Note: Descriptions are shown in the official language in which they were submitted.
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HINGE LID PACKAGE
FIELD OF THE INVENTION
The present invention pertains to the field of hinge lid packages and to
blanks for
making such packages. In particular, the present invention pertains to a hinge
lid package
with good opening and closing capabilities.
BACKGROUND
In the past, considerable effort has been invested in producing cigarette
packages that
are lightweight, easy to open and close and which are aesthetically pleasing
to the eye.
Conventional hinge lid cigarette packages are well known in the art and are
usually
produced from a either a single blank or two blanks as outlined in U.S. Patent
No.
6,276,600, U.S. Patent No. 5,586,648 and U.S. Patent No. 5,553,773 and
constructed of
paperboard substrate which may be coated with a fluidized mixture of finely
particulated
minerals and binders resulting in a smooth luxurious appearance.
There are several problems that occur with extended use of prior art hinge lid
cigarette packages. Such problems include damage to the paper-board material
as a result of
repeated openings and closings of the package lid and "smiling" which is
defined in the art
as a "popping open" or slight separation of the lid away from a fully closed
position.
Smiling is generally observed as soon as the outer wrapping is removed from
the package
and will increase following the initial opening of the package. The degree to
which smiling
occurs usually increases with extended use of the package.
U.S. Patent No. 6,276,600 attempts to solve the problem of "smiling" by
providing a
container comprising a round-corner body and lid wherein the lid is hingedly
attached to the
body along a curved perimeter. However, although the curved hinge lid reduces
the
occurrence of "smiling" the package becomes difficult to open and close due to
the
curvature of the lid perimeter.
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Similarly, others, for example as described in German patent DE 39 26 621 Al,
have
attempted to overcome this problem by increasing the pivot point height of the
hinge to
above the intersection point of the rear lid panel and rear box panel.
However, as with U.S.
Patent No. 6,276,600, the force required to open and close the lid of such a
cigarette package
as disclosed in DE 39 26 621 Al is much greater than for other types of prior
art cigarette
packages. This results in damage to the cigarette package itself, for example
ripping and
tearing, as well as damage to the contents (cigarettes) housed within the
package.
Another problem associated with prior art cigarette packages is that they can
be
difficult to open, and excessive force is often required to open the package
lid either because
there is internal interference, or the lid distorts sideways from its closing
position when
opened. Further, prior art cigarette package lids routinely "hang-up" or
become snagged by
interfering or catching on the inner frame or collar when being opened.
U.S. Patent No. 3,874,581 discloses inclined slits that are provided at the
ends of the
hinge line to facilitate easier opening of the lid. Attempts have been made to
facilitate hinge
lid cigarette packages that are easier to open and which remain completely
closed when not
in use.
U.S. Patent 5,553,773 discloses a blank having collar side tabs angled off to
an
oblique edge which, when assembled, are intended to ensure easy opening and
closing of the
lid. Similarly, U.S. Patent No. 5,586,648 discloses a package made from a
blank with collar
side tabs designed with special contours such that recesses are formed that
result in inner
side webs with less height, in an attempt to simplify the extraction of the
cigarettes and
reduce interference between the collar and lid when opening the cigarette
package.
U.S. Patent No. 5,586,648 discloses the use of material webs formed by
punching
perforations in corresponding regions between the front wall of the main blank
and the inner
lid of the collar or inner frame blank. Although these material webs retain
the lid in a tightly
closed position, once these webs are broken upon the initial opening of the
hinge lid of the
package it becomes difficult to properly close the lid. In order to close the
hinge lid a user
must ensure that each web tab properly aligns with its corresponding web
cavity before
closing the lid. Not only is this a difficult and arduous task, but if used
incorrectly this
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configuration prevents proper full closure of the lid onto the box part or
main frame of the
cigarette package.
GB 2 151 212 discloses that an inclination of the side and front edges of the
blank
facilitates closure of the packet by the effective removal of the front upper
corners of the
collar which would otherwise engage the reinforcing panel during closure. In
addition to this
type of package it is also known to employ an inner frame that is tapered, in
that it grows
larger as you move toward the top of the pack as disclosed in U.S. Patent No.
5,392,905.
However, the ever-widening shoulder of this type of package although
functional, is not
aesthetically appealing which is a major consideration in the field of tobacco
packaging.
There remains a need, therefore for cigarette packages having improved opening
and
closing capabilities that require reduced force to open and which prevent
"smiling" of the
package during use. In addition, these packages must remain tightly closed
when stored as
well as maintain a luxurious feel and an aesthetically appealing appearance
throughout the
lifetime of the product.
This background information is provided for the purpose of making known
information believed by the applicant to be of possible relevance to the
present invention.
No admission is necessarily intended, nor should be construed, that any of the
preceding
information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a hinge lid package, for
example a
cigarette package, that requires less force to open and close than
conventional hinge lid
packages while preventing the occurrence of package "smiling". In accordance
with an
aspect of the present invention, there is provided a hinge lid package with an
improved
opening and closing mechanism comprising a cam assembly as illustrated in
Figure 4 which
facilitates a reduction in the force required to open and close the lid of the
hinge lid cigarette
package.
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In accordance with another aspect of the present invention, there is provided
a
package having a hinge lid assembly, a cam resting in the interior portion of
the lid, and a
set of latching tabs comprising an unconventionally modified profile that
provides a smooth
and progressive frictional engagement with the cam assembly within the lid of
the main
package frame and that co-operate to provide a cigarette package having a lid
with improved
opening and closing properties.
In accordance with another aspect of the present invention, there is provided
a hinge
lid package comprising a cam resting in the interior portion of the lid, and a
set of latching
tabs comprising a modified profile that provides a smooth and progressive
frictional
engagement with the cam assembly within the lid of the main package frame and
a modified
raised hinge lid pivot point that co-operate to provide a cigarette package
having a lid with
improved opening and closing properties.
In accordance with another aspect of the invention, there is provided a hinge
lid
package having a cam assembly frictionally engageable with an modified
latching tab
profile, a modified inner frame profile and a raised hinge lid pivot point
that provides a
hinge lid cigarette package that requires significantly less force to open and
close, decreases
the occurrences of package "smiling" and has a luxurious feel and elegant
appearance.
In accordance with another aspect of the invention, there is provided a
package
comprising: (a) a box part having a pair of opposed front and rear panels, a
pair of opposed
side panels and a bottom panel; (b) a lid having a pair of opposed front and
rear panels, a
pair of opposed side panels and a top panel, said lid being pivotally moveable
between an
open and a closed position about a hinge connection defined by a pivot axis
along a fold
between the rear panels of said lid and box part and being substantially
parallel to said top
and bottom panels; (c) an inner frame closely received in and having a portion
projecting
upwardly from said box part, said inner frame having a front panel and a pair
of opposed
side panels each connected to an opposite end of the front panel along a fold
line
substantially parallel to said side panels, said projecting portion being
closely received by
said lid when in the closed position; (d) a pair of latching tabs, each
latching tab extending
outwardly from one of said fold lines of said inner frame and having a forward
facing
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surface and a rearward facing surface; and (e) a pair of cam panels, each cam
panel being
secured to the inside of each lid side panel and having a forward facing edge
in closely
spaced relation to the inside of said front panel, or a corresponding ridge
formed between
each of the side panels and said front panel, and defining a latching tab
retaining zone
therebetween, whereby when said lid is moved from said open position to said
closed
position, said latching tabs are closely received and wedged within said
corresponding
latching tab retaining zones.
BRIEF DESCRIPTION OF THE FIGURES
The invention is illustrated in particular by reference to the accompanying
drawings
in which:
Figure 1 is a perspective view illustrating a prior art hinge lid cigarette
package.
Figure 2A is a plan view of a blank for a prior art hinge lid cigarette
package and
Figure 2B is a plan view of a standard inner frame in an unfolded
configuration.
Figure 3 is a perspective view illustrating a hinge lid cigarette package
comprising a
lid side panel having a non-engaging curved profile.
Figure 4A is a perspective view a hinge lid cigarette package according to one
embodiment of the present invention comprising a cam panel. Figure 4B is an
enlarged view
of the cam panel.
Figure 5 depicts a cross-sectional view of the lid of the package depicted in
Figure 4,
which is in a fully closed configuration. The enlarged view depicts the
position of a latching
tab and its corresponding cam panel in relation to the lid and inner frame of
the fully closed
package.
Figure 6 is an enlarged view of a cam panel according to one embodiment of the
present invention, in which the region between the dashed lines is the wedging
zone and the
inclination angle is shown.
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Figure 7 illustrates the relative positions of a cam panel, having a non-
functional
inclination angle of greater than 45 , a latching tab and the lid inside front
panel when the lid
is in a partially closed position.
