The invention relates to a cigarette shell , a method o f production thereof , and an assembly for storage and transportation thereof .

Unfilled cigarette shells known to the public as pre-rolled cigarette tubes are des irable among smokers who prefer to mix- and-match their own tobacco without having to roll their own cigarettes . These unfilled cigarette shells have an appearance similar to a finished cigarette , but are without any tobacco or smokable material inside which makes their structure inherently weak and easily collapsible during storage and transport . Even partially collapsed cigarettes shells become di f ficult to fill and can be rendered unusable . Cone-shaped cigarettes are popular because as the cigarette burns the flavor tends to get progressively stronger . A cone furthermore allows for more tobacco to be burned at the beginning than the end, allowing for an even f lavor . Even separately from the above mentioned cone- shaped, also known as f rustoconical , cigarettes are simply highly popular among smokers . These f rustoconical cigarette shells are presently filled by hand . A user wil l urge a smokeable into the body using a packing stick, a toothpick, each of which is easy to lose , can be inconvenient in transport . More importantly, the use of a stick or toothpick may lead the user to exerci se excessive force , thus damaging the cigarette shell from the inside . Accordingly, there exists the problem that present cigarette shells are vulnerable in transport and are easily damaged during the filling thereof .

It is an obj ect of the current invention to provide solutions for the aforementioned problem or at the very least to provide the smoker with alternative cigarette shell options .

This and other obj ects which will become apparent from the following disclosure , are provided with a cigarette shell , a method of production thereo f , and an assembly of a trape zoidal box and a trapezoidal tray within the box , having the features of one or more of the appended claims . Trapezoid is throughout the application given to mean a non-parallelogram trapezoid with two paral lel sides , and a line of symmetry . In British English this is also more speci fically referred to an I soceles Trapezium, whereas in American Engl ish this is referred to as an I soceles Trapezoid . This is to clearly distinguish this shape from any sort of rectangle , which would provide an uneven level of surface friction while uncoiling from top to bottom i f coiled into a f rustoconical shape .

According to a first aspect of the invention, the cigarette shell comprises : a hollow f rustoconical body defining a narrow end and a broad end; a tip provided within the narrow end of the body; and a removable insert in a nested pos ition with the body for supporting the body from the inside against collapse .

Beneficially, the presence of a nested insert wi ll forti fy the body against collapsing inwardly as pinching forces may be supported by the body onto the insert . To this end the insert may be chosen so as increase the total rigidity of the shell .

In addition, the insert has a portion that , when in the nested position, protrudes form the body, such as from the broad end, for being manually engaged by a user . This makes the insert easily manipulatable by said user, who can pull out the insert by simply grabbing the protruded portion of said insert . This protruding portion may even be furnished with a pull ing tab so as to further increase the ease with which the insert is engaged by a user .

Suitably, the insert forms a chute for funneling a smokable into the body of the shell . This simplifies the process of filling the cigarette shell by maintaining the form of the cigarette shell whi le f ill ing and by broadening the opening of cigarette shell . More speci fically thi s provides the body with a protective inner lining so as to protect the body against tearing during a processing of filling the shell with a smokable .

In an advantageous embodiment of the invention, the insert i s made of a first sheet that is at least in part elastically deformed so as to , in the nested position, provide an outward pressure against a portion of the inner surface of the body above the tip . In one example , the sheet may be curved along the inner surface of the body to form a protective inner lining that adapts to the local inner diameter of the body .

Additionally, the first sheet may be curved such as to form at least one coil so that the insert is able to progress ively uncoil while being removed from the nested position through the broad end of the body so that during the removal the insert substantially maintains a pressure against an increasingly smaller portion of the inner surface of the body until it is fully removed . Advantageously, the portion of the insert that is in contact with the body substantially not only retains the inner shape and si ze of the portion of the body with which it is engaged, but also allows the one part of the sheet to sl ide out from underneath another part . Thus , reducing friction with any smokable already provided to the shel l upon removal of the insert from the body . Accordingly, this enables the smooth removal of the insert without removing the smokable material and without compromising the structure of the cigarette shell .

