Patent Abstract:
Systems and methods are provided for making a hard pack cigarette package composed of a transparent material that includes an inner frame that is also composed of a transparent material. The package is assembled using a hot-melt adhesive material to bind the package together as well as to bind the inner frame insert and a foil wrapped assemblage of smoking articles to the package. The hot-melt adhesive material is applied by an electronically controlled hot-melt adhesive applicator working in conjunction with a uniform contrast roller.

Full Description:
[0001]    This application is a divisional of U.S. patent application Ser. No. 12/101,529, filed Apr. 11, 2008, the disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to tobacco products, such as smoking articles, and in particular, to packages for containing tobacco products. 
         [0003]    Popular smoking articles, such as cigarettes, conventionally have been sold in packages. Typically, each full package contains about 20 cigarettes. Cigarettes have been packaged in containers known as so-called “soft-packs.” See, for example, U.S. Pat. Nos. 3,695,422 to Tripodi; 4,717,017 to Sprinkel, Jr., et al.; and, 5,333,729 to Wolfe; which are incorporated herein by reference. Cigarettes have also been packaged in containers known as so-called “hard-packs” or “crush proof boxes.” See, for example, U.S. Pat. Nos. 3,874,581 to Fox et al.; 3,944,066 to Niepmann; and, 4,852,734 to Allen et al.; which are all incorporated herein by reference. 
         [0004]    Various modifications have been proposed to the so-called “hard pack” cigarette package designs to enhance the consumer acceptance of the package. For example, it has been disclosed to round off the portions leading to the corners of the package to yield a “pillow-type” cigarette package, such has been disclosed in U.S. Pat. No. 6,694,708 to Brizzi et al. which is incorporated herein by reference. Alternatively, it has been disclosed to provide multiple methods of accessing the cigarettes. For example, U.S. Pat. Nos. 5,682,986 to Cobler, 5,139,140 to Burrows et al., and 5,248,031 to Burrows et al., which are herein incorporated by reference, disclose a removable portion of the lid of a hard-pack thereby providing for soft-pack style accessibility in addition to the hard-pack flip-top. In addition to these structural modifications, it is desirable to develop more attractive packaging for cigarettes. 
       SUMMARY 
       [0005]    Systems and methods for manufacturing at least partially transparent containers for smoking articles from materials not traditionally used in packaging smoking articles are provided. The invention may include any of the following aspects in various combinations and may also include any other aspect described below in the written description or in the attached drawings. 
         [0006]    One embodiment of the present invention relates to a system for manufacturing a container for smoking articles, such as cigarettes. This embodiment of the system includes a hopper that holds container blanks, a gear train that is coupled to and drives a feed belt, a hot-melt adhesive applicator, an encoder coupled with the gear train and configured to track the translational movement of the blanks through the system, an electronic blank sensor approximately opposite from the hot-melt adhesive applicator, and an electronic control unit in communication with the encoder, the electronic blank sensor, and the hot-melt adhesive applicator. In operation, the feed belt moves blanks from the hopper to the hot-melt adhesive applicator. As blanks enter the hot-melt adhesive applicator, the blank sensor signals the electronic control unit, which causes the hot-melt adhesive applicator to apply a pre-determined pattern of adhesive to the blank. After the hot-melt adhesive applicator glues the blank, the blank passes to a folding station which is configured to fold the blank into a container about an assemblage of smoking articles. 
         [0007]    One embodiment of a representative method of manufacturing a transparent or partially transparent container for smoking articles includes providing a blank of a transparent material, feeding the blank to a hot-melt adhesive applicator, applying hot-melt adhesive to selected portions of the blank, and folding the blank so that at least some of the selected portions are pressed against corresponding portions of the blank, to form a container with an interior volume for receiving smoking articles. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         [0008]    The invention may be more fully understood by reading the following description in conjunction with the drawings. 
           [0009]      FIG. 1  shows a front perspective view of an assembled package according to an embodiment of present invention. 
           [0010]      FIG. 2A  shows a plan view, looking at the inside surface, of an embodiment of a container blank that may be used in an embodiment of the present invention. 
           [0011]      FIG. 2B  shows a plan view, looking at the opposite surface, of the embodiment of the container blank shown in  FIG. 2A . 
           [0012]      FIG. 3  shows a plan view of an example of a prior art paperboard blank. 
           [0013]      FIG. 4  shows a plan view of an embodiment of an inner frame insert prior to assembly of the container. 
           [0014]      FIG. 5  shows a schematic representation of a blank passing through a cigarette packaging machine. 
           [0015]      FIG. 6  shows a side view of an adhesive applicator and mounting frame. 