Figure 8 illustrates the relative positions of a cam panel, having a non-
functional
inclination angle of greater than 45 , a latching tab and the lid inside front
panel when the lid
is in a fully closed position.
Figure 9 illustrates the relative positions of a cam panel, having a non-
functional
inclination angle of less than 15 , a latching tab and the lid inside front
panel when the lid is
in a partially closed position.
Figure 10 illustrates the relative positions of a cam panel, having a non-
functional
inclination angle of less than 15 , a latching tab and the lid inside front
panel when the lid is
in a fully closed position.
Figure 11 illustrates the relative positions of a cam panel, having a
functional
inclination angle of approximately 33.8 , a latching tab and the lid inside
front panel when
the lid is in a partially closed position.
Figure 12 illustrates the relative positions of a cam panel, having a
functional
inclination angle of approximately 33.8 , a latching tab and the lid inside
front panel when
the lid is in a fully closed position.
Figure 13 illustrates the relative positions of a cam panel, having a
functional
inclination angle, a latching tab and the lid inside front panel when the lid
is in a partially
closed position. The dashed lines represent the zero interference latching tab
trajectories of a
damaged, or not fully deployed latching tab and an undamaged, fully deployed
latching tab.
Also shown in Figure 13 is the position of the wedging zone with respect to
the upper and
lower limits of the assembly play.
Figure 14A is a perspective view a hinge lid cigarette package according to
one
embodiment of the present invention comprising a cam panel with a recessed
cavity. Figure
4B is an enlarged view of the cam panel.
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Figure 15 illustrates an inner frame comprising a modified latching tab
according to
one embodiment of the present invention.
Figure 16 is an enlarged view of a latching tab according to one embodiment of
the
present invention.
Figure 17 is a perspective view of a latching tab according to one embodiment
of the
present invention.
Figures 18A and 18B depict latching tabs having a non-functional contact angle
and
a functional contact angle, respectively.
Figure 19A is a front view of a fully closed package comprising a modified
latching
tab according to one embodiment of the present invention. Figure 19B is an
enlarged view
of the latching tab showing its position relative to the cam panel and lid
side panel of the
package.
Figure 20A shows a modified inner frame according to one embodiment of the
present invention in the folded configuration maintained within box part 10.
Figure 20B
depicts the same inner frame in its unfolded configuration. The dashed lines
represent the
shape of a standard inner frame.
Figure 21 shows a modified inner frame according to one embodiment of the
present
invention in the its unfolded configuration. The dashed lines represent the
shape of a
standard inner frame.
Figure 22 is an enlarged view of the bevelled front corners of a modified
inner frame
according to one embodiment of the present invention. The dashed lines depict
examples of
different front corner profiles that can be incorporated into the modified
inner frame of the
present invention.
Figure 23 is a perspective rear view of a hinge lid cigarette package
according to one
embodiment of the present invention having a raised lid pivot axis position.
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Figure 24 is a side view of a package having a raised pivot axis and a
modified inner
frame according to one embodiment of the present invention, wherein the
package is in a
partially closed position.
Figure 25 is a side view of a package having a raised pivot axis and a
standard inner
frame, wherein the package is in a partially closed position.
Figure 26 is a side view of a package having a standard pivot axis position
and a
modified inner frame according to one embodiment of the present invention,
wherein the
package is in a partially closed position.
Figure 27 is a side view of a standard package having a standard pivot axis
position
and a standard inner frame, wherein the package is in a partially closed
position.
Figure 28 is a perspective view illustrating one embodiment of a hinge lid
cigarette
package according to the present invention, which comprises cam panels,
modified latching
tabs and a standard inner frame.
Figure 29 is a perspective view illustrating one embodiment of a hinge lid
cigarette
package of the present invention, which comprises cam panels, modified
latching tabs and a
modified inner frame.
Figure 30 is a perspective view illustrating one embodiment of a hinge lid
cigarette
package of the present invention, which comprises cam panels, modified
latching tabs, a
modified inner frame and a raised pivot axis.
Figure 31 depicts a blank for manufacture of the box part of the package
depicted in
Figure 30.
Figure 32A and 32B illustrate a standard "drop test" procedure used to measure
the
amount of "smiling" (the opening gap) between the lid and the main body of
various hinge
lid cigarette packages. Figure 32A demonstrates the first step of the "drop
test" wherein the
test package is dropped from a height of 100 mm. Figure 32B shows how the
opening gap is
measured using a ruler.
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Figure 33(A-C) illustrate the series of steps used to measure the force
required to
open (opening force) using a standard "PCA score bend tester". Figure 33A
illustrates the
first step of placing the cigarette package on holder and attaching the lid
clamp to the lid of
the cigarette package. Figure 33B illustrates the second step of attaching the
lid clamp chain
to the "PCA score bend tester". Figure 33C illustrates the final step of
activating of the
"PCA score bend tester" and measuring the force required to open the lid as
recorded on the
scale.
Figure 34 is a graphical representation of the results of a "drop test"
showing the
degree of "smiling" versus the number of times the test packages were opened.
This graph
includes results obtained from a control (commercial hinge lid cigarette
packages) and from
various improved hinge lid cigarette packages of the present invention.
Figure 35 is a graphical representation of the results of a test to determine
the degree
of opening force required to open a control package and three improved hinge
lid cigarette
packages according to specific embodiments of the present invention.
Figure 36 depicts various latching tab and inner frame configurations.
DETAILED DESCRIPTION OF THE INVENTION
The numbers in bold face type serve to identify the component parts that are
described and referred to in relation to the drawings depicting various
embodiments of the
invention. Unless defined otherwise, all technical and scientific terms used
herein have the
same meaning as commonly understood by one of ordinary skill in the art to
which this
invention belongs.
The present invention provides a hinge lid cigarette package that requires
less force
to open and close than conventional hinge lid cigarette packages and
significantly reduces
the occurrence of package "smiling".
The hinge lid package (hereinafter referred to as "package") of the instant
invention
comprises some of the features of a standard flip top cigarette package, for
example those
found in the package of U.S. Patent No. 5,392,905. With reference to Figures
1, 2A and 2B,
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which depict a conventional hinge lid cigarette package and the blanks used to
form such a
package, the features of a standard flip top cigarette package include a main
frame or box
part 10, and a lid 20. A cigarette group can be wrapped in an inner wrap of
paper, tin-foil,
or the like, and thus forms a cigarette bundle 11, an example of the intended
contents of the
package. Box part 10 comprises a box front panel 30, a box rear panel 32
(Figure 2A), and a
box bottom panel 34 (Figure 2A). The sides of box part 10 (only one side shown
in Figure 1)
are formed from mutually overlapping side frame panels 40 and 44 (Figure 2A),
which can
be connected to one another by adhesive bonding. The side frame panels 40 and
44 can
partially or fully overlap one another when the box sides are formed.
Analogous to the box part 10, the lid 20 comprises a lid front panel 50, a lid
rear
panel 52 (Figure 2A), and a lid top panel 60. The lid sides (only one of the
lid sides is
shown in Figure 1) are formed from mutually overlapping lid side frame panels
70 and 72
(Figure 2A), which can be adhesively bonded to one another. Lid side frame
panels 70 and
72 can partially or fully overlap one another when the lid sides are formed.
Lid 20
additionally comprises lid inside front panel 54, which is folded under lid
front panel 50 and
can be adhesively attached to front lid panel 50 to add strength to the lid
20, and lid frame
panels 74, which are folded under and secured to the lid top panel 60.
Box part 10 and lid 20 are pivotally connected to one another along a fold
line at
which box rear panel 32 meets lid rear panel 52. The fold line forms pivot
axis 102, one end
of which is identified by the arrow in Figure 1, about which lid 20 pivots
upon opening and
closing of the package. With reference to Figure 2A, short inclined slits 106,
may be
provided at the ends of pivot axis 102, to facilitate opening of lid 20 by
allowing flexibility
of lid 20 and to compensate for interference during opening and closing.
A further constituent part of most conventional flip top cigarette packages is
inner
frame 80, or collar, which comprises inner frame front wall 90, having top
front corners 92,
and inner frame side walls 100 (only one of which is shown in Figure 1) each
having a top
edge 104. When assembled into the package, inner frame 80 is seated within box
part 10
such that a lower region of inner frame 80 is fixed on the inner side of box
front panel 30
and/or box side panels 44, optionally by adhesive bonding. The region of inner
frame 80,
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that projects above box part 10, is surrounded by lid 20 when the package is
in the closed
position. Inner frame front panel 90, on the one hand, and inner frame side
walls 100, on the
other hand, are folded about perforation lines 130 (Figure 2B). The inner
frame 80 depicted
in Figures 1 and 2B additionally comprises two latching tabs 140 extending
outwardly from
along a portion of each of perforation lines 130. When the package is in the
closed position,
latching tabs 140 frictionally engage the inner side of lid side frame panels
70 and 72.
