GB2511296A

GB2511296A - Smoking article packs and apparatus and methods for packing smoking articles

Info

Publication number: GB2511296A
Application number: GB1302285.0A
Authority: GB
Inventors: Andrew Jonathan Bray
Original assignee: British American Tobacco Investments Ltd; British American Tobacco Co Ltd
Current assignee: British American Tobacco Investments Ltd
Priority date: 2013-02-08
Filing date: 2013-02-08
Publication date: 2014-09-03
Also published as: GB201302285D0; WO2014122057A1

Abstract

An inner container 14 can be formed from a blank around cigarettes 16; then paired with a spacer 18 formed from another blank; the pair then being enclosed in an outer container 12 formed from a third blank. The cigarettes may be wrapped prior to being enclosed in the inner container. Ideally the spacer is a cuboid formed from a blank having a top face and a bottom face integrally connected by a third face with half faces also extending from the top and bottom faces to meet in the middle and oppose the third face. One face of the spacer engages the outer container from within and an opposed face engages an outer face of the inner container; these engagements can be glued and the inner container can also be glued to a panel of the outer container. The depth 36 of the outer carton is equal to the depth of the inner container 34 and the spacer 38 combined. Ideally the spacer and inner container are stacked and the outer container is folded around them. A box 10 made by this method in which the spacer has spaced opposed faces has hinged lid 22.

Description

Smoking Article Packs and Apparatus and Methods for Packing Smoking Articles

Field of the Invention

The invention relates to smoking article packs and apparatus and methods for packing smoking articles such as cigars, cigarillos and cigarettes, all of which articles will be referred to herein for simplicity as cigarettes.

Hingcd lid boxcs have long been used as cigarette packs. This type of cigarette pack is often made to a standard size that allows packs made by different cigarette manufacturers to be sold through a common vending machine. In cases in which a cigarette manufacturer wishes to supply cigarettes that have a smaller diameter than a standard cigarette or a reduced number of cigarettes in a pack, the volume of the pack filling (ie the bundle of cigarettes) will less than the internal volume of the standard size box.

Usually, the cigarette bundle has a smaller depth than the standard size box resulting in there being an empty space between the cigarette bundle and one of the major faces of the box. In some cases in which a reduced number of cigarettes is supplied, cigarettes are omitted from within the cigarette bundle so that the external size of the bundle is not affected. However, if too many cigarettes are omitted, the cigarette bundle may be unstable and prone to collapse during assembly or transportation, which can lead to consumer quality issues.

Summary of the Invention

The invention provides a method of assembling a cigarette pack comprising: forming an inner frame blank into an inner container containing a bundle of cigarettes; forming a spacer by erecting a spacer blank; forming a pack contents assembly comprising a said inner container containing a bundle of cigarettes and a said spacer; and forming a cigarette pack by forming an outer blank into an outer container containing said pack contents assembly.

The invention also includes a cigarette pack forming apparatus comprising: a cigarette wrapping unit operable to assemble an inner frame blank into an inner container containing a bundle of cigarettes; a blank erecting unit operable to erect a spacer blank to form a spacer; a combining unit operable to assemble an outer blank into an outer container containing a said inner container and a said spacer to form a cigarette pack.

The invention also includes a cigarette pack comprising: an outer container comprising a main body and a lid that is hinge connected with said main body; an inner container formed by folding an inner frame blank; a cigarette bundle contained in said inner container; and a spacer formed by folding a spacer blank to provide a spacer body having a first major surface and a second major surface disposed opposite and spaced apart from said first major surface, wherein said spacer and said inner container containing said cigarette bundle are each disposed in said outer container.

Brief Description ofthe Drawings

In the disclosure that follows, reference will be made to the drawings in which: Figure 1 is a schematic front elevation of a hinged lid cigarette pack with the lid in an open condition; Figure 2 is a schematic side elevation of the hinged lid cigarette pack of Figure 1; Figure 3 is a schematic plan view of the hinged lid cigarette pack of Figure I; Figure 4 is a plan view of an outer blank; FigureS is a plan view of an inner frame blank; Figure 6 is a plan view of a spacer blank; Figurc 7 is a schematic plan view of a cigarcttc forming apparatus that may be used in forming the cigarette pack of Figure 1; Figurc 8 is a schematic perspective view of a cigarette wrapping unit of the apparatus of Figure 7; Figure 9 is a schematic perspective view of a blank erecting unit of the apparatus of Figure 7 Figure lOis a schematic perspective view of an upstream part of a combining unit of the apparatus of Figure 7; Figure 11 is a schematic perspective view of a downstream part of a combining unit of the apparatus of Figure 7; and Figure 12 is a schematic view of paths of the blanks shown in Figures 4 to 6 through an apparatus such as the cigarette pack forming apparatus of Figure 7.