           [0016]      FIG. 7  shows a front expanded view of a slider plate and depending portion of an adhesive applicator frame. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    For the sake of simplicity, the same reference number is used for any common part shown in any of the various figures throughout this Detailed Description. Referring to  FIG. 1 , there is shown a front perspective of various components of an assembled container  10  that is representative of one embodiment of the present invention. For clarity, a portion of the front wall  22  is shown cut away, as is a portion of the inner frame insert  60 . The container  10  includes an outer body portion  20  and a lid portion  40  and an inner frame insert  60 . The body portion  20  includes a front wall  22 , a back wall  24 , a right side wall  26  connecting the front wall  22  to the back wall  24 , a left sidewall  28  (visible in  FIG. 2A ) connecting the front wall  22  to the back wall  24 , and a bottom wall  32  that closes the opening formed by the front wall  22 , back wall  24 , right side wall  26  and left side wall  28 . The front wall  22 , back wall  24 , right side wall  26 , left side wall  28 , and bottom wall  32  together form a volume closed at one end and having a rectangular cross-section. The body  20  forms a top opening  30  opposite the bottom wall  32 . 
         [0018]    A lid  40  is formed having a front wall  42 , a back wall  44 , a right wall  46  that connects the front wall  42  and back wall  44 , and a left wall  48  (visible in  FIG. 2A ) that also connects the front wall  42  and the back wall  44 . The lid  40  defines a rectangular cross-section of similar size and shape to the cross-section of the body  20 . The lid includes a top wall  50  closing off the rectangular cross section. Preferably, the lid  40  is hingedly attached to the body  10  by a hinge  52  that is integral with the back wall  24  of the body  20  and the back wall  44  of the lid  40 . The hinge  52  is preferably formed by a crease or scoring or perforation in the material of the back wall  24  of the body and the back wall  44  of the lid. The hinge delimits each back wall  24  and  44 . 
         [0019]    Preferably, the lid  40  is integrally connected with the body  20  as shown in  FIG. 1 , so that it may be movable between an open position and a closed position without being physically separated from the body  20 . However, those skilled in the art understand that the lid  40  may be composed of a separate portion that is hingedly connected to the body  20  by extra tab portions. These tab portions may be adhesively or otherwise connected to the inner surfaces of the body  20  and lid  40  portions. The lid  40  most preferably is adapted to cooperate with the body  20  portion, and hence, act to cover the top region of the body  20  portion (e.g., the lid  40  can fit over the top region of the body  20  portion, and can be maintained in place, such as by friction fit between the outer surface of the inner frame insert  60  and the inner surface of the inner side walls  45  (visible in  FIG. 2A) and 47  of the lid  40 , such as in the manner described above), and hence, provide the container  10  in a closed configuration. The lid  40  preferably is movable relative to body portion  20 , in order to provide a container  10  that is in an opened or closed configuration. 
         [0020]    As shown in  FIGS. 1 and 4 , the inner frame insert  60  (collar) of the assembled container  10  includes a right sidewall  62  and a left side wall  64 , and a front wall  66  connecting the right side wall  62  and left side wall  64 . Centered in the front wall  66  of the insert is a lowered portion  68 , which exposes the wrapping material and allows for easier removal of all or a portion of the wrapping material and the smoking articles. A right shoulder portion  70  and a left shoulder portion  72  are disposed to the right and left of the lowered portion  68 , and these shoulder portions  70  and  72  extend to a height above the lowered portion  68 . The inner frame insert  60  is positioned in the body  20  such that the front wall  66  of the insert  60  is substantially flush with the inside surface of the front wall  22  of the body  20 . The right and left side walls  62  and  64  of the inner frame insert  60  are substantially flush with the inside of the inner right and left side walls  25  (visible in  FIG. 2A) and 27  of the body  20 . The inner frame insert  60  extends above the top opening  30  of the body  60  such that the right and left shoulder portions  70  and  72  are just below the top wall  50  of the lid  40  when the lid  40  is in a closed position. The inner frame insert  60  is preferably adhesively attached along its right and left side walls  62  and  64  to the right and left inner side walls  25  and  27  of the body  20 . In each of the corners  74  and  76 , friction tabs or ears  78  and  80  extend outwards from the right and left walls  62  and  64  in the plane of the front wall  66 . These friction tabs  78  and  80  provide frictional contact with the inner surface of the right and left inner side walls  45  (visible in  FIG. 2A) and 47  of the lid to assist in keeping the lid  40  in a closed position over the inner frame insert  60  and adjacent to the body  20 . 
