A pack for smoking articles

Field of the Invention

The present invention relates to a pack for smoking articles such as cigarettes.

Background

It is very common to sell cigarettes in a hinged-lid (HL) carton or pack made of cardboard or other such material. A HL pack is generally provided with a transparent outer cellophane wrapping. This wrapping is then removed by a consumer in order to gain access to the cigarettes or other smoking articles contained in the pack.

A HL pack is usually rectangular in shape and comprises a body portion and a lid portion having a hinged attachment to one another. The body comprises opposing front and back panels, two opposing side panels, and a bottom panel, while the lid comprises opposing front and back panels, two opposing side panels, and a top panel opposing the bottom panel of the body. The back panels of the lid and body are joined together by the hinged attachment. The side panels and front panel of the body abut corresponding side and front panels of the lid when the lid is closed. The hinge line between the back panels is generally higher (nearer the top of the pack) than the line of abutment between the front panels, so the lines of abutment between the lid and body side panels slope diagonally downwards towards the front of the pack.

HL packs are generally provided with an inner frame which is glued to the inside of the body portion of the pack. The inner frame typically comprises a front panel and opposing side panels which extend past the line of abutment between the body and the lid. Consequently, if the lid does not mate exactly with the body of the pack, the inner frame prevents the product inside the pack from being exposed.

One known problem with existing HL packs is that the lid may not always stay completely shut, especially after the cellophane wrapping has been removed. Most frequently, the lid may sit slightly ajar of the pack, although in more extreme cases, the lid may flop open completely. This tendency is sometimes known as yawning. Such yawning can assist unwanted ingress/egress to/from the pack - e.g. moisture loss from the cigarette tobacco. If the lid becomes very loose, there is a risk that some of the contents may fall out when the pack is lifted. In addition, a pack with an improperly closed lid generally has a low quality appearance.

Yawning tends to become an increasing problem as cigarettes or other smoking articles are consumed from the pack. There are two main reasons for this. Firstly, movement of the lid may be opposed by frictional engagement with the inner frame. However, this frictional engagement is generally reduced by repeated opening and closing of the lid (to access products in the pack), for example as the cardboard of the pack becomes worn and/or bent. Secondly, a pack is normally designed such that there is a slight interference (usually less than 1mm) between the product in the pack (when full) and the opening action of the lid. In other words, opening the lid of a full pack of cigarettes requires a slight, temporary compression of some of the cigarettes in the pack. However, after some of the cigarettes have been removed from the pack, this allows space for the remaining cigarettes to move at least partly towards the rear of the pack, thereby removing any interference between the cigarettes and the opening action of the lid.

<patcit id="pcit0001" dnum="US5904244A"><text>US 5904244</text></patcit> discloses a hinge-lid carton for cigarettes with a closure aid to help keep the pack shut. The closure aid involves inner side tabs that extend up from the side walls of the body of the pack to engage inner side tabs within the lid of the pack. Another known mechanism to address yawning is to provide outwardly facing lugs or ears on the inner frame where it extends above the body of the pack. These lugs frictionally engage the lid when it is closed, and thereby help to hold the lid in place to prevent yawning. An example of such ears can be seen in <patcit id="pcit0002" dnum="WO9609230A"><text>WO 96/09230</text></patcit>. However, such lugs are not always effective, and they can sometimes lead to creasing of the inner frame (which may be formed of a less rigid material than the main body of the pack).

It is known from <patcit id="pcit0003" dnum="DE1078934"><text>DE 1078934</text></patcit> to provide a hinged-lid pack for smoking articles. The pack comprises a body and a lid each having respective front, back and opposing side panels. The back panel of the lid is hinged to the back panel of the body. At least one side panel of the lid is provided with an inner tab extending substantially coplanar with the side panel of the lid to resist opening of the lid. The inner tab may therefore serve as a form of anti-yawn mechanism to help ensure that the pack remains properly closed.

SUMMARY OF THE INVENTION

The present invention is <b>characterised in that</b> the inner tab engages the front panel of the body when the pack is closed to resist opening of the lid wherein the body front panel extends diagonally upwards adjacent the side panel where the front panel is engaged by the inner tab, said diagonal extension serving to deflect the inner tab inwardly as the lid is closed.