As shown in Figure 2B, latching tabs 140 can be integrally formed from inner
frame
80 as a result of cuts made in the inner frame blank. In this case each
latching tab edge is
defined by a cut line in inner frame side walls 100 that intersects
perforation lines 130 at
upper intersection points 142 and lower intersection points 144.
Alternatively, latching tabs
140 are secured to inner frame 80, for example, using an appropriate adhesive.
In the closed configuration, box part 10 and lid 20 abut one another at the
box front
top edge 36 and box side edges 38 (only one side edge shown in Figure 1) of
box part 10
and lid bottom edge 56 and lid side edges 58 (only one side edge shown in
Figure 1) of lid
20. Side edges 38 of box part 10 may be inclined to slope towards box front
panel 30. In this
case, lid side edges 58 are correspondingly sloped to form a diagonal running
from pivot
axis 102 to lid bottom edge 56 of lid front panel 50.
Box part 10 and lid 20 of the conventional cigarette package depicted in
Figure 1 are
formed from a single blank. Further, the package that includes inner frame 80
can be made
from one blank plus an inner frame or, alternatively, from a single blank,
which incorporates
the inner frame and the box blank, as taught in U.S. Patent No. 3,874,581.
Package blank
110 depicted in Figure 2A is used to form box part 10 and lid 20 whereas inner
frame blank
120 depicted in Figure 2B is used to form inner frame 80.
The package of the present invention contains the features of the conventional
cigarette package described above and it additionally contains features that
are not found in
conventional cigarette packages. The additional features maximise the degree
to which a
package according to the present invention remains closed when not in use and,
at the same
time, minimise the force required to open the package to obtain one or more
units contained
within the package.
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The additional features that act individually or collectively to achieve these
desired
results include: latching tabs projecting outwardly from the inner frame; cam
panels in place
of inside lid side frame panels 72 of the conventional package, each having a
cam shape that
engages a corresponding latching tab during the closing of the lid to maintain
the package in
the closed position; a modified inner frame profile; and a raised lid pivot
axis or hinge.
Cam Panel
Figure 3 depicts a configuration of a lid side panel 170 having a non-engaging
curved profile 180. The radius and position of curved profile 180 were
selected to ensure
that there was no interference with latching tab 140 during the opening and
closing action of
lid 20. Although, this configuration minimised the damage of latching tab 140
and the
propensity for lid 20 to "hang-up" during the opening action of lid 20, it has
been found that
this configuration does not exhibit an improvement in the degree of "smiling"
in comparison
to analogous packages comprising standard inside lid side panels 72.
It has now been found that, in place of the non-engaging curved profile, a lid
side
panel modified to include an angled camming portion to engage latching tab
140, which
latching tab acts as a cam follower, both minimises damage to latching tab 140
and the
propensity for lid 20 to "hang-up" during the opening action of lid 20. In
addition, packages
comprising such a cam panel exhibit an improvement in the degree of "smiling"
observed in
comparison to analogous packages comprising standard inside lid side panels
72.
In accordance with one embodiment of the present invention there is provided a
package that includes two cam panels in the interior of the lid for engaging
two
corresponding latching tabs on the inner frame. Said cam panels provide a
smooth and
progressive lid locking action. The cam panel profile can vary in shape, as
described herein,
and functions to engage the corresponding latching tab to provide smooth
opening and
closing action of the lid while minimising the force required to open the lid,
occurrences of
smiling, and unintentional opening of the package lid.
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As depicted in Figures 4A and 4B, according to one embodiment the improved
package of the present invention comprises cam panels 150 having a profile
adapted to
engage the latching tabs 140 on the inner frame 80.
During package closing, cam panels 150 act to guide, progressively engage and,
ultimately, wedge the latching tabs 140 at the wedging zones of cam panels
150. Figure 5A
is a cross-section view through lid 20 of a package comprising cam panel 150.
As depicted
in the detail shown in Figure 5B, when the package is closed each cam panel
150 acts to
wedge the corresponding latching tab 140 between the camming edge 160 of the
cam panel
150 and ridge 78 formed by crease line 76 defining the corner formed by lid
front panel 50
and lid side panel 70. In particular, latching tab 140 is wedged such that the
rear face of the
latching tab is in direct contact with the forward facing camming edge 160 of
a cam panel
150 and the front face of the latching tab is in direct contact with ridge 78.
This wedging
action maintains the package in the closed position until an external force is
applied to open
the lid 20. The region defined by ridge 78 and camming edge 160 can be
referred to as a
latch retaining zone.
In an alternative embodiment there is no ridge 78 at the corner formed by lid
front
panel 50 and lid side panel 70, for example, if crease line 76 is replaced by
a score line. In
this embodiment, the latching tab retaining zone is defined by the inside face
of lid front
panel 50 and camming edge 160.
In a preferred embodiment, six specific segments define the profile of the
camming
edge 160 of cam panel 150. These segments are identified by profile points A,
B, C, D, E, F
and G in Figures 4B and 6. The dashed line identified by the arrow in Figure
4B represents
the trajectory of an undamaged, fully deployed latching tab, in relation to
the cam panel,
during opening and closing of the package. The trajectory shown in Figure 4B,
which
represents a theoretical zero interference line, defines the path that would
be taken by the
latching tab during opening and closing of the package, if there was no
interference between
the latching tab and the cam panel and ridge 78 or the inside face of lid
front panel 50 of lid
20.
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As used herein in relation to latching tabs, "deployed" refers to the operable
position
of the latching tab. When initially formed by the packer the latching tab may
not be fully
deployed, but rather in an inoperable position wherein the tab is not
outwardly projecting
from the inner frame. During use, operation of cam panel 150 acts to move an
undeployed
latching tab into an operable, deployed state.
The cam panel of the present invention has an angled profile defined by a
first linear
segment along the axis defined by points A and B and a second linear segment
along the
axis defined by points F and G. In order to act effectively, it has been found
that the angle
between the first and second linear segment (hereinafter the "inclination
angle"), as shown
in Figure 6, should be greater than about 15 and less than about 45 .
Figure 7 illustrates a cam panel 152 having a camming edge 162 comprising an
inclination angle of 45 , which is beyond the maximum effective angle, in a
partially closed
lid 20 of a cigarette package. Figure 8 depicts the same package, in which lid
20 is in the
fully closed position. In particular, Figures 7 and 8 depict cam panel 152,
which has an
inclination angle that is too large, or abrupt, to allow the latching tab to
function as a cam
follower along the cam profile. The dashed lines in Figures 7 and 8 represent
the trajectory
of an undamaged, fully deployed latching tab and, again, define the path that
would be taken
by the latching tab during opening and closing of the package if there were no
interference
between the latching tab and the cam panel and ridge 78 or the inside face of
lid front panel
50. The use of an inclination angle of 45 or greater does not generally
result in a cam panel
that facilitates a balance between an improved ease of opening of the package
with minimal
damage to the latching tabs and a reduced occurrence of smiling.
At an inclination angle of greater than about 45 , it was found that the
latching tab
will not properly engage the cam panel during the closing action of lid 20 and
will not act as
a cam follower. Instead, the latching tab will override the cam panel, by
moving along the
inside facing surface of the cam panel. This results in damage of the latching
tab, for
example, by delamination in the case of a latching tab constructed from
paperboard. As
depicted in Figures 7 and 8, when the inclination angle is at 45 the latching
tab is not able to
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engage the cam panel effectively and moves along the inside facing surface of
the cam panel
rather than along the cam profile edge.
Figure 9 illustrates a cam panel having a cam panel 154 having a camming edge
164
comprising an inclination angle of 15 , which is beyond the minimum effective
angle, in a
partially closed lid 20 of a cigarette package. Figure 10 depicts the same
package as in
Figure 9, in which lid 20 is in the fully closed position. The dashed lines in
Figures 9 and 10
represent the trajectory of an undamaged, fully deployed latching tab and,
again, define the
path that would be taken by the latching tab during opening and closing of the
package if
there were no interference between the latching tab and the cam panel and
front inside panel
54. The use of an inclination angle of 15 or less does not generally result
in a cam panel that
facilitates a balance between an improved ease of opening of the package with
minimal
damage to the latching tabs and a reduced occurrence of smiling.
An inclination angle of 15 or less generally was found to result in a cam
panel that
does not exert sufficient pressure on the latching tab during opening and
closing of lid 20 to
increase the friction between latching tab 140 and the inside face of lid
front panel 50 and to
wedge latching tab 140 between the ridge 78 or the inside face of lid front
panel 50.