         [0021]    Referring to  FIG. 4 , there is shown an unfolded inner frame insert  60 . The inner frame insert  60  consists of a right side wall  62  and a left side wall  64  connected by a front wall  66 . The fold lines  74  and  76  between the right side wall  62  and the front wall  66 , and the left side wall  64  and the front side wall  66  are illustrated as dashed lines in  FIG. 4 . The right and left fold lines  74  and  76  are preferably scored or micro-perforated, but they may alternatively be creased or formed using methods known to those skilled in the art. Each fold line  74  and  76  includes a friction tab  78  and  80  as described in association with  FIG. 1 . The embodiment illustrated in  FIG. 4  shows a depending base portion  82  of the front wall  66 . The depending base portion  82  may be the same width as the lowered portion  68 . The length of the inner frame insert  60  from the bottom of the depending base portion  82  to the top of the shoulder  72  may be adjusted. In some embodiments, a longer inner frame insert  60  may be used to help reinforce the front wall  22  (visible in  FIG. 1 ) of the container. Additionally, longer inner frame inserts  60  may allow the edge of the depending base portion  82  to be placed flush with the bottom of the container and thus hidden from view. The inner frame insert  60  may be produced by the packaging machine in the conventional manner known to those skilled in the art. However, producing longer inner frame inserts may require costly modifications to the packaging machine. While the preferred embodiment discussed features a separate inner frame insert  60 , it is understood that such insert could be formed integrally with the blank as disclosed in U.S. Pat. No. 3,874,581 to Fox et al., which was previously incorporated by reference. 
         [0022]    Referring to  FIG. 2A , there is shown a view of the blank  100  from which one embodiment of the container  10  in  FIG. 1  is formed. The blank  100  is formed from a substantially rectangular piece of material. Preferably, this material is a transparent material, as discussed below. Selected areas  102 ,  104 ,  106 ,  108 ,  110 , and  112  represent the preferred areas to which adhesive is applied (adhesive areas or selected areas). In contrast to the prior art paperboard blank illustrated in  FIG. 3 , the embodiment shown in  FIG. 2A  may not include adhesive areas in the front and back walls. Desirably, adhesive is not visible in the transparent unprinted regions of the blank  100 . As known in the art, the adhesive areas  201  and  203 , visible in  FIG. 3 , provided a method of attaching the wrapped assemblage of smoking articles to the container material. The adhesive regions  205 ,  206  and  208  in the prior art blank  200  provided an adhesive connection between the inner frame insert piece and the container material. In the embodiment of the present invention shown in  FIG. 2A , the transparent inner frame insert  60  (visible in  FIGS. 1 and 4 ) is attached to the container material by adhesive areas  106  on right inner side wall  25  and  108  on left inner side wall  27 . The inner side walls  25  and  27  are integrally attached to the back wall  24 . The right and left cut away spaces  21  and  23  between the right and left inner lid side walls  45  and  47  and the right and left inner side walls  25  and  27  of blank  100  are smaller than the right and left cut away spaces  221  and  223  in the prior art paperboard blank  200  shown in  FIG. 3 . The smaller right and left cut away spaces  21  and  23  allow for larger adhesive areas  106  and  108 , and a better connection with the inner frame insert  60 , while still providing sufficient tolerance between the tops of inner side walls  25  and  27  and outer side walls  26  and  28  when the blank  100  is folded. Right adhesive area  106  extends further towards the bottom wall  32  such that it extends below the bottom of the inner frame insert  60  and may thereby provide an adhesive connection to the wrapped assemblage of smoking articles. In some embodiments, the left adhesive area  108  may be extended instead of the right adhesive area  106 , or both may be extended. Adhesive areas  114  on the front wall  22  and  116  on the back wall  24  may be included in some embodiments to assist in attaching the foil wrapped assemblage of smoking articles. However, these additional adhesive areas  114  and  116  are optional and may be omitted to help prevent the hot-melt adhesive from being transferred to other parts of the packaging machine. 
         [0023]    In a preferred embodiment, the blank  100  may be covered on the inside and outside surfaces with a coating of a varnish material. Advantageously, this varnish material may reduce or eliminate the build up of static, which may help prevent multiple blanks  100  from sticking together and being fed from the hopper  610  (visible in  FIG. 5 ) simultaneously. In one preferred embodiment, the varnish applied to the inside surface of the blank  100  is applied so that varnish free areas  103 ,  105 ,  107 ,  109 ,  111 , and  113  are located in and around the adhesive areas. In embodiments including adhesive areas  114  and  116  in the front wall  22  and back wall  24 , respectively, additional varnish free areas  115  and  117  may be included.  FIG. 2B  shows a plan view of the outside surface of an embodiment of the blank  100 . As shown in  FIG. 2B , the outside surfaces of the right and left inner side walls  25  and  27  may include varnish free areas  125  and  127 . Similarly, the right and left lid inner side walls  45  and  47  may include varnish free areas  145  and  147 . These varnish free areas  125 ,  127 ,  145 , and  147  correspond to the adhesive areas  102 ,  105 ,  106 , and  108  in the container made from the folded blank  100 . The varnish free areas may improve the bonding formed by the hot-melt adhesive material. However, those skilled in the art understand that the varnish-free areas may be omitted, or, alternatively, the varnish may be omitted. 