Detailed Description

Referring to Figures 1 to 3, a cigarefte pack 10 comprises an outer container 12, an inner container 14 containing a cigarette bundle 16 and a spacer 18. In the illustrated example the cigarette bundle 16 comprises a group of cigarettes (not shown) wrapped in foil. The outer container 12 comprises a main body 20 to receive and hold the inner container 14 and spacer 18 and a lid 22 that is hinge connected to the main body 20 along a hinge axis 24. The lid 22 can move from the fully open position shown in Figure 2 to a fully closed position in which a leading edge 26 of the lid 22 abuts an edge 28 of the main body 20 thereby completely enclosing the inner container 14, cigarette bundle 16 and spacer 18.

As is shown in Figures 2 and 3, the outer container 12 has a container volume that is greater than the volume of the inner container 14. The inner container 14 has a container volume corresponding substantially to the volume of the cigarette bundle 16. The width and hcight 32 of thc inncr containcr 14 and thc width 30 and hcight 32 of thc outcr containcr 12 arc substantially thc samc. Although not csscntial, thc ratio of thc hcight to the width may be 2:1. The depth 34 of the inner container 14 is less than the depth 36 of thc outcr containcr 12. Thc dcpth 38 of thc spaccr 18 is substantially cqual to thc dcpth 36 of thc outcr containcr 12 minus thc dcpth of thc inncr containcr 14. Accordingly, thc inner container 14 and spacer 18 combine to at least substantially fill the full depth of the outer container. In the illustrated example, the spacer has a width and height corrcsponding at lcast substantially to thc width 30 and hcight 32 of thc outcr containcr so that the inner container and spacer at least substantially fill the volume of the outer container 12.

Rcfcrring to Figurc 4, an outcr blank 50 that is crcctcd to makc thc outcr containcr 12 comprises a first main panel 52, a second main panel 54, a lid section 56 and a bottom panel 58. The lid section 56 is interconnected with the first main panel 52 along a hinge line 60 that defines the hinge axis 24 and includes side panels 61. The hinge line 60 may be defined by, for example, scoring or perforations. The first main panel 52 has longitudinal margins 62, 64 from which depend respective side flaps 66, 67, 68, 69. The second main panel 54 has longitudinal margins 70, 72 from which depend respective side panels 74, 76.

When the outer blank 50 is erected, the lid section 56 is folded to form the lid 22, the first and second main panels 52, 54 are brought into opposed spaced apart relation and the side flaps 66, 68 and side panels 74, 76 are folded so that the side flaps lie against the inner sides of the side panels. The depth 36 of the outer container 12 corresponds at least substantially to the width of the bottom panel 58 and side panels 74, 76. The faces of the first and second main panels 52, 54 and side panels 74, 76 visible in the drawing form the outer surfaces of the main body 20. The side flaps 66, 68 are secured to the side panels 74, 76 by means of an adhesive, which may be applied to the inner faces the side panels from where it transfers to the outer faces of the side flaps 66, 68 when the parts are brought together.

Referring to Figure 5, an inner frame blank 90 that is erected to make the inner container 14 comprises a first inner container main panel 92, a second inner container main panel 94 and an inner container bottom panel 96. The first inner container main panel 92 has longitudinal margins 98, 100 from which depend respcctivc side panels 102, 104. The second inner container main panel 94 has longitudinal margins 106, 108 from which depend respective side flaps 110, 112. The ends of the side flaps 110, 112 disposed furthest from the inner container bottom panel 96 are provided with respective secondary side flaps 114, 116. The free end of the sccond inner container main panel 94 (ic the end opposite the end that adjoins the inner container bottom panel 96) is provided with a cut-out 118. The cut-out 118 is configured to allow a consumer to access cigarettes contained in the inner container 14. The end of the second inner container main panel 94 provided with the cut-out 118 has respective lugs 122, 124 extending along the longitudinal margins 106, 108. The lugs 122, 124 are disposed adjacent the cut-out 118 and generally opposite the secondary side flaps 114, 116. The lugs 122, 124 are configured to retain the lid 22 in a closed condition.