Furthermore , in order to provide the cigarette shell with the optimum structural support without compromising on the ease of use , the first sheet is coiled from a substantially square or trapezoidal shape , such as with rounded or cut edges , into a f rustoconical shape . In addition, the hollow f rustoconical body is made of rolling paper with a thickness between 10-20 gsm, and wherein the first sheet is substantially made of a paper with a thickness that exceeds the thickness o f rolling paper, such as 21- 140 gsm, preferably 60- 90 gsm . Thickness here is intended to mean areal density, instead of actual height in microns . The term thickness and areal density are interchangeably used hereinafter . Preferably, the shape is substantially trapezoidal so as to prevent unnecessary overlap between paper portions which might otherwise add to surface friction . The trapezoidal shape thus saves on paper and promotes even uncoiling .

In order to optimi ze the storing space inside of a box, or in general , the shell may be nested with another shell like it so that the insert acts as a spacer between the body o f the shell and the body from the next shell nested . In this example the insert is pre ferably arranged as a chute . However, other forms may al so be poss ible . In one example , the insert may simply be a ring or a series of connected rings . In any of the before mentioned cases , the nesting of shells will also allow the shells lend support to each other against collapse , thus further increas ing the resi stance o f the shells against collapse . This means that inserts may be reduced in thickness and would stil l lend support due to the cumulative strength of inserts across at least a part of the series of nested shells .

In an example compatible with all embodiments of the invention the insert may have a broad end, and a narrow end, and wherein a portion of said narrow end is folded inwardly or crumpled . Beneficially this allows the inwardly folded portion to support a series of nested cigarette shells against compress ion in the length direction, as opposed to only protect against radial compression . With certain insert pressure along the length direction of the shell may rip the shell . This occurs most commonly when a user holds a cone between index finger and thumb, such as for showcasing the shell to friends . Or when one simply handles the cone too enthusiastically, such as during a filling process . Surprisingly, it was found that by folding a portion of the narrow end inwardly the fil ling isn' t hindered, as this usually occurs with a small stick for compressing the smokeable . This same pressing action can also fold the inwardly folded portion outward, allowing the insert to still serve as a chute for any filling operation . It is theorized that in the inwardly folded variant the inwardly folded portion acts as an upstanding inner ledge that provides support against compression, whereas in the variant of the crumpled narrow end it are likely irregularities in in the shape of the inner diameter at the narrow end that provide support against compression . In one example , the crumpled variant can be produced by coiling the sheet of the insert , and tapping it on a surface , such as a table , with a distal end prior to its insertion into a hollow f rustoconical body with said distal end . In another example the inwardly folded variant can be produced by folding a precoiled sheet inwardly at its distal end, prior to insertion . Insertion being the insertion of the insert into a hollow f rustoconical body to form the shell .

According to a second aspect of the invention, the method for producing a cigarette shell comprises the steps of : providing the shell having a hollow f rustoconical body defining a narrow end and a broad end and wherein a tip is provided within the narrow end of the body; and providing a removable insert made of a first sheet ; elastically deforming the first sheet , such as into a coil , so that the de formed sheet f its into the broad end of the body; moving the insert into a nested position with the body for supporting the body from the inside against collapse .

In order to optimi ze the storing space inside a box, or in general , the method wherein the insert forms a chute , comprises the step of being nesting another shell with the shell by fitting a narrow end of the other shell into the broad end of the shell such that the insert spaces the body of the shell from a body of the other shell . In particular the spacer extends along at least a part of the length of both bodies . It shall be understood that the nesting of such shells need not be limited to merely two shells , but may extend infinitely . That is to say, every shell that is itsel f nested may receive another shell for nesting in the same manner .

According to a third aspect of the invention there i s provided an assembly of a trapezoidal box and a trapezoidal tray . The tray of the assembly has upstanding lateral edges for reinforcing the sides of the box, wherein the tray i s foldable along its longitudinal l ine , such as through the middle of the tray, for forming an M-shaped slide . The above may understood as fol lows . The tray may as sume a tray configuration, in which the tray is U-shaped, and a slide configuration in which the tray is M-shaped . In the tray configuration the tray is suitable for carrying a plurality of shells , or a plurality of series of nested shells , laid side by side . In the M-shaped configuration the tray can be used as a s lide for receiving smokables en for using it in the process of filling a cigarette shell as discussed herein above .