         [0024]    As shown in  FIG. 2A , corresponding portions  25 ,  27 ,  45 , and  47  represent the preferred areas to which the selected areas are folded and pressed. Right adhesive area  102  on the right side wall  26  and left adhesive area  104  on the left side wall  28  are ultimately attached to the right and left inner side walls  25  and  27  once folded. When the blank  100  is folded, right adhesive area  110  on the right lid side wall  46  and left adhesive area  112  on the left lid side wall  48  are attached to the right and left inner lid side walls  45  and  47 , respectively. 
         [0025]    The solid lines in  FIG. 2A  represent cut lines, whereas the dashed lines represent fold lines. In one embodiment, the fold lines are scored or micro-perforated to help relieve stresses and enable better folding of the blank  100 . The embodiment shown in  FIG. 2A  includes several modifications over the prior art blanks, such as the representative embodiment  200  shown in  FIG. 3 . As can be seen, the prior art blank includes a reinforcing lid flap  243 , whereas the embodiment shown in  FIG. 2A  eliminates this additional portion. The advantages of eliminating the lid tuck flap  243  will be discussed below. To enable proper feeding and handling of the blank using packaging machines such as the G.D. X2, the right and left bottom dust flaps  34  and  36  as well as the right and left lid dust flaps  54  and  56  are modified. Right and left bottom interlock cutout portions  33  and  35  are preferably rectangular-shaped and cut away from the right and left bottom dust flaps  34  and  36 . Similarly, right and left lid interlock cutout portions  53  and  55  are preferably rectangular-shaped and cut away from the right and left lid dust flaps  54  and  56 . These interlock cutouts  33 ,  35 ,  53 , and  55  help prevent the blanks in the hopper  610  from sticking together and causing multiple blanks to be fed together. In one embodiment the right and left lid interlock cutout portions  53  and  55 , and the right and left bottom interlock cutout portions  33  and  35  have widths of approximately 3-6 mm. 
         [0026]    To achieve proper gluing using the hot-melt adhesive and applicator  542  coupled to a cigarette packaging machine such as the G.D. X2, it is preferred to keep the blanks  100  as flat as possible. Accordingly, it is desirable to eliminate residual stresses that may arise in cutting and micro-perforating the blanks. Eliminating the lid tuck flap (lid 180 degree fold-over flap)  243 , and the 180 degree fold it requires, from blank  100  helps reduce stresses that may affect the gluing and folding as well as the functionality of the lid portion of the modified blank  100 . 
         [0027]    The prior art paperboard blank shown in  FIG. 3  differs from the embodiment of the blank  100  shown in  FIG. 2A  in numerous ways. For example the right and left lid dust flaps  254  and  256  span the full distance from the side lid flaps  246  and  248  to the inner lid side walls  245  and  247 . Similarly, the bottom lid flaps  234  and  236  span the full distance from inner side walls  225  and  227  to outer side walls  226  and  228 . Furthermore, adhesive areas  205 ,  206 , and  208  on the front wall  222  and right and left inner side walls  225  and  227  are used only to attach the inner frame insert. Whereas, adhesive areas  203  and  201  are used to attach the foil wrapped assemblage of smoking articles. Additionally, the top edges of the right and left inner side walls  225  and  227  are shaped differently in the paperboard blank so that the cut away spaces  221  and  223  are larger than the cut away spaces  21  and  23  in the transparent blank  100  shown in  FIG. 2A . As noted above, the smaller cut away spaces  21  and  23  in the blank  100  shown in  FIG. 2A  provide more space for larger adhesive areas  106  and  108  and thus allow for a more secure connection with the inner frame insert  60 . 
         [0028]    The body  20  and lid  40  shown in  FIGS. 1 and 2A  are preferably formed of a sheet made from a transparent material, such as a plastic. In one embodiment, an amorphous polyethylene terephthalate (APET) material such as Pentafood® FD 670/70 from Klockner Pentaplast of Gordonsville, Va. may be used. In another embodiment, polyethylene terephthalate glycol (PETG) or polyethylene terephthalate-glycol-amorphous glycol (PET-GAG) may be used. In yet another embodiment, the body  20  and lid  40  may be formed from other transparent materials. Preferably, the inner frame insert is also made from the same transparent material. 
         [0029]    Although the preferred container and associated components are formed from transparent plastic materials, such as an APET material, the container and other certain associated components can be constructed from a variety of other materials. For example, those components can be constructed from composite materials, laminated materials, or the like. Typically, the thickness of the blank material is in the range of about 0.25 millimeter to about 0.40 millimeter. In one embodiment, the thickness of the blank material used to construct the outer body and the lid of the container is about 0.28 millimeter to about 0.36 millimeter. In another embodiment, the thickness of the blank material is about 0.30 millimeter. Although not required, generally the thickness of the material used to construct the inner frame insert portion of the container is the same thickness as the body of the container. 
