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 Hd 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 Hd. Consequently, if the Hd 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.

US 5904244 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 WO 96/09230. 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).

Summary of the Invention

Accordingly, one embodiment of the invention provides 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.

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 engages the front panel of the body when the pack is closed. For example, 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 the above embodiment, the engagement between the inner tab and the front panel resists opening of the lid. In other embodiments, opening of the lid may be resisted by some other mechanism, such as by friction between the inner tab and the interior of a corresponding side panel of the body portion of the pack. For example, in one embodiment, the inner tab of the Hd side panel is shaped to engage a restraining

member having a complementary shape on the inside of the corresponding body side panel. The inner tab includes a protrusion that engages a complementary notch in the restraining member. In this embodiment, each body side panel may comprise an inner layer and an outer layer, wherein the restraining member forms part of the inner layer.

In one embodiment, the portion of the inner tab adjacent the back of the pack lid extends, below and within the side panel of the body adjacent the back of the pack. This configuration helps guide the inner tab to the inside of the pack body as the pack is being closed, from which position it can then engage the front panel of the body.

In one embodiment, the front panel of the body portion extends diagonally upwards adjacent the side panel where the front panel is engaged by 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 folly 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).

Brief Description of the Drawings

Various embodiments of the invention will now be described in detail by way of example only with reference to the following drawings:

Figures Ia and Ib illustrate the general configuration of a hinged lid pack. Figure 2 is a more detailed front view of a hinged lid pack in accordance with one embodiment of the invention.

Figure 3 is a front view of the hinged lid pack in Figure 2, but with the lid removed.

Figure 4 is a side view of the hinged lid pack of Figure 2 with the lid open. Figure 5 is a side view of the hinged lid pack of Figure 2 with the lid closed. Figure 6 is a detail of the hinged lid pack of Figure 2 with the lid closing. Figure 7 is a side view of the hinged lid pack of Figure 2 with the lid half open.

Figure 8 depicts a blank for a conventional hinged lid pack. Figure 9 depicts a blank for a hinged lid pack in accordance with one embodiment of the invention.

Figure 10 depicts a blank for a hinged lid pack in accordance with one embodiment of the invention.

Figure 11 depicts a blank for a hinged lid pack in accordance with one embodiment of the invention.

Figure 12 is a side view of the hinged lid pack formed from the blank of Figure 10 with the lid closed.

Detailed Description

Figures IA and IB 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 HA, HB, and a bottom panel (not shown in Figures IA and IB). The lid comprises opposing front 22 and back 23 panels, two opposing side panels 21A ₅ 21B (aligned with body side panels 1 IA and 1 IB 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.

Figure 2 illustrates in more detail the front of an HL pack in accordance with one embodiment of the invention. As can be seen in Figure 2, 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.

Figure 3 shows the HL pack of Figure 2 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 11 IA, 11 IB (frame side panel 11 IB is shown in Figure 4A; the opposing side panel 11 IA 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, 11 IA and 11 IB, are normally glued to the interior surface of the corresponding side panels (1 IA and 1 IB respectively) of the body portion 4.

The front 112 and side panels 11 IA, 11 IB 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 1 IA and lid side panel 21 A and/or at line of abutment 37B between body side panel 1 IB and lid side panel 2 IB. 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.

Figure 4 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 20 IB that extends beyond the side panel 2 IB of the lid. The opposing side panel 21A of the lid is also provided with such a curved extension 201A (not visible in Figure 4).

Figure 5 depicts the HL pack of Figure 4 with the lid closed. When the lid 5 is closed, tab 20 IB slides between the body side panel 1 IB and the inner frame side panel 11 IB, likewise for the tab on the opposing side of the pack. The position of tab 20 IB behind side panel HB is shown in dotted outline in Figure 5.

Tab 20 IB 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 20 IB provides resistance to opening the lid 5. Accordingly, tab 20 IB 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 20 IB 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 20 IB 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 20 IB to return to the position shown in Figure 5 (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 20 IB is guided by side panel 1 IB 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 20 IB 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 Figure 6. 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 1 IA-. 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 comer 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 20 IA is then able to return resiliently to its original planar configuration, this action also being assisted as the tab 20 IA is received between the body side panel 1 IA and the inner frame side panel 11 IA (not visible). Finally, when the lid is fully closed, tab 201 A is back to the anti-yawn configuration shown in Figure 5.

In another embodiment, there is no overlap between the body front panel 12 and the tab 20 IB. In this embodiment, resistance to opening the pack is provided by friction between the tab 20 IB and the internal surface of the corresponding side panel 1 IB of body portion 4. For example, with reference to Figure 6, to open lid 5, tab 201A slides past side panel 1 IA (which is substantially coplanar with tab 201A). The friction associated with this sliding movement helps to keep the Hd 5 closed. This resistance is increased if the pack is also provided with an inner frame 102, since tab 201 A is now located between the side panel 1 IA of body portion 4 and the side wall 11 IA (not shown in Figure 6) of inner frame 102. This sandwich arrangement for the tab 20 IA provides greater friction for withdrawing the tab 20 IA from the side panel 1 IA of body portion 4 and the side wall 11 IA of inner frame 102.