Generally an inclination angle of greater than 15 and less than 45 , or more
preferably between 20 and 40 , has been found to be suitable. Figures 11 and
12 depict cam
panel 150 according to one embodiment of the present invention, in which the
inclination
angle is at or near 33.8 . Figure 11 illustrates the relative positions of cam
panel 150,
latching tab 140 and ridge 78 of the package when it is in a partially closed
position. Figure
12 illustrates the relative positions of cam panel 150, latching tab 140 and
lid inside front
panel 54 of the package when it is in a fully closed position. The dashed
lines in Figures 11
and 12 represent the trajectory 167 of an undamaged, fully deployed latching
tab and, again,
define the path that would be taken by the latching tab during opening and
closing of the
package if there were no interference between the latching tab and the cam
panel and front
inside panel 54.
As demonstrated in Figures 11 and 12 cam panel 150 having an inclination angle
of
33.8 is effective in frictionally engaging and wedging the corresponding
latching tab. This
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observation has been made using computer drawings and using packages prepared
with a
transparent window in place of lid side panel 70, which permits the
observation of the actual
latching tab trajectory during opening and closing of lid 20. The actual
positions of latching
tab 140 in a partially closed package and a fully closed package are depicted
in Figures 11
and 12, respectively.
In selecting the dimensions of the cam panel it is important to consider the
situation
in which the latching tab is damaged or is not fully deployed. In order to
ensure that the
latching tab will be able to engage the cam panel, the position of the cam
panel is
determined on the basis of the theoretical zero interference trajectory 167 of
a damaged or
not fully deployed latching tab. Figure 13 illustrates trajectory 167 of an
undamaged, fully
deployed latching tab in comparison to trajectory 168 of a damaged or not
fully deployed
latching tab. Each trajectory, again, defines the path taken by the respective
latching tab
during opening and closing of the package when there is no interference
between the
latching tab and the cam panel and ridge 78 or the inside face of lid front
panel 50.
Profile point A of a cam panel according to the present invention is located
inside the
latching tab trajectory 168 defined for a latching tab that is not fully
deployed or is damaged.
Cam profile segments AB and BC clear the inner frame latching tab during the
opening and
closing action of the lid and minimise damage of the latching tab and the
propensity for lid
20 to "hang-up" or snag during the opening action of lid 20. In addition,
during the closing
action, the cam profile segment BC is positioned and angled to straighten the
inner frame
latching tab if it is damaged or not fully cut and/or properly deployed, for
example, by the
cigarette packer during packaging.
During closing action, the cam profile segment CD progressively lifts the
inner
frame latching tab and progressively creates friction and interference with
cam panel edge
160 and ridge 78 or the inside face of lid front panel 50. In response, the
latching tab
partially bends toward ridge 78 or the inside face of lid front panel 50 (See,
for example,
Figure 13). Thus, segment CD comprising a latching tab lifting zone. Segment
CD also
comprises a zone at which the maximum interference with the latching tab
occurs.
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Segment CD is defined by an arc extending from point C to point D. The radius
of
the arc extending from point C to point D is determined, in part, by the
limitations of the
equipment used to manufacture and cut the blanks used to make the package. The
smaller
the radius, the larger the wedging zone (i.e., segment DE), however, a small
radius is also
more difficult to tool. In designing a cam panel according to the present
invention, the radius
of the arc defined by points C and D is selected by taking into consideration
(i) the need to
maximise the size of the wedging zone; (ii) the limits of the equipment used
to manufacture
and cut the blanks; and (iii) the material used to manufacture the cam panels
and the latching
tabs. The type of material is an important consideration since the amount of
damage (e.g.,
delamination) caused to the latching tabs and cam panels during use will vary
depending on
the thickness and rigidity of the material.
Cam profile segment CD is also positioned to compensate for the lower limit of
the
inner frame 80 vertical position play. When the package is assembled by a
packer, the inner
frame is incorporated within box part 10 as described above. The position of
the inner frame
80 relative to box front top edge 36 of box front panel 30 can vary within an
upper and
lower design limit. This variation is referred to as the vertical position
play of the inner
frame. The lower limit of the inner frame 80 vertical position play is the
lowest position of
inner frame 80 relative to box front top edge 36 of box front panel 30 that
can be tolerated.
Segment CD must be positioned such that it properly interferes with the
latching tab, even
when the inner frame is at the lowest allowable position.
As described in more detail below, the latching tabs are an integral part of,
or are
secured to, the inner frame. Thus, the vertical position of the latching tabs
relative to box
front top edges 36 is dependent on the position of the inner frame within box
part 10. The
existing variation in the design, available settings and speed of the packing
machinery used
to assemble a package according to the present invention determines the
magnitude of the
vertical position play of the inner frame and, consequently, the latching
tabs. It is important
to evaluate the amount of vertical position play (e.g., by observation,
measurement of
packages produced at different packer speeds, etc.) in order to properly
position cam profile
segment CD to ensure that it is able to interfere with the latching tab when
the inner frame is
at the lowest position within the observed or measured vertical position play.
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Cam profile segment DE is referred to as the "wedging zone" and wedges the
latching tab between camming edge 160 and ridge 78, or the inside face of lid
front panel
50, when lid 20 is in a closed position, thereby minimising the occurrence of
"smiling". The
wedging zone can comprise a straight edge or a curved edge. In the case of a
cam profile
segment DE that is curved outwardly, the maximum distance of the edge of the
curve from
the straight line between point D and point E is approximately equivalent to
the three times
the thickness of the material used in the construction of the latching tab. In
the case of a cam
profile segment DE that is curved inwardly, the maximum distance of the edge
of the curve
from the straight line between point D and point E is approximately equivalent
to the
thickness of the material used in the construction of the latching tab. As
would be readily
appreciated by a worker skilled in the art, the actual dimensions of the
inward or outward
curve in relation to the straight line between point D and point E is
partially dependent on
the rigidity of the material used to construct the latching tabs. This is
especially important in
the case of an inwardly curved segment DE.
An inwardly curved segment DE can be designed to create a recessed cavity that
engages the latching tab upon closing of the lid. An outwardly curved segment
DE can be
used in order to increase the degree of wedging of the latching tab that the
cam panel is
capable of in comparison to that of a straight segment DE.
As illustrated in Figure 13, cam profile segment DE also compensates for the
upper
limit of the inner frame 80 vertical position play that may occur during
assembly of the
package and, thereby, maintains the wedging effect on the latching tab
irrespective of the
exact position of the inner frame in relation to box front top edge 36 of box
front panel 30.
The upper limit of the wedging zone defined by segment DE corresponds to the
maximum
height, in relation to box front top edge 36 of box front panel 30, that the
uppermost portion
of the latching tab reaches when the lid is closed. Similarly, the lower limit
of the wedging
zone defined by segment DE corresponds to the minimum height, in relation to
the upper
edge 36 of the front panel 30, that the latching tab reaches when the lid is
in the closed
position.
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Finally, cam profile segments EF and FG abut and, consequently, support the
inside
of lid front panel 50 or ridge 78, thereby facilitating vertical alignment of
lid front panel 50
and box front panel 30. These cam profile segments provide support to the
front of lid 20
and thereby maintain the configuration of the lid 20 such that when the
package is closed lid
20 will be flush with box part 10. Segments EF and FG do not taper away from
or toward
lid front panel 50, but rather are positioned such that they form a straight
edge
approximately parallel to the inside surface of lid front panel 50. In
accordance with a
specific embodiment of the invention, segments EF and FG define a straight
edge spaced
from the inside face of lid front panel 50 or ridge 78 a distance that is
within 1/4 to 1/2 of the
thickness of the material used to manufacture the lid.
Prior to its first use the package is typically assembled by a packer in such
a way that
the latching tabs are located between the cam panel edge 160 and ridge 78 or
the inside face
of lid front panel 50. The profile of the cam panels 150 creates the desired
level of friction
and interference with the latching tabs to maintain the package in a closed
position. It should
be understood that varying levels of friction can be created by varying the
configuration,
angles and/or profile of the cam panels within the limits defined above.
During package opening, the latching tabs act as cam followers and will follow
the
segments of the cam profile on cam panel edges 160 from segment DE to AB.
During
package closing, the latching tabs again act as cam followers and will follow
the segments
of the cam profile on the cam panel edges 160 from segment AB to DE.
Figure 14A depicts a package according to a further embodiment of the present
invention, in which the cam panels 190 (only one shown in Figure 14A) are each
designed to
include a recessed cavity that specifically engages the corresponding improved
latching tab
210 (described further below). As depicted in the detail shown in Figure 14B,
the cam panel
190 has a camming edge 200 that comprises all six segments, AB, BC, CD, DE, EF
and
FG. In this case, however, segments DE and EF are designed to specifically
engage
improved latching tab 210. During closing of lid 20, the rear face of improved
latching tab
210 progressively interferes with camming edge 200 until lid 20 reaches its
fully closed
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position, at which point segment DE is in direct contact with the rear face of
improved
latching tab 210.
Cam panels 150 and 190 can be used with any latching tab and are not limited
to use
with latching tabs 140 and 210 described herein.