         [0030]    In the preferred embodiment, the adhesive is applied in areas on the opposite side of the blank  100  that feature printed designs. In one embodiment, a transparent hot-melt adhesive is used to affix the selected overlapping (corresponding) portions of the blank  100 . The hot-melt adhesive may be a pressure sensitive hot-melt adhesive, which is preferably non-solvent based and contains 100 percent solids. In a preferred embodiment, the hot-melt adhesive material conforms to food grade regulations in compliance with 21 C.F.R. §175.105. In one embodiment, the hot-melt adhesive may contain Styrene-Butadiene-Styrene (SBS) polymer with plasticizers, tackifiers, waxes, and/or stabilizers. However, those skilled in the art will understand that other polymer materials may be used. In another embodiment, the hot-melt adhesive is a pressure sensitive, quick setting adhesive such as Primamelt® 37-613 from Henkel Adhesives of Elgin, Ill., or Uni-Flex® 70-007A from National Starch and Chemical Company of Bridgewater, N.J. However, other adhesive materials may be used as is apparent to those skilled in the art. Preferably, a transparent, pressure-sensitive, quick setting adhesive that is compatible with the blank material is used. 
         [0031]    The texture of the applied adhesive in the areas in  FIG. 2A  differs from the texture of the applied adhesive in the areas in the prior art illustrated in  FIG. 3 . In  FIG. 2A , the adhesive is shown as applied in continuous strips. In the prior art example of  FIG. 3 , a polyvinyl acetate glue is shown as applied on paperboard using, for example, a gravure glue wheel applicator. As visible in  FIG. 3 , the adhesive was not applied uniformly or continuously but instead in selected locations, such as in a non-continuous polka-dot pattern, that correspond to the texture of the gravure applicator. A gravure wheel gluing apparatus may not provide desirable gluing for the transparent materials considered for the embodiments of the present invention. Furthermore, a gravure glue wheel applicator may not be compatible with the preferred adhesive materials. Therefore, it may be desirable to modify the packaging machine as described below. 
         [0032]    As described above, varnish materials may be used to reduce static build-up among the blanks and to prevent simultaneous blanks from being fed from the hopper. Preferably the varnish material used is a flexible, high gloss, UV-curable, top lacquer with low sensitivity to static charge. In one embodiment, the varnish is of the type described above such as SunCure LO 7500T from Sun Chemical of Parsippany, N.J. However, those skilled in the art and following the teachings herein will understand that other varnish materials may also be used. 
         [0033]    In a preferred embodiment, a commercially available cigarette packaging machine, such as the G.D. X2 from G.D. SpA of Bologna, Italy or the 350S from Focke &amp; Co. of Verden, Germany, is modified to form packages made of a transparent plastic material instead of paperboard. The G.D. X2 cigarette packaging machine is described in U.S. Pat. No. 6,694,708, which is herein incorporated by reference.  FIG. 5  is a schematic representation of a packaging machine to make the transparent container described above. The packaging machine for assembling the packages of the present embodiment is modified by replacing the gravure glue wheel applicator with a hot-melt adhesive applicator  542 . Furthermore, the textured contrast wheel used with the gravure applicator is replaced with a uniform contrast roller  640  to apply uniform pressure to the area of adhesive application. With hot-melt adhesive it is preferable to apply a thin layer of adhesive in order to prevent the material from extruding out the sides of the overlapping portions and contacting other parts of the blank or parts of the packaging machine. Because the hot-melt adhesive applicator  542  receives a pressurized feed of hot-melt adhesive, it is preferable to maintain uniform pressure between the blank and the applicator. The uniform contrast roller  640  is used in the preferred embodiment to allow for a uniformly thin application of adhesive. In one embodiment, the spacing between the hot-melt adhesive applicator  542  and the uniform contrast roller  640  is between about 0.27 millimeters to about 0.44 millimeters. However, this spacing may vary depending on the thickness of the material used for the container blank  100  and also the type of hot-melt adhesive used. 
         [0034]    To achieve the desired adhesive pattern, it may be desirable to attach several hot-melt applicators  542  to a manifold  530  (visible in  FIG. 6 ). For example, in one embodiment, three hot-melt adhesive applicators  542  are attached to a manifold  530  in order to replicate the gluing pattern of the stock gravure glue wheel applicator. Hot-melt adhesive applicators, such as the HME-500F from Baumer hhs of Krefeld, Germany, may be used to apply the hot-melt adhesive. Those skilled in the art following the teachings herein may recognize that other applicators may be used as well. 