When the inner frame blank 90 is erected, the first inner container main panel 92 and second inner container main panel 94 are disposed in opposite spaced apart relation and the side flaps 110, 112 and side panels 102, 104 are folded so that the side flaps lie against the inner sides of the side panels. The secondary side flaps 114, 116 are folded so that they lie against the inner side of the first inner container main panel 92. The faces of the first and second inner container main panels 92, 94 and side panels 102, 104 shown in the drawing form outer surfaces of the inner container 14. The side flaps 110, 112 may be secured to the side panels 102, 104 by an adhesive that may be applied to the inner faces of the side panels from where it transfers to the outer faces of the side flaps when the parts are brought together.

Referring to Figure 6, a spacer blank 130 that is erected to make the spacer 18 comprises a spacer blank first main panel 132, a bottom panel 134, a top panel 136 and spacer blank second main panel parts 138, 140. The spacer blank second main panel part 138 adjoins the top panel 136 at a margin 142 and the spacer blank second main panel part 140 adjoins the bottom panel 134 at a margin 144 so that the parts 138, 140 define opposite cnds 146, 148 of thc spaccr blank 130. Thc spaccr blank first main pancl 132 has opposcd longitudinal margins 150 152 from which dcpcnd rcspcetivc sidc flaps 154, 156.

The spacer blank second main panel parts 138, 140 have respective opposed longitudinal margins that arc aligned with the longitudinal margins 150, 152 and from which depend rcspcctivc sidc panels 158, 160, 162, 164. The ends of the side panels 162, 164 that arc disposed furthest from the margin 142 are provided with cut-outs to define a tapered flap 166 at the end 146 of the spacer blank second main panel part 138.

When the spacer blank 130 is erected, the ends 146, 148 are brought together so that the spacer blank second main panel parts 138, 140 form a substantially continuous spacer blank second main panel disposed in opposed spaced apart relation to the spacer blank first main panel 132. The side flaps 154, 156 of the spacer blank first main panel lie against the inner sides of the side panels 158, 160, 162, 164 and may be secured to the side panels by means of an adhesive, which may be applied to the inner faces of the side panels from where it transfers to the outer faces of the side flaps when the parts are brought together. The flap 146 may be disposed against the inner or outer side of the spacer blank second main panel part 140. The provision of the flap 146, which in some examples may be omitted, makes the side of the spacer blank defined by the spacer blank main panel parts 138, 140 more stable. The flap 146 may be secured to the part 140 by means of an adhesive.

The blanks 50, 90, 130 are formed of relatively thin cardboard or the like and may be plain or coated with a plastics material, film, varnish or the like. The blanks may be part or finish printed. Where a coating material is used, parts of the blank that are to be secured by an adhesive may be treated to ensure that adhesion can take place. For example, the surface of the blanks may be scored or otherwise roughened as indicated by the cross-hatching in Figures 4 to 6.

A cigarette pack made from the blanks 50, 90, 130 includes an outer container 12 with a main body 20 having inner major surfaces defined by the first and second main panels 52, 54 of the outer blank, an inner container 14 having outer major surfaces defined by the first and second inner container main panels 92, 94 of the inner frame blank 90 and a spacer 18 having first and second major surfaces defined by the spacer blank first major panel 132 and a combination of the first and second spacer blank second main panel parts 138, 140. One outer major surface of the inner container 14 abuts an inner major surface of the outer container whilc the other abuts a major surfacc of the spacer. The other major surface of thc spacer abuts the other inner major surface of the outer container.

Thus the inner container 14 and spacer 18 fully occupy the depth of the outer container.

At least some of the abutting major surfaces may be secured to one another with an adhesive.

A cigarette pack forming apparatus 200 shown in Figure 7 may be used in forming the cigarette pack 10. The cigarette pack forming apparatus 200 comprises three different units: a cigarette wrapping unit 202, a blank erecting unit 204 and a combining unit 206.

The cigarefte wrapping unit 202 is configured to form inner containers 14 containing a bundle of cigarettes 16. The blank erecting unit 204 is configured to form spacers 18.

The combining unit 206 is configured to form cigarette packs 10 by forming an outer blank 50 into an outer container 12 containing an inner container 14 and a spacer 18.