Improved Latching Tab
In accordance with another embodiment of the present invention there is
provided a
package that includes a pair of cam panels and a corresponding pair improved
latching tabs.
The improved latching tabs can vary in shape, as described herein, but always
function in
combination with the corresponding cam panels to provide smooth opening and
closing
action of the lid while minimising the force required to open the lid,
occurrences of smiling,
and unintentional opening of the package lid.
As indicated above, standard cigarette packages often include a pair of
latching tabs
140, each extending outwardly from along a portion of each of the perforation
lines 130 of
inner frame 80. Latching tabs 140 frictionally engage the inside of lid side
frame panels 70
and/or 72, and thereby contribute to the force required to open and close lid
20. Latching
tabs 140 are formed from an integral portion of the inner frame 80 and have a
front face 216
and a rear face 217.
It has now been found that an improved latching tab comprising an inlet ramp,
a
bearing area and an exit ramp can be formed from an integral portion of inner
frame 80. As
with the latching tabs 140 found in standard cigarette packages, the improved
latching tabs
210 depicted in Figure 15 are formed from cuts made in the inner frame blank.
The cuts are
configured so that when inner frame side walls 100 are folded about
perforation lines 130
the outwardly extending latching tabs 210 are formed.
Latching tab 210 consists of three segments, which define the profile of the
latching
tab edge 211. These segments are identified by profile points X, Y, Z and Q as
depicted in
Figure 16.
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The uppermost portion of latching tab edge 211 comprises an exit ramp defined
by
points Z and Y. Segment ZY is inclined to slope down and away from top front
corner 92 of
inner frame 80. Latching tab 210 further comprises a bearing area along
latching tab edge
211 at segment YX and an inlet ramp at segment XQ, which are depicted in more
detail in
Figure 16.
Inlet and exit ramps XQ and ZY, respectively, and radius W of the arc defining
the
bearing area YX combine to improve the functionality and operation of lid 20
by reducing
the force required to open the package, decreasing the tendency of package to
open
spontaneously when a user does not require access to the contents of the
package and at the
same time preserving the aesthetic appearance of the cigarette package. It
would be readily
appreciated, however, by a worker skilled in the art that the geometry of X
and Z, can be
modified in order to properly balance the force required to open the lid 20
with that required
to maintain the lid 20 in a closed position when the package is not in use.
With reference to Figures 16 and 17, inlet ramp XQ of latching tab 210
provides the
required level of rigidity and flexibility to permit latching tab 210 to flex
and thereby permit
rear face 217 to act as a cam follower over a cam panel, for example, cam
panel 150 or 190,
without damaging the material from which latching tab 210 is constructed
(e.g.,
paperboard). For simplicity, the following description will refer only to cam
panel 150,
having cam panel edge 160. The configuration of inlet ramp XQ allows lid 20 to
progressively disengage upon opening of the package.
Exit ramp ZY also influences the required level of rigidity and flexibility to
permit
latching tab 210 to flex and thereby permit rear face 217 to act as a cam
follower over cam
panel 150 without damaging latching tab 210. Exit ramp ZY is defined by a
straight line, an
arc or a combination of a straight line and an arc. When all or a portion of
exit ramp ZY
consists of an arc, the arc is an extension of the are defining bearing area
YX. Further, with
reference to Figure 16, when all or a portion of exit ramp ZY is defined by a
straight line the
uppermost point of latching tab 210 is at P. The configuration of the exit
ramp ZY allows
latching tab 210 to progressively disengage lid 20 upon opening and engage lid
20 upon
closing of the package.
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Bearing area YX is the portion of latching tab edge 211 that bears the
greatest
pressure from frictional engagement of latching tab 210 and the inside of the
lid side panel
70. With reference to Figure 17, latching tab 210 comprises front bearing area
218, which is
the region of front face 216 adjacent to bearing area YX, and rear bearing
area 219, which is
the region of rear face 217 adjacent to bearing area YX. Front bearing area
218 bears the
greatest pressure from ridge 78, while rear bearing area 219 bears the
greatest pressure from
camming edge 160. Bearing area YZ concentrates the friction and interference
forces
between latching tab edge 211 and side panel 70, and is positioned as high as
possible on
inner frame 80 in order to maximise the working range associated with the lid
opening
action. The outermost point S of latching tab 210 is positioned such that it
is above segment
CD of the corresponding cam panel 150 when lid 20 is in the closed position.
The initial contact point between latching tab 210 and lid 20, is the point at
which the
bottom edge of lid side panel 70 first comes into contact with latching tab
210 during
closing of the package. Lid side panel 70 is flush with box side panel 40 when
the bottom
edge of lid side panel 70 is in contact with latching tab 210 at the initial
contact point.
In one embodiment of the present invention, all or a portion of exit ramp ZY
is
defined by an arc that extends to also define bearing area YX and the initial
contact point is
on the arc. In this case, the radius of the arc determines the latching tab
contact surface angle
T at the lid side edge 58 upon closing of the package. In particular, the
contact surface angle
T is the angle between lid side panel 70 and the tangent at the initial
contact point between
latching tab 210 and lid side edge 58.
In an alternative embodiment of the present invention, all or a portion of
exit ramp
ZY is defined by a straight line and the initial contact point is on a
straight portion of exit
ramp ZY. In this case, the latching tab contact surface angle T is the angle
between the lid
side panel 70 and the straight line defining the straight portion of exit ramp
ZY.
Irrespective of the configuration of exit ramp ZY it has been found that
latching tab
contact surface angle T must be less than about 60 in order to avoid "hang-
up" during
opening of lid 20. It has also been found that latching tab contact surface
angle T must be
less than about 50 in order to provide smooth operation of lid 20 during
opening and
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closing. Latching tab 210 having an angle T of less than about 50 , is able to
smoothly
engage cam panel 150 as a cam follower during opening and closing of lid 20.
The interference level between latching tab 210 and the inside of side panel
70 is one
parameter that contributes to the lid holding force and can be adjusted by
adjusting the
geometry of the latching tab.
As noted above, one embodiment of the present invention provides latching tab
210
having an exit ramp ZY comprising at least portion defined by a straight line.
Angle V is the
angle between this straight line and a line parallel to box front top edge 36
(not shown in
Figure 16). It has now been found that angle V can be varied by increasing or
decreasing
distance P between the outermost point S of bearing area YX and a straight
line defined by
perforation line 130, essentially to form a latching tab 210 that extends
outwardly to a lesser
or greater amount from perforation line 130. The force required to close the
package is
directly proportional to contact surface angle T. The minimum distance P has
now been
found to be approximately equivalent to the thickness of the material used to
manufacture
cam panel M. The maximum distance P is the distance at which latching tab 210
is
significantly bent toward inner frame side panel 100 when lid 20 is in the
closed position. As
would be appreciated by a worker skilled in the art, this maximum distance P
is influenced
by the overall dimensions of the package and by the strength and rigidity of
the material
used to manufacture latching tab 210.
It has also been found that the material used to form the inner frame limits
the
tolerable geometry of latching tabs 210, which are formed from an integral
portion of the
inner frame. For example, in the case where the inner frame is formed from
paperboard, the
paperboard foldability and thickness, as well as the delaminating resistance
will have an
effect on the limits of tolerable geometry of latching tabs 210.
Figures 18A and 18B depict latching tabs 212 and 214, having a non-functional
angle T and a functional angle T, respectively. Each latching tab has the same
radius W,
which is the radius of the arc defining bearing area YX. The difference
between the two
latching tabs in Figures 18A and 18B, is the distance P between the outermost
point S of
bearing area YX and perforation line 130. Latching tab 212 in Figure 18A has
an increased
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distance between bearing area YX and perforation line 130 in comparison to
that of latching
tab 214 in Figure 18B. As a result, angle T of latching tab 212 is greater
than that of latching
tab 214. In fact, angle T of latching tab 214 is beyond the maximum tolerable
angle. As
depicted in Figure 18A, as a result of the large angle T lid side panel 70
hits latching tab 212
during closing of lid 20 such that side panel 70 does not effectively slide
along exit ramp
ZY. This, in turn, causes damage of latching tab 212.
In contrast, latching tab 214 has a preferred angle T that allows lid side
panel 70 to
slide along exit ramp ZY during closing of lid 20, such that latching tab 214
is then able to
frictionally engage cam panel 150. It has been found that angle T should be
less than about
60 , or more preferably less than about 50 , in order for the latching tab to
smoothly engage
cam panel 150 as a cam follower during opening and closing of lid 20.
Similarly, when the
distance P between the outermost point S of bearing area YX is maintained and
radius W is
varied, the force required to open and close the package will be altered.