In one embodiment, the pack further comprises an inner frame attached to the inside of the body. The inner tab is received between the inner frame and the side panel of the body when the pack is closed. This configuration between the inner frame and the body side panel helps to avoid the inner tab from becoming bent or folded. In addition, friction between the inner tab and the inner frame and side panel helps to resist opening of the pack.

In one embodiment, the inner tab may have an overlap with the front panel of the body, where the overlap is in the range 0.3-3mm, or more particularly 0.5-2mm, for example, approximately lmm. Other embodiments may have a different degree of overlap, as appropriate.

In one embodiment, the inner tab is provided with a corner to engage the front panel of the body when the pack is closed to resist opening of the lid. The inner tab is further provided with a curved edge extending away from the corner. The curved edge is shaped to remain substantially clear of the front panel of the body during opening of the lid. Consequently, once the initial resistance to opening the lid has been overcome and the corner has disengaged from the front panel, the lid can then be opened further without significant additional resistance from the inner tab.

(In one particular embodiment, the diagonal extension comprises a continuation at the same angle of a diagonal forming the top edge of the side panel of the body). The diagonal extension helps to deflect the inner tab inwardly as the lid is closed. This therefore facilitates overcoming any engagement between the inner tab and the front panel to close the pack, and also helps to guide the inner tab to the appropriate location between the side panel and the inner frame.

In one embodiment, the inner tab is formed from material folded in from the back panel of the lid, for example, by modifying a panel that is already present in many existing HL packs (although in conventional HL packs this panel is fully contained inside the lid). Accordingly, it is relatively easy to make a pack having such an inner tab using existing machinery.

In one embodiment, each of the- two side panels of the lid is provided with an inner tab to engage the front panel of the body to resist opening of the lid when the pack is closed. In general the two inner tabs are the same, to provide symmetrical resistance, and may share any of the features described above.

Another embodiment of the invention provides a blank for manufacturing such a hinged-lid pack. Such a blank may be formed by modifying a blank for a conventional HL pack, such that the size and shape of some of the panels in the blank are changed (along with the overall size and shape of the blank).

Various embodiments of the invention will now be described in detail by way of example only with reference to the following drawings: <ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">Figures 1a and 1b</figref> illustrate the general configuration of a hinged lid pack;</li><li><figref idref="f0001">Figure 2</figref> is a more detailed front view of a hinged lid pack in accordance with one embodiment of the invention;</li><li><figref idref="f0002">Figure 3</figref> is a front view of the hinged lid pack in <figref idref="f0001">Figure 2</figref>, but with the lid removed;</li><li><figref idref="f0002">Figure 4</figref> is a side view of the hinged lid pack of <figref idref="f0001">Figure 2</figref> with the lid open;</li><li><figref idref="f0003">Figure 5</figref> is a side view of the hinged lid pack of <figref idref="f0001">Figure 2</figref> with the lid closed;</li><li><figref idref="f0003">Figure 6</figref> is a detail of the hinged lid pack of <figref idref="f0001">Figure 2</figref> with the lid closing;</li><li><figref idref="f0004">Figure 7</figref> is a side view of the hinged lid pack of <figref idref="f0001">Figure 2</figref> with the lid half open;</li><li><figref idref="f0005">Figure 8</figref> depicts a blank for a conventional hinged lid pack; and</li><li><figref idref="f0005">Figure 9</figref> depicts a blank for a hinged lid pack in accordance with one embodiment of the invention.</li></ul>

<figref idref="f0001">Figures 1A and 1B</figref> illustrate the general configuration of a hinged-lid (HL) pack 1. The HL pack is generally rectangular in shape and comprises a body portion 4 and a lid portion 5 having a hinged attachment to one another. The body comprises opposing front 12 and back 13 panels, two opposing side panels 11A, 11B, and a bottom panel (not shown in <figref idref="f0001">Figures 1A and 1B</figref>). The lid comprises opposing front 22 and back 23 panels, two opposing side panels 21A,21B (aligned with body side panels 11A and 11B respectively), and a top panel 15 opposing the bottom panel of the lid. The body back panel 13 and the lid back panel 23 are joined together by a hinge-line 38 which is generally parallel to the bottom of the pack.