Referring to Figure 8, cigareftes are fed to the cigarette wrapping unit 202 through a cigarette intake chute 210. The cigarettes are aligned by an alignment conveyor 212 to prepare the cigarettes for individual bundle formation. At a foil wrap station 214 foil wrap 216 is fed from a spool or bobbin to wrap a group of cigareftes to form a cigarette bundle 16. The cigarette bundle 16 may be formed with a cigarette group having a desired number of cigarettes, for example, seven, thirteen or twenty.

The alignment conveyor 212 feeds cigarette bundles 16 from the foil wrap station 214 to an inner frame blank conveyor 218. The blank conveyor 218 is provided with individual folding stations to receive individual inner frame blanks 90 from an inner frame blank chute 220. The blank conveyor 218 moves the folding stations loaded with respective inner frame blanks 90 past the downstream end of the alignment conveyor 212 so that a cigarette bundle 16 can be deposited onto each inner frame blank. Upstream of the location at which the cigarette bundles 16 are deposited on the inner frame blanks 90, a small dot of adhesive may be applied to the upwards facing side of the first inner container blank main panel 92 so that the cigarette bundle 16 will remain stationaiy on the panel. After placement of a cigarette bundle 16 onto an individual inner frame blank 90, the folding operations to fold the inner frame blank 90 around the cigarette bundlel 6 commence. A second dot of adhesive may be placed on the inner side of the inner container blank second main panel 94 before folding commcnccs so that the cigarette bundle 16 will be securely held within the inner container 14. After placement of the second adhesive dot on the inner container blank second main panel 94, the blank is folded around the cigarette bundle 16 in the folding and adhesive application stations 222 and the partially formed inner container 14 and cigarette bundle 16 are then passed through an inspection station where improperly folded inner frame blanks 90 are rejected.

After the inspection station, an adhesive is applied to the sidc panels 102, 104 prior to the folding operation that brings the side flaps 110, 112 and side panels 102, 104 together.

The adhesive may be applied by an adhesive drum. The now formed inner container 14 containing a cigarette bundle 16 is passed into a drying drum 224. The container and cigarette bundle assembly may be moved from the blank conveyor 218 to the drying drum 224 by a plunger 226, a conveyor mechanism or a combination of a plunger and conveyor mechanism. The conveyor mechanism may be an overhead conveyor, which may comprise a chain to which a plurality of conveyor flights is attached to drive the assembly over the adhesive drum to the drying drum. As the inner container 14 passes around the drying drum the adhesive is able to dry. The completed inner container 14 with its cigarette bundle 16 is then passed from the drying drum 224 to an exit conveyor 228 via an exit aperture 230 formed in the drum. The inner container 14 is then fed to the combining unit 206 by the exit conveyor 228.

The blank erecting unit 204 shown in Figure 9 is similar to the cigarette wrapping unit 202. In the illustrated example, the main difference between the two units 202, 204 is that the blank erecting unit does not have a cigarette chute, alignment conveyor and foil wrap station. Also, elements of the filing and adhesive application stations 322 are configured differently in order to correctly fold the spacer blanks 130, which have a two-part second main panel rather than a one piece second main panel. Otherwise, the parts of the two units may be substantially the same and so for economy of presentation, like pails arc indicated by thc samc rcfcrcncc numcrals incrcrncntcd by 100 and will not bc dcscribcd in dctail again.

As shown in Figures 7 and 10, thc two cxit convcyors 228, 328 arc disposcd in side-by-sidc relationship as thcy cntcr thc combining unit 206. Thc cxit conveyor 228 is vertically displaced with respect to the exit conveyor 328 so that it is on a higher plane than the exit conveyor 328. Respective plungers 400, 402 are disposed adjacent the ends of thc cxit conveyors 228, 328. Thc plungcrs 400, 402 arc actuable by pneumatic pistons 404 or other suitable actuating devices to push the inner containers 14 from the exit conveyor 228 and spacers 18 from the exit conveyor 328 onto an input conveyor 406 of the combining unit 206. The actuation of the plungers 400, 402 is timed so that a spacer 18 is first pushed onto the input conveyor 406 and then an inner container 14 is pushed onto the spacer. The vertical displacement of the exit conveyors 228, 328 preferably corresponds substantially to the depth 38 of the spacers so that the inner containers can readily slide onto the upwards facing surface of the spacer. Optionally, an adhesive applicator 405 may be provided upstream of the plunger 402 to apply an adhesive to the upwards facing surface of the spacers 18 so that the inner containers 14 will be held in place on the spacers.