Optionally, the upstanding lateral edges decrease in height along a direction of mutual convergence so that in cross-section the M-shape decreases in si ze from a first end to a second end thereof . This provides the slide with a natural tilt towards the second end . This end may be provided with two fold lines with converge in the opposite direction to the upstanding lateral edges . This allows an upstanding wall to be formed by a user, i f so des ired . The tilt then prevents materials from slide out of the slide , but are retained at the narrow end .

For ease o f use , the tray may comprise a pull tab at the first end of the tray for manually removing the tray from the box , wherein the tab protrudes from the tray and extends across the longitudinal line of the tray .

For an increased structural support said trapezoidal box decreases in height from a first end to a second end thereof so that the height of the box matches the height of the upstanding lateral edges of the tray .

Advantageously, the assembly further comprises a shell provided between the upstanding edges on the tray; wherein the height of the upstanding edges at the first end is substantially equal to the diameter of the broad end of the body of the shell , and wherein the height of the upstanding edges at the second end is substantially equal to the diameter of the narrow end of the body o f the shel l . This prevents the shel ls from moving within the package while also reducing the amount of packaging .

The invention will hereinafter be further elucidated with reference to the drawing of an exemplary embodiment of an cigarette shell and an assembly according to the invention that is not limiting as to the appended claims .

In the drawing : figure 1 shows a schematic drawing of a cigarette shell according to the invention in a front view; figure 2 shows a schematic representation of the steps for forming the shell according to the invention using an insert ; figure 3 shows a schematic representation of the steps for forming the shell according to the invention using an alternative insert figure 4 shows an assembly according to the invention containing cigarette shells ; figure 5 shows a schematic drawing of a trapezoidal tray of the assembly according to the invention in various configurations ; figure 6 shows the tray in an M-shaped configuration in use for filling a shell according to the invention; figure 7 shows a cigarette shell according to the invention loaded with a smokable wherein the insert is being removed; and figure 8 shows two cigarette shells of the invention in a front view;

Whenever in the figures the same reference numerals are applied, these numerals refer to the same parts.

Figure 1 shows a cigarette shell 1 according to the invention. The shell has a hollow f rustoconical body 3 made of rolling paper and defining a narrow end 3.1 and a broad end 3.2. Within the narrow end of the body a tip 5 is provided. This may be any sort of traditional rolled paper tip or filter. Besides these features the shell is provided with an insert 7 that is nested within the body 3 of the cigarette shell 1. The insert is nested with the body and supports the body from the inside against collapse. The insert is designed to be removable through the broad end 3.2. To this end the length of the insert exceeds the distance between an end of the tip within the body and the broad end 3.2 of the body. This allows a portion 7.1 of the insert 7 to project out from the body for being engaged by a user. Preferably the projecting portion 7.1 is no shorter than 1 mm so as to at least allow a human nail to pinch the portion for removal. In one example, not shown herein, the projecting portion may form a pull tab or lip.

Figure 2 shows a schematic representation of the steps that are required for forming the shell according to the invention using an insert. Figure 2 shows from left to right an insert 7 formed as a trapezoidal paper sheet with a thickness of 60-90 gsm and with rounded corners. This insert being elastically deformed so as to obtain a substantially f rustoconical shape which is coiled so that its narrow end fits into the broad end 3.2 of the body 3 . The insert is then slid into the body until it abuts an inner end 5 . 1 o f the tip 5 . This is the deepest nested pos ition that the insert can reach . In this final arrangement the shell 1 sees a portion 7 . 1 of said insert 7 still protruding from the f rustoconical body 3 of the shell 1 . This is of course optional . After all , an insert does not need to protrude , but may instead be scraped out with a tamping stick (not shown, but customary) , such as commonly used by smokers . In this example though, a user can easily grab the protruded portion 7 . 1 to manipulate the position of the insert . In its coiled form and in the nested position the insert forms an inner lining that protects the body forti fying the structure of the cigarette shell 1 and al lowing it to maintain its shape against outside forces . It can also be seen that the coiled insert forms a funnel for funneling smokable material inside the f rustoconical body 3 of the cigarette shell 1 .