The following table summarises the effects of altering various components of
the
latching tab geometry:
Table 1: Elements of Latching Tab
Effect on latching tab operation
Latching Tab Alteration
component Resistance to Impact on cam Latching tab
damage panel wedging zone flexibility
Exit Ramp ZY: Arc only
decrease decrease increase increase
Radius W
increase increase decrease decrease
Exit Ramp ZY: Straight portion plus curved portion adjacent bearing area YX
decrease decrease increase increase
Radius W
increase increase decrease decrease
decrease decrease increase increase
Angle V
increase increase decrease decrease
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Effect on latching tab operation
Latching Tab Alteration
component Resistance to Impact on cam Latching tab
damage panel wedging zone flexibility
Inlet Ramp XQ: Straight portion only
Distance from
Q to radius W decrease decrease none increase
Inlet Ramp XQ: Straight portion plus curved portion at bottom of latching tab
Distance from increase increase not as effective as decrease
radius of curved cam follower
portion to radius
w decrease decrease minimal increase increase
The components of latching tab 210 act in combination, therefore, it is
possible to
optimise the latching tab configuration depending on the material used to
construct the inner
frame, the application of the package and the configuration of the lid and cam
panel of the
package.
As described above, latching tab 210 acts as a cam follower during opening of
lid 20
from box part 10, and will follow the cam profile segments on the cam panel
edge 160 of the
cam panel 150 from segment EF through to segment AB. Upon closing, latching
tab 210
reverses its course following the cam profile of cam panel 150, from segment
AB to
segment EF. Cam profile segment DE creates the required level of friction and
engagement
between rear bearing area 219 of latching tab 210 and camming edge 160 and
between front
bearing area 218 and ridge 78, or the inside face of lid front panel 50, to
maintain the
package in a closed configuration until application of an external force.
During engagement with the cam panel, the outermost portion of bearing area YX
of
latching tab 210 is in contact with the inner surface of side panel 70. As
depicted in Figures
19A and 19B, latching tab 210 slightly deforms side panel 70 causing it to
bend outwardly
as the latching tab moves along the camming edge of the cam panel.
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Improved Inner Frame Profile
In accordance with another embodiment of the present invention there is
provided a
cigarette package that includes an improved inner frame profile, which has
been modified in
order to reduce the interference between the lid inside front panel 54 and the
top edge 92 of
the inner frame.
As depicted in Figures 20A and B, in addition to the features of inner frame
80 used
in standard cigarette packages, inner frame 220 of the present invention
further includes
bevelled front corners 230, inclined downward from the upper horizontal
portion 232, on
each inner frame side panel 234. Figure 20A shows inner frame 220 in the
folded
configuration maintained within box part 10. Figure 20B depicts inner frame
220 in its
unfolded configuration.
The incorporation of bevelled front corners 230 reduces the interference
between
inner frame 220 and lid front panel 54, in comparison to the same package
including a
standard inner frame 80, during opening and closing of the package. In
addition, the
configuration of bevelled front corners 230 maintains inner frame top edge 232
close to the
inside of lid frame panels 74, thereby minimising the extent to which the lid
side panels 70
"hang-up" or snag behind side panels 234 of the inner frame 220.
Figure 21 depicts inner frame 220 in its unfolded configuration. The dashed
lines
represent the geometry of the front corners of a standard inner frame. The
bevelled front
corners of inner frame 220 are lower in height in relation to inner frame top
edge 232 than
the analogous height of the front corners of a standard inner frame. As a
result, interference
of front corners 230 with lid inside front panel 54 is reduced during opening
and closing of
lid 20 in comparison to the interference observed in a package comprising a
standard inner
frame, for example, inner frame 80. It has now been found that the maximum
distance
between front corners 230 and the inner surface of lid frame panels 74, as
measured when
lid 20 is in the fully closed position, is equivalent to approximately 35% of
the height of lid
front panel 50. Distances greater than 35% of the height of lid front panel 50
result in a
reduction in the interference between the latching tabs and corresponding cam
panels. This
is, in part, due to the fact that the height of the latching tabs must be
lowered when the
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distance between front corners 230 and lid frame panels 74 is increased. As
indicated
previously, however, the latching tab should be positioned as high as possible
in order to
maximise the wedging action.
A specific embodiment of the present invention provides a packages comprising
standard box part 10 and lid 20 having the dimensions commonly used in
cigarette packages,
wherein the maximum reduction of the height of top corners 230 is
approximately 4.25 mm
from the existing standard of 0.75 mm from the top edge 232 of the inner frame
80.
The shape and degree of downward incline of bevelled front corners 230 can
vary
widely. The dashed lines in Figure 22 depict examples of different front
corner profiles that
can be incorporated into the improved inner frame of the present invention.
The position of top edge 232 of inner frame 220 should be at or near the top
of the
lid 20 such that it is close to the inside surface of lid frame panels 74.
However, the position
of top edge 232 relative to lid frame panels 74 is partially dependent upon
the thickness of
the package, the length of the extension panel 54 and the location of the lid
pivot axis 102 in
relation to the top of package. A friction fit must exist between lid 20 and
top edge 232 of
inner frame 220 that is sufficiently loose to permit lid 20 to slip past inner
frame 220 and,
when present, to facilitate engagement of the cam panels with the
corresponding latching
tabs.
A plurality of inner frames 220 can be produced from one continuous strip of
material, such as paperboard. In order to make the production economical and
reduce
material waste, it is desirable to make the top and bottom profiles of the
inner frame of the
same shape. In this way, one inner frame in its unfolded configuration will
nest into another.
This is depicted in the top and bottom profiles of inner frame 220 depicted in
Figures 20B
and 21.
Raised Lid Pivot Point
In accordance with another embodiment of the present invention there is
provided a
package that includes a pivot axis that is raised in comparison to the pivot
axis used in
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conventional cigarette packages. As in standard packages raised pivot axis 240
is defined by
a fold line between box rear panel 32 and lid rear panel 52, which extends
from one side of
the package to the other side in order to pivotally connect box part 10 to lid
20.
As depicted in Figure 23 the cigarette package of the present invention can
additionally comprise an elevated or raised lid pivot axis 240, which is
raised toward the top
of the package in comparison to the position of the lid pivot axis 102 of a
standard package.
Raising pivot axis 240 decreases the resistance required to open lid 20 and
the friction
between the lid 20 and box part 10, having inner frame 80, in comparison to a
conventional
hinge. With the decreased resistance, lid 20 is more easily moved to its
opened position.
Raised pivot axis 240, thereby substantially reduces the force required to
open the package.
The use of raised pivot axis 240 in combination with the additional features
of a cam panel,
an improved latching tab and an improved inner frame further reduces the force
required to
open and close the cigarette package of the present invention.
The use of raised pivot axis 240 in a standard cigarette package would result
in the
occurrence of increased smiling. In accordance with the present invention,
however, raised
pivot axis 240 can be incorporated into the package without causing an
increase in the
occurrence of smiling.
The pivot axis 240 can be raised closer to the top of lid 20 by an amount that
is just
enough to change the trajectory of lid 20 during opening and closing of the
package and,
thereby, reduce the interference between the lid inside front panel 54 and
bevelled front
corners 230. A minimum distance must be maintained between pivot axis 240 and
the top of
the package, to allow the user to securely grasp lid 20. The portion of lid 20
defined by pivot
axis 240 and the top of the lid can be referred to as a "gripping zone" since
this portion of
the lid is gripped by the user during opening of the package. In packages
having the
dimensions commonly used in cigarette packages, the minimum distance from
pivot axis
240 to the top of the package has been found to be approximately 10.5 mm. At
this
minimum distance reduction of force required to open and close the package is
maximised
while maintaining a comfortable gripping zone on lid 20. The term "comfortable
gripping
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zone" as used herein refers to a gripping zone that is sufficiently large to
permit the user to
comfortably grip the lid during opening of the package.
As would be readily apparent to the skilled worker, the minimum distance
between
the pivot axis and the top of lid 20 can vary depending on the overall
dimensions of the
package and the nature of the material used to construct the package. For
example, the
exterior surface of the package can be selected to have a rough texture, which
would
improve the ability of the user to grip lid 20 during opening and closing.
This, in turn, could
permit a smaller minimum distance between pivot axis 240 and the top of the
package to be
functional and still provide a comfortable gripping zone.
In a related embodiment of the present invention, the elevated or raised lid
pivot axis
240 and the modified profile of the inner frame 220 together contribute to
reduce the
interference between the lid inside front panel 54 and front corners 230
and/or with cigarette
bundle 11 within the package.
Figure 24 depicts package 300, according to one embodiment of the present
invention, which has overall dimensions that are equivalent to those of a
standard cigarette
package and comprises an improved inner frame. Package 300 also has a raised
pivot axis.
In Figure 24, lid 20 is shown in a fully closed position using solid lines and
in a partially
open position using dashed lines. By drawing package 300 in this manner it was
determined
that the amount of interference between bevelled front corners 230 and lid
inside front panel
54 was significantly less than that observed for package 302, which is
depicted in Figure 25.