         [0035]    In one embodiment, an encoder device  622 , such as a Series H35 Sealed Hollow Shaft Encoder from Dynapar of Gurnee, Ill., is coupled to the gear train  620  of the cigarette packaging machine. The gear train  620  drives the translational movement of the container blanks  100  through the cigarette packaging machine. The encoder  622  tracks the translational movement of the blanks  100  through the packaging machine and assembly process based on readings taken from the gear train  620 . The encoder  622  is in electronic communication with an electronic control unit  630  for the hot-melt adhesive applicator  542 . The electronic control unit  630  is used to control the pattern of hot-melt adhesive applied by the applicators  542 . Furthermore, the electronic control unit  630  may be used to adjust the feed pressure to apply the proper amount of adhesive based on a variety of system parameters including the feed rate of blanks into the packaging machine. Typically, a machine such as the G.D. X2 may operate at a feed rate of up to about 400 blanks per minute, or more often up to about 300 blanks per minute, or most often between 150 and 250 blanks per minute. The electronic control unit  630  may be a model XT-E4 glue control unit from Baumer hhs of Krefeld, Germany. However, other control units may be used. Additionally, the electronic control unit  630  may be coupled to a hot melt adhesive tank and pump, for example a model HMP-08 Promelt tank and pump from Baumer hhs of Krefeld, Germany. 
         [0036]    In some embodiments, an electronic blank sensor  641  may be placed adjacent to the uniform contrast roller  640  to assist in initiating adhesive control. The electronic blank sensor may assist the electronic control unit  630  in achieving a more precise adhesive application pattern by providing precise information regarding when each blank enters the hot-melt adhesive applicator  542 . Information is received by the electronic control unit  630  from the electronic blank sensor  641  to supplement translational movement information received from the encoder device  622  to enable precise adhesive application patterns. In one embodiment, the electronic blank sensor may be an amplifier and fiber optic sensor. In another embodiment, the electronic blank sensor may be a model FU-2303 fiber optic sensor and FS-V20 Series Digital Display Amplifier from Keyence Corporation of America, Woodcliff Lake, N.J. Those skilled in the art and following the teachings herein will understand that other electronic sensors may be used for the electronic blank sensor. 
         [0037]    In some embodiments, the hot-melt adhesives have application temperatures between about 145 to 180 degrees Celsius, thus causing the applicator  542  to have a similar temperature. Many of the transparent plastic materials that may be used to form transparent containers for smoking articles have relatively low melting temperatures. To prevent container blanks from melting to the hot-melt adhesive applicator  542  when the packaging machine stops, it may be desirable to lift the hot-melt adhesive applicator  542  into an operating position when the machine is running and then to retract the applicator  542  when the machine is stopped. 
         [0038]    Referring to  FIG. 6 , the hot-melt adhesive applicator  542  may be mounted to a frame assembly  550  designed to correspond to the mounting arrangement of the stock gluer in the cigarette packaging machine, such as the gravure glue wheel of the G.D. X2. In one embodiment, the hot-melt adhesive applicator  542  is attached to a frame  550  having connections that correspond to the pattern of connections for the stock glue pot to the G.D. X2 or whichever packaging machine has been modified. In this embodiment, the frame  550  includes a stabilizing bar  504  designed to slide over a rail component  502  of the packaging machine. A tightening screw  505  may be included to clamp the frame assembly  550  and the stabilizing bar  504  against the rail component  502 . On the other side of the frame  550 , a cylindrical opening  506  is provided to slide over a post portion  508  of the packaging machine. 
         [0039]    While the frame  550  remains stationary once mounted onto the packaging machine, a mounting assembly  510  for the hot-melt adhesive applicator  542  may lift into a gluing position or retract into an off position. The mounting assembly  510  includes a slider plate  512 . The slider plate  512  slides within an opening  513  (visible in  FIG. 7 ) between two vertical portions  552  of the frame  550 . The mounting assembly  510  is positioned by the lever-type action of a movable support  520  composed of a pneumatic cylinder  514  coupled to a lever  516  that is pivotably mounted in a connecting block  518 . The pneumatic cylinder  514  is connected to the frame  550  at a depending tab  515 , which is located at the end opposite the driving rod  522 . 
