Apparatus and Method for Manufacturing a Smoking Article Pack

Abstract

A method of manufacturing a pack of smoking articles. The method comprises providing a planar blank of an inner support frame comprising a front panel and a rear panel connected by a bottom panel, and folding the front and rear panels together about the bottom panel to form an inner support frame in a receiving configuration. In the receiving configuration, the front and rear panels diverge in a direction away from the bottom panel and define an opening remote from the bottom panel. The method includes inserting a bundle of smoking articles through the opening into the inner support frame and folding the front and rear panels together about the bottom panel from the receiving configuration to an enclosed configuration to enclose the bundle of smoking articles. The method includes wrapping the bundle of smoking articles and inner support frame with a film to form a sealed pack of smoking articles. Also an apparatus for manufacturing a pack of smoking articles according to such a method.

1 . A method of manufacturing a pack of smoking articles comprising providing a planar blank of an inner support frame comprising a front panel and a rear panel connected by a bottom panel, folding the front and rear panels together about the bottom panel to form an inner support frame in a receiving configuration, in which the front and rear panels diverge in a direction away from the bottom panel and define an opening remote from the bottom panel, inserting a bundle of smoking articles through the opening into the inner support frame, folding the front and rear panels together about the bottom panel from the receiving configuration to an enclosed configuration to enclose the bundle of smoking articles, and wrapping the bundle of smoking articles and inner support frame with a film to form a sealed pack of smoking articles. 
     
     
         2 . A method according to  claim 1  wherein at least one of the front and rear panels includes side panels extending from lateral side edges thereof either side of the bottom panel, the method including folding the side panels relative to the front and/or rear panels to form side panels of the inner support frame between the opening and the bottom panel. 
     
     
         3 . A method according to  claim 1  wherein the front panel comprises first side panels connected to its lateral side edges, and the rear panel comprises second side panels connected to its lateral side edges, the method including folding the first and second side panels relative to the respective front and rear panels before folding the front and rear panels together, such that the part of the first side panels overlaps the second side panels in the receiving configuration of the inner support frame. 
     
     
         4 . (canceled) 
     
     
         5 . A method according to  claim 1  further comprising feeding the inner support frame in the receiving configuration into a pocket of an assembly wheel of a packaging apparatus, and inserting the bundle of smoking articles into the inner support frame and folding the inner support frame into the enclosed configuration within the pocket. 
     
     
         6 . A method according to  claim 5  wherein the pocket of the assembly wheel includes a plurality of walls, at least one wall comprising a plate which is moveable to alter the size of the pocket, and wherein the front and rear panels are folded together from the receiving configuration to the enclosed configuration by movement of the plate from a first position to a second position. 
     
     
         7 . (canceled) 
     
     
         8 . A method according to  claim 5  wherein two opposing walls defining the pocket of the assembly wheel comprise plates which are moveable towards and away from each other to alter the size of the pocket. 
     
     
         9 . A method according to  claim 6  wherein the assembly wheel comprises an actuation mechanism operable to move the at least one plate from the first position to the second position, and wherein the assembly wheel is rotatable to move the pocket between a plurality of pack assembly positions and wherein the actuation mechanism is operated to move the at least one plate from the first position to the second position upon rotation of the assembly wheel from a first assembly position to a second assembly position. 
     
     
         10 . (canceled) 
     
     
         11 . A method according to  claim 10  wherein the first assembly position comprises an insertion position at which the bundle of smoking articles is inserted into the inner support frame, and the second assembly position comprises an ejection position at which the bundle of smoking articles enclosed within the inner support frame is ejected from the pocket. 
     
     
         12 . A method according to  claim 5  comprising retaining the inner support frame within the pocket of the assembly wheel by suction force. 
     
     
         13 . A method according to  claim 1  wherein the inner support frame blank is folded such that the front and rear panels diverge by an angle greater than 10 degrees in the receiving configuration. 
     