Package 302 has overall dimensions that are equivalent to those of a standard
cigarette
package and comprises a standard inner frame and a raised pivot axis. In
Figure 25, lid 20 is
shown in a fully closed position using solid lines and in a partially open
position using
dashed lines. Clearly, this demonstrates the reduced interference that is
caused by lowering
the height of the front corners of the inner frame. "Interference," as used
herein, refers to the
length of the portion of lid inside front panel 54 that contacts the inner
frame front corners
during opening and closing of the package.
This advantage is further demonstrated in Figure 26, which depicts a package
304,
that has overall dimensions that are equivalent to those of a standard
cigarette package and
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comprises an improved inner frame and a standard pivot axis. In Figure 26, lid
20 is shown
in a fully closed position using solid lines and in a partially open position
using dashed lines.
By drawing package 304 in this manner it was determined that the amount of
interference
between bevelled front corners 230 and lid inside front panel 54 is
significantly less than
that observed in standard package 306. Package 306 which has overall
dimensions that are
equivalent to those of a standard cigarette package. Package 306 comprises a
standard inner
frame and a standard pivot axis. In Figure 27, lid 20 is shown in a fully
closed position using
solid lines and in a partially open position using dashed lines. This
demonstrates that the
lowered height of the front corners of the inner frame compensates for part of
the increase in
interference caused by the increased distance between the lid pivot axis and
the top of
package 304.
To further demonstrate the findings noted above, interferences were calculated
between inner frame front corners and lid inside panel 54, using a Computer
Aided Design
drawing program, in packages having the overall dimensions of a standard hinge
lid 25 -
100 mm - Slims cigarette package except for varying pivot axis heights and
varying heights
of the inner frame front corners. The results are summarised in the following
table:
Table 2: Calculated Interference Values
Changing the inner frame profile to lower the Change the pivot axis height
front corners (Inner frame front corners fixed at 4.57 mm
(Lid hinge fixed at 11.5 mm from top of from lid inside panel 54, as per
standard
package, as per standard package*) package*)
Distance between inner Interference between Interference between
frame front corners inner frame front Pivot axis distance inner frame front
from top of package
and lid inside front corners and lid inside corners and lid inside
panel 54 front panel 54 (mm) (mm) front panel 54 (mm)
*4.57 1.40 8.5 0.54
5.1 1.22 9.5 0.78
5.62 1.05 10.5 1.07
6.12 0.91 * 11.5 1.40
6.62 0.77 12.5 1.77
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The four improvements described above operate individually or in combination
to
provide a package wherein the degree to which the package remains closed when
not in use
is maximised, while the force required to open the package is minimised.
During opening of
conventional packages there is almost no force required initially such that
the maximum
force required to open the package occurs when the package is partially open.
The fact that
almost no initial force is required causes the "smiling" to occur. In
contrast, the package of
the present invention comprises a pair of cam panels that interact with a
corresponding pair
of latching tabs and thereby increase the initial force required to open the
package. This
effect is more pronounced when, as depicted in Figure 28, the package
additionally
comprises a pair of improved latching tabs 210.
As depicted in Figures 29 and 30, a specific embodiment of the present
invention
provides a package 320 comprising two cam panels 150 (only one shown), a
modified inner
frame 220 and improved latching tabs 210 (only one shown). The package
depicted in
Figure 30 additionally comprises raised pivot axis 240. These features
contribute to the
elimination or minimisation of "hang-ups", or snags, of the inner frame 220 on
lid 20 upon
opening. In addition, the combined effect of all four improvements
significantly reduces the
maximum force required to open lid 20. The force required to open the package
is relatively
constant throughout the opening action rather than having a steep increase
followed by a
sharp decrease as found in conventional packages. The combination of all four
improvements also provides a positive locking force to maintain the package in
its closed
position until the application of an external force.
Package 320 depicted in Figure 30 can be formed from an inner frame and a
blank
330 as shown in Figure 31. Alternatively, it can be formed from a single frame
that
incorporates the features of the inner frame, the box part and the lid.
Design Protocol
The present invention further provides a method of designing a package having
improved opening and closing capabilities in comparison to conventional
packages. The
steps of this method are outlined below and are not necessarily performed in
the order in
which they are listed.
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Once the overall package dimensions are selected, for example, based on the
dimensions required to accommodate the desired contents of the package, the
position of the
pivot axis can be determined. The pivot axis is positioned at the highest
possible location
while maintaining an acceptable gripping zone for the user.
The acceptable interference level between the inner frame and the lid is
determined
and the inner frame is modified such that the interference does not go beyond
the acceptable
interference level. As indicated previously, the term "interference" is used
herein to refer to
the length of the portion of lid inside front panel 54 that contacts the inner
frame front
corners during opening and closing of the package. In accordance with an
embodiment of
the present invention, the acceptable interference is less than 10% of the
package depth.
More particularly, the acceptable interference can be less than 8% of the
package depth or,
even more particularly, approximately 2.5% of the package depth. It should be
recognized
that some degree of interference should be maintained since it is useful for
guiding the lid to
the correct position during closing to allow the camming action between the
cam panels and
latching tabs.
The inner frame is modified by lowering the top front corners to reduce the
interference between the inner frame top front corners and the lid inside
front panel to an
acceptable level. Although the inner frame is modified by lowering the top
front corners, the
inner frame position must be maintained as high as possible within the box
part of the
package.
The profile of the edge of the latching tab is selected based on required
interference
between the cam panel and the latching tab. When the package includes a
modified latching
tab as described herein, the latching tab is designed by first locating the
outermost point S as
close as possible to the package top panel. The latching tab protrusion, or
distance between
the perforation lines on the inner frame and the outermost point S, is
selected such that the
latching tab will engage the cam panel and will interfere with the lid side
panel with
minimal bending and damage.
The cam panel profile is designed by first determining the latching tab zero
interference trajectory for both the damaged (or not fully deployed) and
undamaged (and
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fully deployed) latching tab. Cam profile point A is positioned inside the
damaged latching
tab trajectory. The cam inclination angle is adjusted in relation with the
desired wedging
zone and the required latching tab flexibility based on the material used to
manufacture the
latching tab. The location and size of the required wedging zone is determined
in order to
compensate for inner frame vertical position play. The radius of cam segment
CD is selected
in order to minimise damage (e.g. delamination) of the cam panel and the
latching tab and to
optimise the wedging zone. Finally, cam segments EF and FG are positioned to
support the
lid inside front panel.
Example 4 demonstrates the use of the above method to design a package
according
to the present invention.
Manufacture
The cigarette package of the present invention is constructed of a paperboard
substrate or any other material which is known or used in the manufacture of
cigarette
packages. For example, the box part blank and the inner frame can be
manufactured from 10
to 14 points (a point is used to specify paperboard caliper; 1 point = 1
thousandth of an inch)
clay coated board, which can be printed and laminated with foil, such as 7
micron foil, or
0.35 mm thick lined/coated manila backed board having a weight of 215 - 230
g/m2. In the
case of a package formed from a single blank that include the inner frame, it
may be
necessary to use thinner material to allow for the additional folding
required.
The blank used to manufacture the lid and box parts, with or without the inner
frame,
can by made from a substance such as, but not limited to, 0.006 - 0.009 mm
gold foil
laminated-white lined hard rolled manila back board having a thickness of 0.33
- 0.39 mm
and a weight of 220 - 248 g/m2; 0.27 - 0.30 mm coated solid bleached sulfate
board having
a weight of 220 - 248 g/m2; polycoated board; direct/indirect metallized board
(e.g. 250
micorn, 235 g/m2 Tako Hilioboard). These materials can be laminated or not,
depending on
the application of the package.
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In an alternative embodiment, the package according to the present invention
can be
manufactured from a plastic, or combination of plastics, such as polyvinyl
chloride (PVC),
polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), or
the like.
The package of the present invention can be constructed from a blank plus an
inner
frame, or a single blank, using standard techniques in the art. For example,
in the case of a
cigarette package of the present invention, which is formed from a blank plus
an inner
frame, the method of construction comprises the following steps: (i) grouping
the cigarettes
to be stored in the package into the desired formation (e.g. a first row of 8,
plus a row of 9,
followed by a second row of 8); (ii) embossing, if necessary, and cutting the
required length
of material from a foil or a paper roll; (iii) wrapping the cigarette group
from step (i) in the
cut foil or paper from step (ii) to form a cigarette bundle; (iv) cutting the
inner frame; (v)
folding the inner frame into the suitable configuration for assembly within
the box part; (vi)
providing a printed and precreased blank for the box part; (vii) assembling
the box part with
the inner frame; (viii) forming the package around the cigarette bundle by the
use of a series
of folding and adhering steps; and (ix) compressing and heating the package
until adhesive
used in step (viii) is cured. Suitable adhesives for use in construction of
the package of the
present invention are well known to workers skilled in the art. For example, a
polyvinyl
acetate (PVA) adhesive, such as, but not limited to, IPACOLLTM LP293 1, can be
used in the
construction of the package.