As shown in Figure 10, the exit conveyors 228, 328 and input conveyor 406 are disposed in parallel relation with the input conveyor 406 having its longitudinal axis disposed intermediate the respective longitudinal axes of the exit conveyors 228, 328. The movement of the inner containers 14 and spacers 18 from the exit conveyors 228, 328 to the input conveyor 406 is transverse (perpendicular in the illustrated example) to the longitudinal axes of the conveyors 228, 328, 406.

Referring to Figure II, the assemblies 408 formed by stacking an inner container 14 atop a spacer 18 are transported by the input conveyor 406 towards a blank conveyor 418.

Individual folding stations provided on the blank conveyor 418 are loaded with respective outer blanks 50 received from an outer blank chute 420, which may be referred to as a blank magazine. Each outer blank 50 is then loaded with an assembly 408 from the input conveyor 406. An adhesive may be applied to the upwards facing surffice of the first main panci 52 upstrcam of thc junction with thc input conveyor 406 so that thc assemblies 408 arc held on thc blanks 50. Then, as dcscribcd previously in conncction with the cigarefte wrapping unit 202, the blank conveyor 418 moves the individual folding stations past a scrics of folding and adhesive application stations 422 which arc configured to fold thc outcr blanks 50 around thc respective assemblies 408. An adhcsivc may be applied to the upwards facing side of the inner container 14 so that when the inner side of the second major panel 54 is folded down onto it, the panel 54 is secured to the inncr containcr. An inspcction station may bc provided to inspcct thc assemblies to ensure that the folding and adhesive operations carried out in the folding stations have taken place correctly.

Thc progrcss of thc outcr blank 50, inner frame blank 90 and spaccr blank 130 through the cigarette pack forming apparatus is illustrated schematically in Figure 12.

In the combining unit 206, a number of glue application nozzles are provided in the folding and adhesive application stations 422. These glue application nozzles may be HHS spray nozzles for spot gluing. This adhesive is similar to the normal adhesive utilised, except that it is more viscous for ready application through the nozzles. Multiple application or nozzles are required in the combining unit 206 for spot application of adhesive to the various corners and positions on the outer blank 50.

A transfer conveyor 425 is located at the downstream end of the blank conveyor 418 to move the part assembled cigarette packs 10 across an adhesive drum which applies an adhesive to inner faces of the side panels 74, 76 of the outer blank 50 prior to bringing them into contact with the outer faces of the side flaps 66, 67, 68, 69 respectively. The transfer conveyor 425 may be an overhead conveyor, which may comprise a chain to which a plurality of conveyor flights is aftached to drive the part assembled cigarette packs 10 across the adhesive drum to the drying drum. As an alternative to a transfer conveyor, the cigarette packs could be moved from the blank conveyor to the drying drum by a plunger of a combination of a plunger and conveyor mechanism. I0

Thc compicted cigarcttc packs 10 arc transfcrrcd from thc transfcr convcyor 425 into individual pockcts 421 of a drying drum 424. At thc cnd of thc rotational cxtcnt, or drying duration, of the drying drum 424, the cigarefte packs 10 are forced from the pockets 421 via an cxit aperture 430. The cigarcftc packs 10 cxiting thc cxit aperture 430 arc received on an cxit conveyor 440. The cxit convcyor 440 transports thc compicted cigarette packs 10 away from the cigarette pack forming apparatus 200 for subsequent handling and placement into cigarette cartons.

The combining unit 206 is configured to perform all of the folding operations that are necessary for formation of the outer container 12. This includes folding of the hinged lid 22 and the folding of the lid over the inner container 14 and spacer 18.

The cigarefte wrapping unit 202 and blank erecting unit 204 may be designed to run at about 140 units per minute. It is to be understood that this is not to be taken as limiting and the units may be designed to run at higher or lower speeds. Furthermore, other configurations of apparatus may be used that run at higher or lower speeds. For example, the cigarette wrapping unit and blank erecting unit may be configured as high speed rotary machines that may allow production speeds of up to 500 units per minute.

The foil wrapping station 214 provided in the cigarefte wrapping unit 202 may be a standard twin foil reel holder with typical rotary cut off and foil perforation units. The foil lining of the cigarette bundles 16 may be perforated as is normally conducted using a straight cut knife or serrated knife so that the upper exposed section on of the foil maybe removed by the user.