         [0040]    In operation, the movable support  520  moves the hot-melt adhesive applicator  542  in response to pneumatic pressures received from a pneumatic pump  650  (visible in  FIG. 5 ). The pneumatic pump  650  causes the movable support  520  to lift to an operating position or retract to a non-operating position based upon signals received from the system processor  652  (visible in  FIG. 5 ) for the packaging machine. When the packaging machine is first turned on, and a first blank  100  enters the system, the system processor  652  sends a lifting signal. When the packaging machine is stopped, the system processor  652  sends a retracting signal. Unlike the contrast wheels used with the stock gravure gluer, the uniform contrast wheel  640  (visible in  FIG. 5 ) used with the hot-melt adhesive applicator  542  is placed in a fixed location. Therefore, the signal originally sent by the system processor  652  to move the contrast wheel may be used to signal the movable support  520 . Alternatively, the system logic may be modified to send a raising and lowering signal. When the activating signal is received, the pneumatic cylinder  514  extends its driving rod  522 , which drives the lever  516  into an extending position. The lever  516  includes a cylindrical post  521  at its distal end. The slider plate  512  includes a rotating pin  519  that spans an opening  517  in the slider plate. The rotating pin  519  includes a hole  523  (visible in  FIG. 7 ) into which the cylindrical post  521  slides. As the driving rod  522  extends, the lever  516  rotates about the connection  524  with the driving rod  522  and the pivot pin  527  in the connecting block  518 . The cylindrical post  521  at the distal end of the lever  516  raises the slider plate  512  by sliding in the hole  523  and driving the rotating pin  519  upwards. The lifting action drives the hot-melt adhesive applicator up about 9 to 16 millimeters. Both the top and bottom positions may be set through use of adjustable stops  526 . A block  530  may be included on the vertical depending portions  552  which blocks the adjustable stop  526  and limits the lifting height of the moveable support  520 . 
         [0041]    Referring to  FIG. 7 , a front view of the slider plate  512  and depending vertical portions  552  of the frame assembly  550  (visible in  FIG. 6 ) is shown. The sliding plate  512  fits in opening  513  between the depending vertical portions  552  and slides in response to the lever action of the lever  516 . As described above, the rotating pin  519  in the sliding plate  512  contacts the cylindrical post  521  of the lever  516  an opening  517 . As the pneumatic cylinder  514  (visible in  FIG. 6 ) extends the rod  522  (visible in  FIG. 6 ), the connection  524  pushes the lever  516  by driving rod  522 . In turn, this causes the lever  516  to rotate about the pivot pin  527  in the connecting block  518 , and cylindrical post  521  at the distal end of the lever  516  to push the sliding plate  512  up by pushing against the inside surface of the hole  523  in the rotating pin  519  spanning the opening  517 . 
         [0042]    Referring now to  FIG. 5 , due to the design of the modified blank  100 , the hopper  610  may be modified. In one embodiment, additional approximately vertical guide posts are placed along the longer sides of the blank  100  to help keep the blanks  100  in an orderly arrangement in the hopper  610 . Additionally, a solid side support may be placed between the guide posts on at least one of the longer sides of the blank  100 . Advantageously, this solid side support may include a textured finish to help prevent multiple blanks  100  from being fed simultaneously into the system. 
         [0043]    In operation, the modified cigarette packaging machine schematically presented in  FIG. 5  starts by sending individual blanks  100  from a hopper  610  into the machine using a transfer device  602 , such as a transfer wheel or a suction cup. The transfer device  602  places individual blanks  100  into a lugged transfer belt or feed belt  604 . Due to the modified shape of the blank  100 , it may be desirable to include guides in the machine, along the feed belt  604 , between the hopper and the adhesive applicators  542 . 
         [0044]    The gear train  620  drives the translational movement of the blank  100  throughout the machine. As noted above, the encoder  622  coupled to the gear train  620  tracks the translational movement of the blank and sends data to an electronic control unit  630  via a communication line  624 . The electronic control unit  630  converts data from the encoder  622  to instructions for the hot-melt adhesive applicator  542 , and sends the instructions to the hot-melt adhesive applicator  542  via a second communication line  632 . The hot-melt adhesive applicator  542  receives hot-melt adhesive via an insulated feed line  644  that connects to adhesive port  528  (visible in  FIG. 6 ) on the manifold  530  (visible in  FIG. 6 ). When in operation, the hot-melt adhesive applicator  542  is raised to an operating position by a movable support  520 , in this case a pneumatic cylinder  514  that receives pneumatic pressures via lines  648 , a lever  516  (visible in  FIG. 6 ), and a connecting block  518  (visible in  FIG. 6 ). When a blank  100  enters the gluing area down flow from the hopper  610 , the electronic control unit  630  signals the hot-melt adhesive applicator  542  to apply a pre-determined pattern of hot-melt adhesive. The uniform contrast roller  640  applies constant pressure to the adhesive areas of the blank  100  as hot-melt adhesive is applied. The glued blank  100  is then passed on to a folding station  660 . The folding station  660  receives a wrapped assemblage of smoking articles  641  from a foil wrapping station  670 . In the foil wrapping station, assemblages of smoking articles  671  are wrapped with wrapping materials  672 . In the folding station  660 , the wrapped assemblage of smoking articles  661  and inner frame insert  60  are placed on the blank  100 , and the blank  100  is folded. Finally, a completed container  10  is formed. 
         [0045]    While conventional paperboard containers generally use an adhesive requiring a heated curing or drying step, this heating step is preferably eliminated when using a hot-melt adhesive material. When the machine is first started, a first blank  100  running through the hot-melt adhesive applicator  542  is rejected to ensure that all completed packages  10  are properly glued. Also, when the cigarette packaging machine is shut down, the hot-melt adhesive applicator  542  is retracted into its non-operating position by the movable support  520 . 