When the pack is closed, the body front panel 12 abuts the lid front panel 22 along line 36, which is generally parallel to the bottom of the pack. The body side panels 1 IA, 1 IB abut corresponding lid side panels 21A, 21B along lines 37A and 37B respectively. Hinge line 38 is generally higher (nearer the top of the pack) than the line of abutment 36 between the body and lid front panels, so that the lines of abutment 37A, 37B between the lid and body side panels slope diagonally downwards towards the front of the pack.

When the pack is opened, the lid portion 5 pivots around hinge line 38. This causes lid front panel 22 to separate from the front panel 12 of the body portion, and likewise for the side panels, thereby giving access to the contents of the HL pack 1.

<figref idref="f0001">Figure 2</figref> illustrates in more detail the front of an HL pack in accordance with one embodiment of the invention. As can be seen in <figref idref="f0001">Figure 2</figref>, the centre portion of the line of abutment 36 between the body front panel 12 and the lid front panel 22 is horizontal (parallel to the bottom of the pack). However, the body front panel 12 and the lid front panel 22 are shaped such that the two ends of the line of abutment 36 (i.e. near the edges with the side panels) are turned diagonally upwards towards the top of the pack, as indicated by line segments 46 A and 46B.

In one embodiment, line 46A is a continuation of line 37A on the side of the panel, and likewise line 46B is a continuation of line 37B. In other words, the angle of inclination for line 46A (to the vertical or horizontal) is the same as for line 37A, and the angle of inclination for line 46B is the same as for line 37B. Another possibility is that the angle of inclination for line 46A to the vertical is more acute than for line 37A (likewise for line 46B).

In one embodiment, the length of lines 46A and 46B is in the range 1-3 mm, for example approximately 2mm, and the inclination angle of lines 46A and 46B to line 36 is in the range 30 to 60 degrees, for example approximately 40 degrees. It will be appreciated that other embodiments may have a different length and/or inclination angle for lines 46A and 46B. For example, the angle of lines 46A and 46B will vary depending on the length of the lid (short lid or extended lid) and the format of the pack.

<figref idref="f0002">Figure 3</figref> shows the HL pack of <figref idref="f0001">Figure 2</figref> with the lid 5 removed. This exposes the inner frame 102 of the pack. The inner frame generally comprises a front panel 112, and two opposing side panels 111A, 111B (frame side panel 111B is shown in <figref idref="f0002">Figure 4A</figref>; the opposing side panel 111A is not visible in the Figures). The inner frame is usually attached to the body portion 4 of the pack by using adhesive to glue the front panel 112 of the inner frame to the interior surface of the front panel 12 of the body portion. In addition, the side panels of the inner frame, 111A and 111B, are normally glued to the interior surface of the corresponding side panels (11A and 11B respectively) of the body portion 4.

The front 112 and side panels 111A,111B of the inner frame 102 extend above the body portion 4 of the HL pack. One reason for providing the inner frame 102 is that due to manufacturing tolerance, the body front panel 12 may not abut exactly against lid front panel 22; in other words, there may be a slight gap at line of abutment 36. Likewise, there may be a slight gap at line of abutment 37A between body side panel 11A and lid side panel 21A and/or at line of abutment 37B between body side panel 11B and lid side panel 21B. The inner frame 102 therefore serves as backing cover for any such gap along lines of abutments 36, 37A, and/or 37B. This then prevents the cigarettes or other smoking articles inside the HL pack from being exposed to view, which would degrade the product appearance. The inner frame also acts as a barrier for ingress/egress to/from the pack, adds strength to the pack (especially when glued to the body portion), and helps to keep the lid closed.

<figref idref="f0002">Figure 4</figref> depicts a HL pack in accordance with one embodiment of the invention with the lid 5 open. It can be seen that the lid includes a curved extension or tab 201B that extends beyond the side panel 21B of the lid. The opposing side panel 21A of the lid is also provided with such a curved extension 201A (not visible in <figref idref="f0002">Figure 4</figref>).

<figref idref="f0003">Figure 5</figref> depicts the HL pack of <figref idref="f0002">Figure 4</figref> with the lid closed. When the lid 5 is closed, tab 201B slides between the body side panel 11B and the inner frame side panel 111B, likewise for the tab on the opposing side of the pack. The position of tab 201B behind side panel HB is shown in dotted outline in <figref idref="f0003">Figure 5</figref>.