The drying drums in the three units 202, 204, 206 of the cigarette pack forming apparatus may all be forty-eight stage heated drums which are temperature controlled to assure proper drying of the adhesive in the formed parts.

The three unit cigarette forming apparatus may be controlled by a standard operable controlling device such as a PLC or similar electronic controller mechanism to control the transfer speeds and production speeds of all three units. Such electronic controllers are

II

known in the art and various electronic arrangements and systems may be utilised to effect control of thc individual units of thc cigarette pack forming apparatus.

Thc cigarettc bundles 16 and assemblies 408 may bc loaded onto respective inner frame blanks 90 and outcr blanks 50 at a stagc at which thc blanks arc csscntially flat.

Alternatively, the blanks may be partially erected before loading on the cigarette bundles 16 or assemblies 408. For example, if as illustrated in Figure 12 the side flaps 110, 112 are folded prior to inserting the cigarette bundle 16, it can be easier to control the location of the blank within the transport pocket and accurately load the cigarefte bundle onto the blank. Similarly, if the side flaps 66,68 of the outer blank 50 are folded upwards prior to insertion on an assembly 408, it can be easier to control the location of the blank within the transport pocket and accurately load the assembly onto the blank.

In the illustrated example the spacer has a height and width that correspond at least substantially to the height and width of the outer container and inner container. This is not essential. In principle, the spacer can be narrower or shorter than the outer and inner containers. However, at least substantial equality of the heights and widths of the outer container, inner container and spacer may provide a stronger more stable structure.

The engagement between the inner major surfaces of the outer container, the outer major surfaces of the spacer and the outer major surfaces of the inner container, particularly where one or more pairs of engaged surthees is secured by an adhesive provides a pseudo-laminate construction that may allow the parts to be made from relatively thinner materials than a conventional hinged lid cigarette pack box.

Conventional hinged lid cigarette pack boxes having an inner frame, or collar, disposed within the box. The collar functionality can be incorporated into an inner container such as the inner container 14 making it unnecessary to fit the outer container 12 with a collar.

In the illustrated example the spacer is a cuboid body. This is not essential. In one alternative example, the spacer may be formed by erecting a blank similar to the inner blank 90 shown in Figure 5 to provide a spacer body that is open at one end. In examples utilising a spaccr body with an opcn end, the spacer may bc assembled into thc outer containcr such that thc opcn end disposcd adjacent the bottom panel of the outer container. This provides a potentially cleaner more aesthetically appealing appearance.

However, in some examples, the open end of the spacer body may be arranged to facc thc outcr container lid. In this arrangement the space within the spaccr body may be usable as a storage compartment.

in the illustrated example the second main panel of the spacer 18 is defined by the two second main panel parts 138, 140, which are folded to bring them into end to end relation.

This is not essential. Instead, the join or overlap may be made at one end of the spacer so that each main panel comprises one part. However, the illustrated example can provide advantages in allowing the spacer to be fornied by a conventional folding sequence.

It is apparent that variations and equivalents to the different cigarefte units of the cigarette forming packs are available while still using concepts disclosed herein and claimed. The configuration of the outer container 12, inner container 14 and spacer 18 as illustrated and variations thereof may be such that individually they may be produced on standard pack forming apparatus with little or no modification required for such apparatus. This provides the advantage that such apparatus may be put to multiple uses and makes possibk the use of high speed machinery, such as high speed rotary machinery that may allow production speeds of up to 500 units per minute. For example, in some implementations, the apparatus may be capable of producing wallet-style cigarette packs by making relatively limited changes to the configuration of the apparatus. Such variations are deemed to fafl within the scope ofthe claims.