Figure 7 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 1 IB adjacent to the body back panel 13 is at a higher level (i.e. overlaps) the bottom corner 21 IB of tab 201B adjacent to hinge line 38 (see also Figure 5). 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 20 IB is received inside (rather than outside) the body side panel 1 IB. Although there is no overlap when the lid is folly open (as shown in Figure 4), the bottom corner 21 IB of the tab portion remains close to the top corner 16B of the body side paneL 1 IB. This restricts the possibility of significant relative movement between the two. Accordingly, when the lid starts to close, the position of corner 21 IB inside corner 16B is maintained, which then guides the remainder of tab 20 IB to pass inside side wall 1 IB to ensure proper operation of the anti-yawn mechanism.

Figure S illustrates a blank for a conventional HL pack, with cut lines indicated by solid lines and fold lines indicated by dashed lines. Figure 9 illustrates a blank for a HL pack in accordance with one embodiment of the invention. It will be appreciated that although the blank of Figure 9 comprises the same set of panels as the blank of Figure 8, 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 Figure 9 compared to Figure 8.

Both Figures 8 and 9 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 61 IA and 6 HB are glued inside side panels 11A and HB; and lid top panels 614A and 614B fold underneath lid panel 15. Note that tabs 20 IA and 20 IB are joined to lid top panels 614A and 614B respectively.

The following are the main points of distinction between the blank of Figure 8 and the blank of Figure 9: a) in the blank of Figure 8, the panels corresponding to tabs 20 IA and 20 IB are coextensive with the corresponding lid side panels 21 A and 2 IB respectively, whereas in the blank of Figure 9, the tabs 201 A and 201B are larger than corresponding lid side panels 21 A and 21b respectively. Accordingly, in the blank of Figure 8 the panels corresponding to tabs 201 A and 201B do not extend below lid side panels 21A and 21B, and therefore, unlike the blank of Figure 9, do not engage front panel 12 and/or corresponding body side panels 1 IA and 1 IB to provide any anti-yawn

mechanism. Note also that because the tabs 20 IA and 20 IB in Figure 9 are larger than corresponding Hd side panels 21 A and 2 IB respectively, during assembly of the pack, the full surface of lid side panel 21 A can be used for gluing to tab 20 IA and the full surface of lid side panel 2 IB can be used for gluing to tab 20 IB. (This is in contrast to the situation with above-cited US 5904244, in which the inner side tabs for the Hd are reduced in size compared to the (outer) Hd side panels). b) in the blank of Figure 9, the tops of the body side panels 1 IA and 1 IB are extended compared to the blank of Figure 8, as indicated by corners 16A and 16B. These extended side panels act as guides to help retain tabs 20 IA and 20 IB inside the body portion of the pack. c) in the blank of Figure 9, the diagonal cut at the tops of the body side panels HA and 1 IB 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 20 IA and 20 IB in the closed position to provide the anti-yawn mechanism, but do allow the Hd to open if the tabs 201A and 201B are deflected slightly inwards. Conversely, when the Hd is being closed, the upward extensions urge the tabs 20 IA and 20 IB inwards to clear the body front panel 12, thereby allowing the lid to be closed without undue resistance. (Note that some existing BDL packs already extend the diagonal cut at the tops of the body side panels 1 IA and 1 IB slightly around to the body front panel of the pack, primarily for aesthetic reasons).

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

Figure 10 illustrates a blank in accordance with another embodiment of the invention. This blank has many similarities with the blank of Figure 9, and accordingly only the differences between these two blanks will be described. The edges of the pack of Figure 10 are rounded (rather than sharp as per the blank of Figure 9), as indicated by parallel lines 80 IB and 80 IA extending the length of the blank. In particular, in the pack assembled from the blank of Figure 10, the edges between the front panel 12, 22 and the two side panels 1 IA, 1 IB, 21 A, 21B, and

likewise the edges between the back panel 13, 23 and the two side panels 1 IA, 1 IB, 21A, 21B are all rounded.

The rounded nature of these edges renders it less effective for the front edge of inner tabs 20 IA and 20 IB to engage the top of front panel 12. Accordingly, the blank of Figure 10 supports a different anti-yawn mechanism, based on the shape of the cut 810 between side inner panels 611 and the inner tabs 201. In particular, the cut 810 involves complementary shaping of the side inner panels 611 and the inner tabs 201 to provide engagement or interlocking of the side inner ^' panels 611 and the inner tabs 201. Note that in the blank of Figure 10, the inner tabs 201 are still larger than the corresponding lid side panels 21 and so extend below these side panels (as for the blank of Figure 9).

Figure 11 illustrates a blank in accordance with another embodiment of the invention. This blank is substantially the same as the blank of Figure 10, except that the cut between the inner tabs 201 and the side panels 611 is different, in particular regarding the complementary shape at 810. It will be appreciated that many further possible cuts for the complementary shape 810 will be apparent to the skilled person.

Figure 12 illustrates the way in which the complementary shaping 810 (as indicated by the dotted line) acts to restrain the lid from opening when the pack is closed. Thus the inner tab 201B includes a protrusion or extension 812B directed downwards towards the base (body) of the pack. This protrusion is received into a corresponding notch or recess formed within the inner body side panel. This recess is bounded at the front of the pack by extension 815 on the side inner panel, which is directed upwards towards the top (lid) of the pack.

If a user tries to open the pack, the protrusion 812 abuts (edge-to-edge) against the extension 815 to resist opening of the pack. As slightly more force is applied to open the pack, protrusion 812 and/or extension 815 deforms (resiliently), so that they are no longer in the same plane. This allows protrusion 812 to therefore slide past extension 815, thereby permitting the lid to open. When the pack is closed, the protrusion 812 and extension 815 return to the positions shown in Figure 12 to reactivate the anti-locking mechanism.

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.