Tab 201B is sized and shaped so that the corner 210B of the tab sits slightly below the corner 15B of the body portion 4 of the HL pack. (Corner 15B represents the point where the top of the body front panel 12 meets the top of the body side panel HB; this also corresponds to the junction of line 46B and line 37B). This overlap between the body front panel 12 and the tab 201B provides resistance to opening the lid 5. Accordingly, tab 201B serves as an anti-yawn mechanism to keep the lid portion 5 fully closed against the bottom portion 4.

The degree of overlap between the body front panel 12 and the tab 201B is approximately lmm, although this may vary from one embodiment to another. This amount of overlap allows the HL pack to be opened, given that an HL pack is generally made of a relatively compliant material such as cardboard. In particular, when the consumer applies suitable force, the HL pack deforms slightly for the tab 201B to disengage from the front panel, thereby permitting the lid-to be opened. The amount of deformation is small enough that the pack returns resiliently to its initial configuration after the lid is opened. A similar, temporary, deformation occurs when the lid is closed again, thereby allowing tab 201B to return to the position shown in <figref idref="f0003">Figure 5</figref> (thereby re-setting the anti-yawn mechanism).

The resilient deformation of the HL pack when the lid is opened and closed is assisted by the upturned ends 46A, 46B of line 36. Thus the main portion of the top of the body front panel, as indicated by line 36, is lower than the corner portion of the top of the body front panel at corner 15B. As an attempt is made to open the HL pack, tab 201B is guided by side panel 11B and body front wall 12 adjacent corner 15B to deflect inwards, towards the region where the top of the front panel is lower (corresponding to line 36). This then allows tab 201B to clear the body front panel 12, thereby permitting the lid to be opened.

The upturned ends of the body front panel 36 axe also of assistance when closing the lid 5, as shown in <figref idref="f0003">Figure 6</figref>. Thus when the lid 5 is nearly closed, the edge of tab 201A adjacent corner 210A contacts corner 15A where the top of the body front panel 12 joins the top of the body side panel 11A. As the lid is further lowered, the diagonal slope of line 46A deflects or urges the corner 210A of tab 201A slightly inwards, in the direction shown by the arrow, out of the plane of side panels HA and 37A. This moves the corner 210A away from the highest part of the body front panel 12 towards the lower portion corresponding to line 36, thereby allowing the tab 201A to clear the body front panel 12 without requiring undue force from the consumer. The tab 201A is then able to return resiliently to its original planar configuration, this action also being assisted as the tab 201A is received between the body side panel 11A and the inner frame side panel 111A (not visible). Finally, when the lid is fully closed, tab 201A is back to the anti-yawn configuration shown in <figref idref="f0003">Figure 5</figref>.

<figref idref="f0004">Figure 7</figref> illustrates an HL pack in accordance with one embodiment of the invention with the lid 5 half-open. The top corner 16B of the body side panel 11B adjacent to the body back panel 13 is at a higher level (i.e. overlaps) the bottom corner 211B of tab 201B adjacent to hinge line 38 (see also <figref idref="f0003">Figure 5</figref>). In one embodiment, the overlap is in the range 0.5mm to 2.5mm, for example approximately lmm. It will be appreciated that other embodiments may have a different amount of overlap.

The overlap helps to ensure that when the lid is closed, tab 201B is received inside (rather than outside) the body side panel 11B. Although there is no overlap when the lid is fully open (as shown in <figref idref="f0002">Figure 4</figref>), the bottom corner 211B of the tab portion remains close to the top corner 16B of the body side panel 11B. This restricts the possibility of significant relative movement between the two. Accordingly, when the lid starts to close, the position of corner 211B inside corner 16B is maintained, which then guides the remainder of tab 201B to pass inside side wall 11B to ensure proper operation of the anti-yawn mechanism.

<figref idref="f0005">Figure 8</figref> illustrates a blank for a conventional HL pack, with cut lines indicated by solid lines and fold lines indicated by dashed lines. <figref idref="f0005">Figure 9</figref> illustrates a blank for a HL pack in accordance with one embodiment of the invention. It will be appreciated that although the blank of <figref idref="f0005">Figure 9</figref> comprises the same set of panels as the blank of <figref idref="f0005">Figure 8</figref>, and may be assembled using the same cuts and folds, the shape of the blank as a whole plus the shape of some of the panels within the blank is different for <figref idref="f0005">Figure 9</figref> compared to <figref idref="f0005">Figure 8</figref>.