The hinge lid package of the present invention can be assembled manually or by
an
automated method using a packer machine. An example of a packer that is
suitable for
assembly of packages according to the present invention is the Hinge Lid
Packer 350 S from
Focke & Co. A packer can be used to assemble cigarette packages according to
the method
outlined above.
To gain a better understanding of the invention described herein, the
following
examples are set forth. It should be understood that these examples are for
illustrative
purposes only. Therefore, they should not limit the scope of this invention in
any way.
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EXAMPLES
EXAMPLE 1: Package "Smiling"
The following test was designed in order to test the occurrences of package
"smiling". Measurements of the degree of smiling were completed on cigarette
packages
according to the present invention, including packages comprising: (i) a cam
panel only; (ii)
a cam panel and improved latching tab only; and (iii) a cam panel, improved
latching tab,
improved inner frame and a raised pivot axis. Conventional cigarette packages
currently on
the market, which did not contain any of the four improvements described
herein, served as
controls.
Each package was dropped from an elevation of 10 cm six times, and the degree
of
smiling measured with a ruler. In each case the package was dropped so that it
would land
with its back panel 32 facing downwards. The gap or opening between the bottom
edge 56
of the lid front panel 50 and the top edge 36 of the box front panel 30 was
considered to be
the smile, as illustrated in Figure 32B. Following the initial drop and after
each subsequent
drop the lid 50 was opened and closed 5 times by hand. Accordingly, at the end
of the test
each package had been opened and closed 25 times to simulate a user opening
and closing
the package to obtain cigarettes.
As expected the degree of smiling increases with the number of openings for
conventional packages as illustrated in Figure 34. The results of this study
are also provided
in Table 3.
Surprisingly, packages having either all four improvements or the cam panel
and
improved latching tab combination only, exhibited no significant difference
between the
degree of smiling that occurred after the first 5 openings compared to that
following 25
openings (Figure 34 and Tables 4 and 5). The reduction of package smiling in
relation to
the control samples was 29% for packages comprising only the cam panel, 92%
for
packages with the cam cut panel and improved latching tab design and 74% for
packages
with the combination of all four improvements. Further, the degree of smiling
was highest
for conventional packages at 0.71 mm (Table 3), followed by 0.54 mm for
packages with the
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cam cut profile only (Table 4), 0.06 mm for packages with the cam panel and
improved
latching tab design (Table 5) and 0.20 mm for the packages having all four
improvements
(Table 6).
EXAMPLE 2 - Required Package Opening Force
The following test was used to determine the degree of opening force required
to
open a cigarette package. Again, measurements of the degree of force required
to open a
package were completed on cigarette packages according to the present
invention, including
packages comprising: (i) a cam panel only; (ii) a cam panel and improved
latching tab only;
and (iii) a cam panel, improved latching tab, improved inner frame and a
raised pivot axis.
Conventional cigarette packages currently on the market, which did not contain
any of the
four improvements described herein, served as controls. The force required to
open a
package was measured a total of six times for each package using a
conventional Packaging
corporation of America (PCA) score bend tester as illustrated in Figure 33(A-
C).
Briefly, packages were placed in a holder so that box part 10 was immobile,
and lid
20 was clamped either on one side (as in most tests) or in the middle (Figure
33A). The lid
clamp chain was then attached to the PCA score bend tester (Figure 33B). The
score bend
tester was activated and the force required to open the package was recorded
(Figure 33C).
Following the initial force test and after each subsequent force measurement
each package
was opened four times by hand. The test was performed a total of five times so
that, at the
end of the experiment, each package studied was opened and closed 25 times to
simulate a
user opening and closing the package to obtain cigarettes.
The observed force required to open the packages was measured in grams, which
can
be converted to Newton meters (Nm) using standard calculations. The average
forces for
the first opening of the package samples as illustrated in greater detail in
Figure 35 and
Tables 3 to 6 are: 275 g for control packages, 173 g for the cam cut profile
design alone, 198
g for the cam cut profile and new latching tab design and 149 g for the
combined four
improvements. As expected and illustrated in Figure 35, following the initial
one or two
openings, the required force to open a package reduces and stabilises for all
types of
packages measured. However, the high standard deviation of 112 g for the
control sample
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force measurements (Table 3) confirms the unpredictability of the existing
latching tab
operation. Hang-ups were observed on 4 of the 10 control samples, causing a
high degree of
variability in opening force for conventional packages. Comparatively, the
degree of
variability in initial and subsequent opening forces for all designs disclosed
in the instant
invention were significantly less, as shown in Tables 4 to 6 than that
observed for the
controls confirming the higher stability of the newly designed cigarette
packages.
Example 3: Latching Tab Configurations
The following inner frame and package blank new profiles were tested in
different
combinations on a Focke 350S high-speed hinge lid packer:
Controls:
- a standard inner frame profile (STD)
- a standard box part blank (STD)
Test Materials:
(As depicted in Figure 36)
- Inner frame "A" with front top corners cut-off and a latching tab profile
"A"
- Inner frame "B" with front top corners cut-off and a latching tab profile
"B"
- Inner frame "C" with front top corners cut-off and a latching tab profile
"C"
- Inner frame "D" with front top corners cut-off and a latching tab profile
"D"
- Inner frame "E" with front top corners cut-off and a latching tab profile
"E"
- Package blank 1, having raised pivot axis, standard inner frame, standard
latching tab, no
cam panel
- Package blank 2, having raised pivot axis, standard inner frame, standard
latching tab,
lid inside panel have a non-engaging curved profile.
The results, which are summarised in Table 7, demonstrate that the standard
inner
frame combined with the standard box part blank did not produce packages
having
consistent opening properties, in fact the packages were sometimes easy and
sometimes
difficult to open. The same inconsistencies were observed with respect to
package smiling;
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sometimes there was no smiling and sometimes there was severe smiling.
Therefore, this
combination gave unpredictable results.
All packages made using package blank 2, having the non-engaging curved
profile
and any latching tab configuration, were easy to open and exhibited no wedging
of the
latching tabs.
The packages made using the latching tab profile "E" demonstrated the least
smiling.
Example 4: Design of Hinge Lid 25 - 100 mm - Slims Package
The overall proportions of the package were as follows:
Package width = 65% of package height (what is the package height? 100mm?)
Package depth = 21 % of package height
Package depth/width ratio = 0.32
Lid j unction line with package box part at 25% of package height.
Pivot Axis
The lid pivot axis was raised to 10.5 mm from the top of the package, or 51 %
of lid
top panel depth.
Inner Frame
The acceptable interference level between the inner frame top front corners
and the
lid inside front panel was determined to be 0.525 mm, or 2.5% of lid top panel
depth.
Therefore, the distance of the inner frame top front corners to the lid inside
top panel (in
closed position) was set at 6.57 mm, or 25% of lid front panel height. The
distance of inner
frame top edge to lid inside top panel was 2 mm, or 7.7% of lid front panel
height.
Latching Tab
The modified latching tab was selected and the distance from outermost point S
to
lid inside top panel was set at 13.7 mm, or 53% of lid front panel height. The
latching tab
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protrusion P was set at 1 mm, which was equivalent to 3.3 times the thickness
of the board
used to manufacture the cam panel.
Cam Panel
The latching tab zero interference trajectories were determined and the cam
profile
point A was set at a distance of 0.5 mm, or 1.9% of lid front panel height,
from the zero
interference trajectory of the damaged latching tab. The cam inclination angle
was set at
33.8 to allow for the flexibility of the latching tab material.
The wedging zone of the cam panel was designed to have the following
dimensions:
length = 3 mm (11.5% of lid front panel height)
distance from point E to lid inside front panel = 10.4 mm (40% of lid front
panel height)
radius of segment CD = 2 mm (7.7% of lid front panel height)
Finally, cam panel segments EF and FG were positioned to support the lid
inside
front panel by using a distance of 10.4 mm (40% of lid front panel height)
between point E
and point G.
All publications, patents and patent applications mentioned in this
Specification are
indicative of the level of skill of those skilled in the art to which this
invention pertains and
are herein incorporated by reference to the same extent as if each individual
publication,
patent, or patent applications was specifically and individually indicated to
be incorporated
by reference.
The invention being thus described, it will be obvious that the same may be
varied in
many ways. Such variations are not to be regarded as a departure from the
spirit and scope
of the invention, and all such modifications as would be obvious to one
skilled in the art are
intended to be included within the scope of the following claims.
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CA 02779032 2012-04-26
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