Claims

Claims 1. A method of assembling a cigarette pack comprising: forming an inner frame blank into an inner container containing a bundle of cigarettes; forming a spacer by erecting a spacer blank; forming a pack contents assembly comprising a said inner container containing a bundle of cigarettes and a said spacer; and forming a cigarette pack by forming an outer blank into an outer container containing said pack contents assembly.
2. A method of assembling a cigarette pack as claimed in claim 1, comprising forming said spacer blank into a cuboid spacer body.
3. A method of assembling a cigarette pack as claimed in claim 2, wherein said bundle of cigarettes comprises a group of eigareftes wrapped in a wrapper and forming said inner container comprises erecting said inner frame blank around said bundle of cigarettes to provide a said inner container containing a bundle of cigarettes.
4. A method of assembling a cigarette pack as claimed in claim 1, 2 or 3, wherein: said spacer blank comprises a spacer blank first main panel, a spacer blank top panel disposed at a first end of said first main panel, a spacer blank bottom panel disposed at a second end of said spacer blank first main panel, a first spacer blank second main panel part extending from said spacer blank top panel and a second spacer blank second main panel part extending from said spacer blank bottom panel; said first and second spacer blank second main panel parts define respective free ends of said spacer blank; and erecting said spacer blank comprises bringing each of said first and second spacer blank second main panel parts into opposed spaced apart relationship with said spacer blank first main panel such that said free ends are disposed in adjoining relationship whereby said spacer blank first main panel and said adjoining spacer blank second main panel pails define said major surfaces of said spacer.
5. A mcthod of assembling a cigarcttc pack as claimed in any one of the preceding claims, wherein forming said spacer comprises erecting said spacer blank to form a spacer having a first major surface and a second major surface, wherein said first and second major surfaces are disposed in opposed spaccd apart relationship and are configured to engage a first outer major surface of said inner container and a first inner major surface of said outer container.
6. A method of assembling a cigarette pack as claimed in claim 5, ifirther comprising applying an adhesive to secure at least one of said first major outer surface of the inner container and said first major inner surface of the outer container to the respective engaged major surface of the spacer blank.
7. A method of assembling a cigarette pack as claimed in any one of claims 5 or 6, further comprising applying an adhesive to secure a second major outer surface of said inner container to a second major inner surface of said outer container.
8. A method of assembling a cigarette pack as claimed in any one of the preceding claims, wherein said outer container has a depth, said inner container has a depth and said spacer has a depth and said spacer and inner container are configured such that the combined depths thereof correspond substantially to said depth of said outer container.
9. A method of assembling a cigarette pack as claimed in any one of the preceding claims, wherein said pack contents assembly is formed by forming a stack comprised of said spacer and said inner container containing a bundle of cigarettes.
10. A method of assembling a cigarette pack as claimed in any one of the preceding claims, wherein forming said cigarette pack comprises erecting said outer blank around said pack contents assembly.
II. A cigarette pack forming apparatus comprising: a cigarette wrapping unit operable to assemble an inner frame blank into an inner container containing a bundle of cigarettes;

ISa blank erecting unit opcrablc to erect a spacer blank to form a spacer; a combining unit operable to assemble an outer blank into an outer container containing a said inner container and a said spacer to form a cigarette pack.
12. A cigarette pack forming apparatus as claimed in claim 11, whercin said blank erecting unit is operable to assemble said spacer blank to form a spacer having opposed spaced apart major surfaces configured to engage a first outer major surface of said inner container and a first inner major surface of said outer container.
13. A cigarette pack forming apparatus as claimed in claim 12, wherein said combining unit comprise an adhesive applicator configured to apply an adhesive to secure said spacer to said inner container.
14. A cigarette pack forming apparatus as claimed in claim 12 or 13, wherein said combining unit comprises an adhesive applicator configured to apply an adhesive to secure said inner container to said outer container.
15. A cigarette pack forming apparatus as claimed in any one of claims 11 to 14, wherein said blank erecting unit is operable to assemble a said spacer blank to form a spacer having a cuboid spacer body.
16. A cigarette pack comprising: an outer container comprising a main body and a lid that is hinge connected with said main body; an inner container formed by folding an inner frame blank; a cigarette bundle contained in said inner container; and a spacer formed by folding a spacer blank to provide a spacer body having a first major surface and a second major surface disposed opposite and spaced apart from said first major surface, wherein said spacer and said inner container containing said cigarette bundle are each disposed in said outer container.
17. A cigarcttc pack as claimcd in claim 16, whcrcin said first major surfacc is in contact with a first inncr major surfacc of said outcr containcr and a first outcr major surface of said inner container.
18 A cigarcttc pack as claimcd in claim 16 or 17, whcrcin said inncr containcr has a second outer major surface that is in contact with a second inner major surface of said outer container.
19. A cigarette pack as claimed in claim 16, 17 or 18, wherein said spacer comprises a cuboid spacer body.
20. A cigarcttc pack as claimed in any onc of claims 16 to 20, wherein said outer container, inner container and spacer have respective heights and widths that are substantially equal.
21. A cigarefte pack as claimed in any one of claims 20 to 21, wherein said outer container, inner container and spacer have respective depths and the depth of the inner container plus the depth of the spacer is substantially equal to the depth of the outer container.