Both <figref idref="f0005">Figures 8 and 9</figref> depict some additional panels that have not previously been described. These additional panels fold behind other panels, except for panel 610, which forms the bottom of the pack. Thus panel 615 folds back up behind front lid panel 22; side base panels 612A and 612B fold in over the bottom of the pack; side inner panels 611A and 611B are glued inside side panels 11A and 11B; and lid top panels 614A and 614B fold underneath lid panel 15. Note that tabs 201A and 201B are joined to lid top panels 614A and 614B respectively.

The following are the main points of distinction between the blank of <figref idref="f0005">Figure 8</figref> and the blank of <figref idref="f0005">Figure 9</figref>: <ol id="ol0001" compact="compact" ol-style=""><li>a) in the blank of <figref idref="f0005">Figure 8</figref>, the panels corresponding to tabs 201A and 201B are coextensive with the corresponding lid side panels 21A and 21B respectively, whereas in the blank of <figref idref="f0005">Figure 9</figref>, the tabs 201A and 201B are larger than corresponding lid side panels 21A and 21B respectively. Accordingly, in the blank of <figref idref="f0005">Figure 8</figref> the panels corresponding to tabs 201A and 201B do not extend below lid side panels 21A and 21B, and therefore, unlike the blank of <figref idref="f0005">Figure 9</figref>, do not engage front panel 12 and/or corresponding body side panels 11A and 11B to provide any anti yawn mechanism. Note also that because the tabs 201A and 201B in <figref idref="f0005">Figure 9</figref> are larger than corresponding lid side panels 21 A and 21B respectively, during assembly of the pack, the full surface of lid side panel 21A can be used for gluing to tab 201A and the full surface of lid side panel 21B can be used for gluing to tab 201B. (This is in contrast to the situation with above-cited <patcit id="pcit0004" dnum="US5904244A"><text>US 5904244</text></patcit>, in which the inner side tabs for the lid are reduced in size compared to the (outer) lid side panels);</li><li>b) in the blank of <figref idref="f0005">Figure 9</figref>, the tops of the body side panels 11A and 11B are extended compared to the blank of <figref idref="f0005">Figure 8</figref>, as indicated by corners 16A and 16B. These extended side panels act as guides to help retain tabs 201A and 201B inside the body portion of the pack;</li><li>c) in the blank of <figref idref="f0005">Figure 9</figref>, the diagonal cut at the tops of the body side panels 11A and 11B are extended into the body front panel of the pack, as indicated by lines 46 A and 46B. These upward extensions at the edges of the body front panel 12 help to retain tabs 201A and 201B in the closed position to provide the anti-yawn mechanism, but do allow the lid to open if the tabs 201A and 201B are deflected slightly inwards. Conversely, when the lid is being closed, the upward extensions urge the tabs 201A and 201B inwards to clear the body front panel 12, thereby allowing the lid to be closed without undue resistance. (Note that some existing HL packs already extend the diagonal cut at the tops of the body side panels 11A and 11B slightly around to the body front panel of the pack, primarily for aesthetic reasons).</li></ol>

It will be appreciated that since the blank of <figref idref="f0005">Figure 9</figref> has the same overall structure as the blank of <figref idref="f0005">Figure 8</figref>, in terms of panels, cuts and folds, factory machinery that already exists for making HL packs from the blank of <figref idref="f0005">Figure 8</figref> can be readily modified to accommodate the blank of <figref idref="f0005">Figure 9</figref>.

Although various embodiments of the invention have been described, many further variations and modifications will be readily apparent to the skilled person. For example, although the present approach has been described generally in the context of cigarettes, it can be applied to a wider range of smoking articles, e.g. cigars. In addition, the embodiments described and illustrated herein refer to packets in which the edges are formed by the panels at right angles with rounded edges. However, a packet could also be formed with any other shape known in the art. Accordingly, the scope of the present invention is defined by the appended claims and their equivalents.