateral wings  33 ′ and fixed to an inner surface of panel  31 ′. 
     As shown in  FIG. 8 , outer container  4  is formed by folding a flat, substantially elongated rectangular outer blank  24 , the parts of which are indicated, where possible, using the same reference numbers, with superscripts, as for the corresponding parts of outer container  4 . 
     Blank  24  has two longitudinal fold lines  25 , and a number of transverse fold lines  26  which define, between longitudinal fold lines  25 , a panel  11 ′ forming an inner portion of bottom wall  11 ; a panel  12 ′ forming one lateral wall  12 ; a panel  10 ′ forming top wall  10 ; a panel  12 ″ forming the other lateral wall  12 ; and a panel  11 ″ forming an outer portion of bottom wall  11 . 
     Panel  10 ′ has two reinforcing tabs  27 , which are located on opposite sides of panel  10 ′, are separated from panel  10 ′ by longitudinal fold lines  25 , and are folded 180° and glued onto panel  10 ′ to reinforce top wall  10 . 
     Panels  12 ′ and  12 ″ each have two retaining pockets  16 , which are located on opposite sides of panel  12 ′,  12 ″, are separated from panel  12 ′,  12 ″ by longitudinal fold lines  25 , and are folded 180° and glued onto panel  12 ′,  12 ″. 
     Panel  11 ′ has two connecting tabs  28 , which are located on opposite sides of panel  11 ′, are separated from panel  11 ′ by longitudinal fold lines  25 , are folded 180° onto panel  11 ′, and are each glued to bottom wall  6  of a respective inner container  3  to hinge inner container  3  to outer container  4 . 
     In the  FIGS. 4, 5 and 6  embodiment, the top end  35  of each control tab  34  is connected to top wall  10  (or, rather, to reinforcing tab  27  of top wall  10 ) of outer container  4  along fold line  37 , so control tabs  34  form an integral part of and are made of the same material as outer blank  24  (and therefore outer container  4 ). 
     One advantage of the  FIGS. 4, 5 and 6  embodiment is that, in the closed position ( FIG. 4 ), the part of each control tab  34  on rear wall  32  of corresponding lid  29  is located between the two inner containers  3  (or, rather, between lids  29  of the two inner containers  3 ), thus keeping inner containers  3  a given distance apart, which has the advantage of keeping inner containers  3  in the correct position, i.e. preventing them from opening slightly, in the closed position. 
     In the alternative embodiment in  FIGS. 9, 10 and 11 , each control tab  34  is initially separate from top wall  10  of outer container  4 , and is simply glued to top wall  10  (or, rather, to the corresponding reinforcing tab  27  of top wall  10 ) of outer container  4 . In this embodiment, when inner container  3  is in the closed position ( FIG. 9 ) inserted inside outer container  4 , control tab  34  folds up into a ‘Z’ and is located entirely between top wall  31  of lid  29  and top wall  10  of outer container  4 . In a preferred embodiment, each control tab  34  is made of highly flexible, deformable plastic material, which can be folded, even 180°, repeatedly with no significant damage (i.e. fatigue failure). In other words, each control tab  34  comprises a strip of plastic material glued on one side (at top end  35 ) to top wall  10  of outer container  4 , and on the opposite side (at bottom end  36 ) to top wall  31  of corresponding lid  29 . Obviously, each control tab  34  may also be made of paper or multilayer material, e.g. comprising plastic and paper. 
     In the  FIGS. 9, 10 and 11  embodiment, the two control tabs  34  may be joined at top ends  35  (as shown in  FIGS. 13 and 14 ) into one piece (one strip of material). 
     Compared with the  FIGS. 4, 5 and 6  embodiment (i.e. in which each control tab  34  forms an integral part of outer blank  24  of outer container  4 ), the  FIGS. 9, 10 and 11  embodiment (i.e. in which each control tab  34  is made of plastic material and initially separate from outer blank  24  of outer container  4 ) has the main advantage of greatly reducing the width of outer blank  24  (as shown by comparing the outer blanks  24  in  FIGS. 8 and 12 ), thus greatly reducing the amount of wastage, and therefore packing material cost, involved in producing outer blanks  24 . The  FIGS. 9, 10 and 11  embodiment also has the advantage of enabling each control tab  34  to be made from a different material from outer blank  24  of outer container  4  (i.e. a material specially designed for the function of the control tab). In this connection, it is important to bear in mind that each control tab  34  is normally much thinner than the material of containers  3  and  4  (i.e. of blanks  17  and  24 ). 