     
         14 . (canceled) 
     
     
         15 . An apparatus for manufacturing a pack of smoking articles including a planar blank of an inner support frame comprising a front panel and a rear panel connected by a bottom panel, the apparatus comprising a folding station configured to fold the front and rear panels together about the bottom panel to form an inner support frame in a receiving configuration in which the front and rear panels diverge away from the bottom panel and define an opening remote from the bottom panel, an assembly apparatus configured to receive the inner support frame in the receiving configuration, and an insertion mechanism configured to insert a bundle of smoking articles through the opening into the inner support frame, a closing mechanism configured to fold the front and rear panels together about the bottom panel from the receiving configuration to an enclosed configuration to enclose the bundle of smoking articles, and a wrapping station configured to wrap the bundle of smoking articles and inner support frame with a film to form a sealed pack of smoking articles. 
     
     
         16 . An apparatus according to  claim 15  configured to receive a blank in which at least one of the front and rear panels includes side panels extending from lateral side edges thereof either side of the bottom panel, the folding station being configured to fold the side panels relative to the front and/or rear panels to form side panels of the inner support frame between the opening and the bottom panel. 
     
     
         17 . An apparatus according to  claim 16  configured to receive a blank in which the front panel comprises first side panels connected to its lateral side edges, and the rear panel comprises second side panels connected to its lateral side edges, the folding station configured to fold the first and second side panels relative to the respective front and rear panels before folding the front and rear panels together, such that the part of the first side panels overlaps the second side panels in the receiving configuration of the inner support frame. 
     
     
         18 . An apparatus according to  claim 17  comprising an adhesive applicator configured to apply adhesive to the first and/or second side panels to bond the adjacent first and second side panels together once the inner support frame is in the enclosed position. 
     
     
         19 . An apparatus according to  claim 16 , wherein the folding station includes a folding mechanism, the folding mechanism comprising a pair of spaced walls and a lifting arm moveable between a first and a second position, the lifting arm configured to convey an inner support frame blank between the spaced walls such that the side panels are folded relative to the front panel by contact with the spaced walls. 
     
     
         20 . An apparatus according to  claim 19  when dependent on  claim 17 , wherein the spaced walls comprise guide portions having a contact surface, and wherein, as the lifting arm conveys the inner support frame blank between the spaced walls, the first side panels are folded by contact with the spaced walls and the second side panels are folded by contact with the contact faces of the guide portions. 
     
     
         21 . An apparatus according to  claim 20  wherein the guide portions are configured to fold the second side panels relative to the rear panel by a greater angle than the first side panels are folded relative to the front panel. 
     
     
         22 . An apparatus according to  claim 21  wherein the contact faces of the guide portions extend inwardly beyond a respective inner face of the spaced walls. 
     
     
         23 . An apparatus according to  claim 15  wherein the assembly apparatus comprises an assembly wheel comprising a pocket configured to receive the inner support frame in the receiving configuration. 
     
     
         24 . An apparatus according to  claim 23  wherein the closing mechanism is configured to fold the inner support frame into the enclosed configuration within the pocket. 
     
     
         25 . An apparatus according to  claim 24  wherein the pocket of the assembly wheel includes a plurality of walls and the closing mechanism comprises at least one wall of the pocket comprising a plate which is moveable between a first and a second position to alter the size of the pocket. 
     
     
         26 . An apparatus according to  claim 25  wherein the at least one plate is pivotable about one end of the plate between the first and second positions. 
     
     
         27 . An apparatus according to  claim 25  wherein two opposing walls defining the pocket of the assembly wheel comprise plates which are moveable towards and away from each other to alter the size of the pocket. 
     
     
         28 . An apparatus according to  claim 25  wherein the closing mechanism comprises an actuation mechanism for moving the at least one plate, and wherein the assembly wheel is rotatable to move the pocket between a plurality of pack assembly positions, and wherein the actuation mechanism is configured to move the at least one plate from the first position to the second position upon rotation of the assembly wheel from a first assembly position to a second assembly position. 
     
     
         29 . An apparatus according to  claim 28  wherein the actuation mechanism comprises a piston connected to the assembly wheel and to the at least one plate. 
     
     
         30 . An apparatus according to  claim 25  wherein the assembly apparatus includes a suction mechanism configured to retain the inner support frame within the pocket by force of suction. 
     
     
         31 .- 32 . (canceled) 
     
     
         33 . An apparatus according to  claim 15  wherein the wrapping station comprises a vacuum mechanism configured to form the pack as sealed contained with an at least partial vacuum within the container.