In Figure 2 a cross-sectional view A-A of an insert while coiled is shown . The insert 7 may have a broad end, and a narrow end 7 . 1 . A portion of said narrow end is folded inwardly . This provides the insert with an inner ledge on which the narrow end of a shell can be supported for nesting . Alternatively, the end is crumpled . Beneficially this allows the inwardly folded or crumpled portion to support a series of nested cigarettes against compression in the length direction, as opposed to only protect against radial compression .

Figure 3 shows an alternative embodiment of the insert 7 * with respect to the insert 7 of Figure 2 . Same features are indicated by same reference numerals . Hereinafter only di f ferences between these inserts will be discussed . The insert 7 * is here shown to be substantial rectangular with two corners in a trans arrangement on opposite edges of the sheet being rounded or cut . This allows the friction of the sheet with itsel f to be reduced during an uncoiling action, such as during removal . This reducing the fluency with which the insert is removed with respect to an rectangular shape without rounded or cut corners .

Figure 4 shows how the cigarette shells according to the invention can be stored, namely by means of an assembly 10 a trapezoidal box 11 and a trapezoidal tray 12 within the box . Shells of nested shells can be placed side by side on the tray between lateral upstanding edges 13 . These edges diverge with an angle that is substantially equal to number of shells placed side by s ide times the angle with which the body of the shells diverge . This ensures a snug fit , and prevents any rolling . The box may be designed for housing two , three , four or more shells side by side . The tray 12 is foldable along a longitudinal line such as through the middle of the tray 12 , for forming an M- shaped slide , which shown in Figure 5 and discussed hereinafter .

Figure 5 shows from left to right the trapezoidal tray 12 in a sheet configuration; the trapezoidal tray 12 in a tray configuration; and the trapezoidal tray 12 in an M-shaped slide configuration . The tray 12 is folded from its sheet configuration into the tray configuration so as to have pronounced lateral upstanding edges 13 . The tray 12 can then receive a number of cigarettes , as seen in figure 4 , and be taken up into the trapezoidal box 11 . The upstanding lateral edges 13 there forti fy the upstanding lateral walls of trapezoidal box 11 and act as a second set of lateral walls .

In order to fill a cigarette shel l 1 with smokable material 9 the user can pull the tray 12 from the box 11 using the tab 14 . This tab is purely optional , but extends across the longitudinal line 12 . 1 , Subsequently, the user may proceed to folding the tray 12 such as to form an M-shaped slide . The M-shaped sl ide formed by the folded tray 12 provides a support for the cigarette shell 1 and for the smokable material 9 , as seen in figure 6 , wherein said smokable material 9 can be easily s lid inside the cigarette shell 1 . Returning to Figure 5 it is pointed out thar the tray may be returned into the tray configuration from the M-shaped sl ide configuration by flattening the fold across the longitudinal line 12 . 1 .

In Figure 6 the smokable material is scooped into the shell . Once the smokable material 9 is inside the cigarette shell 1 , the user can grab the protruding portion 7 . 1 of the insert and pull the insert 7 out of the cigarette shell 1 before sealing the broad end 3 . 2 of the cigarette shell 1 .

Figure 7 depicts from left to right the removal of the insert from the body, from partially to fully removed, Figure 8 show an exemplary application of the invention wherein an cigarette shell 1 can be nested with another same cigarette shell 1 ' . In this manner the insert 7 of the cigarette shell 1 serves as a spacer that spaces the body 5 of the cigarette shell 1 from a body 5 ' of the other cigarette shell 1 ' . It is in such a case also possible that the other cigarette shell 1 ' itsel f comprises an insert 7 ' . While not shown it is possible for yet another cigarette shell to be nested in the same manner with the other cigarette shell 1 ' .

Although the invention has been discussed in the foregoing with reference to an exemplary embodiment of the method of the invention, the invention is not restricted to this particular embodiment which can be varied in many ways without departing from the invention . The discussed exemplary embodiment shall there fore not be used to construe the appended claims strictly in accordance therewith . On the contrary the embodiment is merely intended to explain the wording of the appended claims without intent to limit the claims to this exemplary embodiment . The scope of protection of the invention shall therefore be construed in accordance with the appended claims only, wherein a possible ambiguity in the wording of the claims shall be resolved using this exemplary embodiment .