     It is important to note that, in all the embodiments described, control tabs  34  serve solely to open lid  29  ‘automatically’, and withdrawal of inner containers  3  from outer container  4  is limited (arrested) solely by the stops (i.e. by retaining tabs engaging retaining pockets  16 ). Consequently, each control tab  34  is designed to only unfold completely if the corresponding inner container  3  exceeds the limit posed by the stops. By virtue of the stops, each control tab  34  therefore never unfolds completely, never limits the withdrawal movement of corresponding inner container  3 , and therefore never runs any risk of tearing. 
     Packet  1  of cigarettes described has numerous advantages. 
     In particular, it enables optimum use of the inner volume of outer container  4 , by the design of control tab  34  allowing the top wall  31  of lid  29  to be positioned extremely close to top wall  10  of outer container  4  when inner container  3  is in the closed position. In the  FIGS. 4, 5 and 6  embodiment, each control tab  34  is relatively thick, but, in the closed position ( FIG. 4 ), large part of control tab  34  is located ‘behind’ lid  29  (i.e. rests on rear wall  32  of lid  29 ) as opposed to ‘on top’ of lid  29  (i.e. between top wall  31  of lid  29  and top wall  10  of outer container  4 ). In the  FIGS. 9, 10 and 11  embodiment, each control tab  34  is very thin (i.e. much thinner than the material of containers  3  and  4 ), by being made of plastic material specially designed to connect top wall  31  of lid  29  to top wall  10  of outer container  4 . 
     Packet  1  of cigarettes described is also cheap and easy to produce, by involving only a few minor alterations to a similar standard packet of cigarettes. 
     A method of producing the above packet  1  of cigarettes will now be described with reference to  FIGS. 13 and 14 . 
     The method comprises forming the two inner packages  2 ; depositing each inner package  2  on a corresponding inner blank  17 ; folding each inner blank  17  about inner package  2  to form the corresponding inner container  3 ; depositing the two inner containers  3  on outer blank  24 ; and folding outer blank  24  about inner containers  3  to form outer container  4 . 
     As shown in  FIG. 13 , the two control tabs  34  are joined at top ends  35 , which are therefore both glued by glue  40  to panel  10 ′ of outer blank  24  (forming top wall  10  of outer container  4 ) or to reinforcing tabs  27  of panel  10 ′ before depositing inner containers  3  on outer blank  24 . Next, as shown in  FIG. 14 , the bottom end  36  of each control tab  34  is glued by glue  41  to top wall  31  of lid  29  of corresponding inner container  3  when depositing inner container  3  on outer blank  24 . 
     As shown in  FIG. 13 , the top ends  35  of control tabs  34  are glued simultaneously by glue  40  to respective reinforcing tabs  27  of panel  10 ′ of outer blank  24 , with control tabs  34  fully unfolded. As shown in  FIG. 14 , each inner container  3  is then deposited on the partly prefolded outer blank  24 , in a position at least partly outside (alongside) outer blank  24  (i.e. inner container  3 , as opposed to resting completely on outer blank  24 , is positioned alongside, possibly slightly overlapping, outer blank  24 ) so as to glue top wall  31  of lid  29  to bottom end  36  of control tab  34  while control tab  34  is unfolded. 
     Finally, each inner container  3  is moved (translated) with respect to outer blank  24  to rest completely on outer blank  24  (i.e. is moved into a position corresponding to the closed position, in which inner container  3  is inserted inside outer container  4 ) and so fold up control tab  34  (from the  FIG. 14  position, the two inner containers  3  are pushed one against the other, inwards of outer blank  24 ). 
     Once the two inner containers  3  are pushed inwards of outer blank  24  (i.e. into the position corresponding to the closed position), outer blank  24  is folded about inner containers  3  to complete packet  1  of cigarettes. 
     As shown in  FIG. 13 , panel  10 ′ (together with panels  12 ′ and  11 ′) is folded 90° with respect to panel  12 ″ about a corresponding transverse fold line  26  before depositing the two inner containers  3  on outer blank  24 ; and the top ends  35  of the two control tabs  34  are preferably glued to reinforcing tabs  27  of panel  10 ′ of outer blank  24  before folding panel  10 ′ (together with panels  12 ′ and  11 ′) 90° with respect to panel  12 ″. 
     Glue  40  and/or  41  may be applied ‘fresh’ just before use (i.e. just before end  35  or  36  of control tab  34  is applied to reinforcing tab  27  of panel  10 ′ or to top wall  31  of lid  29 ), or may be applied in advance (even well in advance), allowed to dry completely before use, and heat-activated when needed (i.e. after applying end  35  or  36  of control tab  34  to reinforcing tab  27  of panel  10 ′ or to top wall  31  of lid  29 ). 
     The above method has numerous advantages. 
     In particular, it provides for producing packets  1  of cigarettes quickly and accurately. 
     Also, it is cheap and easy to implement, even on existing packing machines, with only a few minor alterations.