         [0046]    The wrapped assemblage of smoking articles, which may include cigarettes, is preferably wrapped in a foil material. Suitable wrapping materials are foil-type materials (e.g., laminated metal foil/paper inner-liner materials). See, for example, US Pat. Pub. 2006/0168909 to Miyaoka et al., which is incorporated by reference herein. In one embodiment, the foil-type wrapper material may include a pattern visible through the transparent container. Such a pattern may be embossed or formed using other means known to those skilled in the art. In feeding the wrapping material into a packaging machine such as the G.D. X2, some feeding mechanisms or feeding wheels may impart a crease into the material. Because the packages formed by the present invention are generally at least partially transparent, it is desirable to modify such feeding mechanisms to avoid imparting creases to the wrapping material or otherwise marring the finish of the wrapping material. 
         [0047]    The maximum height of each container can vary. The height of each container typically is dependent upon factors such as the lengths of the cigarettes that are contained therein. Generally, the height of each container is within the range of about 70 mm to 130 mm. For example, for a container designed to contain 20 cigarettes, each about 99 mm in length, a representative container can have a height of about 100 mm to about 103 mm. Alternatively, for example, for a container designed to contain 20 cigarettes, each about 84 mm in length, a representative container can have a height of about 85 mm to about 89 mm. 
         [0048]    A representative assembled container has a maximum height of about 87 mm, a width of about 67 mm, a maximum depth of about 33 mm, and a minimum depth of about 23 mm. A typical cigarette is about 84 mm in length and about 24.5 mm in circumference. The containers are generally rectangular in cross-sectional shape, and generally rectangular box shape in overall appearance of dimensions to contain cigarettes in rows having either a ten-ten or seven-six-seven configuration. The dimensions of the container may vary depending on the desired number of cigarettes to be packaged in the container. Thus, such an assembled container has a height slightly greater than the smoking articles contained therein, and the width of the container is preferably greater than its depth. However, the container may be constructed to resemble any other non-rectangular shapes. Although the preferred container possesses vertically extending walls that extend in a almost truly vertical direction, those vertically extending walls can be adapted so as to extend generally vertically, and hence, provide a container that can be considered to be somewhat frusto-pyramidial in shape (e.g., the side walls can extend slightly outward from top to bottom, or the side wall can extend slightly inward from top to bottom), or form other geometric shapes. 
         [0049]    Once the container is formed and filled with smoking articles, such as cigarettes, the container may be overwrapped. Exemplary overwrap materials include polypropylene, or such films characterized as “cellophane-type films” that conventionally have been employed for wrapping packaged cigarettes. Less preferably, overwrap materials such as the types set forth in U.S. Pat. Nos. 5,139,140 to Burrows et al., and 5,542,529 to Hein, III et al., may be used. Both U.S. Pat. Nos. 5,139,140 and 5,542,429 are incorporated herein by reference. 
         [0050]    The outer wrapping material assembly can be equipped with tear tape. See, for example, U.S. Pat. Nos. 4,717,017 to Sprinkel, Jr. et al.; 4,836,378 to Lephardt; 5,192,262 to Amendola et al.; 5,595,803 to May et al.; and 7,118,792 to Hewitt et al.; each of which is incorporated herein by reference. Representative types of tear tape materials suitable for use in association with other cigarette packaging materials are available from sources such as Arlin Mfg. Co., Inc. of Lowell, Mass., and P. P. Payne Limited of Nottingham, United Kingdom. 
         [0051]    The assembled container can be used in a variety of ways. In use, outer wrapping materials (e.g., clear, colorless polypropylene film) are removed from the assembled outer container, and those outer wrapping materials are discarded. The lid is moved to an open position to expose the relevant wrapping materials (e.g., an optional overwrap material, and the preferred piece of embossed paper/foil laminate that overlies the ends of the cigarettes) that cover the cigarettes contained in that packet. 
         [0052]    The disclosed method, system, and materials provide an aesthetically pleasing appearance to a package of smoking articles, such as cigarettes. As described above, the modification of conventional packaging equipment in accordance with the teachings herein, such as precise placement of adhesive in coordinated patterns on transparent packaging materials, enables the creation of transparent packaging without visual impairment caused by the adhesive extending into visible areas. In comparison to conventional paperboard materials, the transparent packaging material requires greater precision to avoid visibly misapplied or squeezed-out adhesive patterns. Advantageously, the transparent packaging material allows decoratively embossed or patterned foil wrapper materials to visibly complement any patterns formed on the packaging material. 
         [0053]    It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and it should be understood that the following claims, including all equivalents, are intended to define the spirit and scope of this invention.

Technology Classification (CPC): 1