WO2016050775A1

WO2016050775A1 - Method and apparatus for making a pack with a printed insert

Info

Publication number: WO2016050775A1
Application number: PCT/EP2015/072439
Authority: WO
Inventors: Fiorenzo Draghetti
Original assignee: Philip Morris Products S.A.
Priority date: 2014-09-29
Filing date: 2015-09-29
Publication date: 2016-04-07

Abstract

There is provided a method of making a pack of consumer goods having a printed insert between an inner frame of the pack and the consumer goods contained in the pack. The method is carried out by feeding individual inner frames and individual printed inserts to a transfer wheel, retaining an inner frame and a printed insert together on the transfer wheel and placing the inner frame and the insert together on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods. One or more laminar blanks are then wrapped around the consumer goods and over the inner frame and the insert to form the pack. A method of providing a printed insert for a pack of consumer goods is also provided, along with an apparatus for making a pack of consumer goods and an apparatus for providing a printed insert for a pack of consumer goods.

Description

METHOD AND APPARATUS FOR MAKING A PACK WITH A PRINTED INSERT

The present disclosure relates to a method and apparatus for making a pack of consumer goods, such as aerosol-generating articles, for example smoking articles, the pack comprising an outer package, one or more consumer goods within the outer package, an inner frame mounted in the outer package, and a printed insert between the inner frame and the consumer goods. The present invention also relates to a method and apparatus for providing a printed insert for a pack of consumer goods, such as aerosol-generating articles, for example smoking articles.

In the case of smoking article packs, there is often a need for the packs to include printed inserts containing information about the smoking articles or serving as a medium for advertising purposes. In other instances, such inserts may take the form of a coupon providing eligibility for the consumer to participate in prize drawings and the like. Smoking article packs typically include a foil wrapped bundle of smoking articles standing in an outer package, such as a hinge-lid pack having a box portion and a lid portion. The outer package typically includes an inner frame or collar inside the front and sides of the box portion of the outer package and extending into at least part of the space covered by the lid in the closed position. In the case of smoking article packs, a printed insert may be positioned between the foil wrapped bundle of smoking articles and the inner frame of the outer package whereby the insert remains in the pack when the transparent outer wrap is removed and is generally visible only when the lid of the pack is opened. Inserts are typically planar and arranged with one or both sides in contact with one or more parts of the pack.

When positioned between the bundle of smoking articles and the inner frame, the insert is typically placed on top of the foil wrapped bundle of smoking articles before the inner frame is delivered to and placed over the insert and bundle. The combination of inner frame, insert and the bundle of smoking articles is then overwrapped by the outer package to form the pack. One disadvantage of this approach is that it is generally not applicable for use with packs containing more than one wrapped bundle of smoking articles. For example, some known packs contain two separately wrapped bundles of smoking articles arranged side-by-side. These two bundles are typically split into two separate channels during manufacture of the pack. Therefore, an insert cannot simply be placed on, and in the middle of, the wrapped bundle of smoking articles, as is the case with a single bundle. Additionally, smoking article packaging machines operate at extremely high production speeds and may require several transport steps of the bundle and insert together before the inner frame is subsequently placed over the two items. In such processes, the inserts can become displaced from the bundle, or misaligned, causing unintended downtime and requiring operator intervention. In addition, by combining the placement of the inner frame and the insert into one device, namely the transfer wheel, the overall size and complexity of the manufacturing apparatus can be reduced.

It would be desirable to provide a method and apparatus for making a pack of consumer goods which can be used with a variety of different arrangements of product and which reduces the risk of incorrect insert placement.

According to a first aspect of the present invention, there is provided a method of making a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, an inner frame mounted in the outer package, and a printed insert between the inner frame and the consumer goods, the method comprising the steps of: feeding individual inner frames and individual printed inserts to a transfer wheel; retaining an inner frame and a printed insert together on the transfer wheel; placing the inner frame and the insert together on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods; providing one or more laminar blanks for forming the outer package; and wrapping the one or more laminar blanks around the consumer goods and over the inner frame and the insert to form the pack.

By combining the insert and the inner frame on the transfer wheel and transferring them together to the bundle of smoking articles, rather than placing the insert directly on the bundle, the process can be used with a variety of different pack arrangements, including packs with multiple individually wrapped bundles of consumer products. Additionally, the correct position of the insert within the package is easier to maintain, since the inner frame holds the insert in place on the bundle during subsequent manufacturing steps.

Preferably, the method is carried out by feeding individual inner frames and inserts to the transfer wheel, then retaining an inner frame and an insert on the transfer wheel, then placing the inner frame and the insert together on the one or more consumer goods and then wrapping the one or more laminar blanks around the consumer goods and over the inner frame and the insert to form the pack.

In some embodiments, the insert may be first placed on the transfer wheel before the inner frame is placed over the insert and the two retained together on the transfer wheel. Preferably, the step of retaining is carried out by first placing the inner frame on the transfer wheel, then placing the insert on the inner frame. In this manner, the insert is the outermost of the two items, so the insert and the inner frame can be removed from the transfer wheel and placed directly onto a bundle of consumer products without requiring any intervening steps to reverse the order of the insert an the inner frame.

Since the insert will be placed between the bundle of consumer articles and the inner frame, during the retaining step, the front face of the insert is retained against the rear face of the inner frame, either directly, or indirectly via one or more intermediate components. As used herein, the terms "top", "bottom", "front", "back" and "sides" refer to the relative positions and parts of components of the pack when the pack is assembled and held in an upright position by a consumer during opening such that products in the pack may be removed through the top side of the pack. These terms are used irrespective of their actual orientation during manufacture.

In any of the above embodiments, the step of retaining may by carried out using any suitable means. For example, the inner frame and the insert may be retained on the inner frame by applying a tacky surface on one or more of the transfer wheel, the insert and the inner frame. For example, a low tack adhesive could be used. Preferably, the step of retaining comprises applying a vacuum to both the inner frame and the insert to retain them on the wheel. This enables the insert and the inner frame to be retained on the transfer wheel using existing equipment and allows control of the force with which the insert and the inner frame are retained on the transfer wheel.

Where the step of retaining comprises applying a vacuum to both the inner frame and the insert to retain them on the wheel, preferably the insert extends beyond the inner frame in at least one direction. That is, the insert is positioned or sized, or positioned and sized, such that at least part of the insert extends beyond the outer shape of the inner frame in the plane of the inner frame. For example, the insert may extend beyond one or both sides of the inner frame. Alternatively, or in addition, the insert may extend beyond the top edge of the inner frame, the bottom edge of the inner frame, or the top and bottom edges of the inner frame. With this arrangement, where the inner frame is placed on the transfer wheel and the insert is placed on the inner frame, the vacuum can be applied to the part of the insert that extends beyond the inner frame as well as to the inner frame. This allows the vacuum to be applied to both the inner frame and the insert by a single vacuum source.

Alternatively, or in addition, the inner frame may comprise one or more holes through with the vacuum is applied to the insert. For example, the inner frame may be formed from a porous or perforated material, from a material having one or more cut-out openings of any suitable size or shape, or any combination thereof. With this arrangement, where the inner frame is placed on the transfer wheel and the insert is placed on the inner frame, the vacuum can be applied to the insert via the holes in the inner frame, as well as to the inner frame. As with embodiments in which the insert extends beyond the inner frame in at least one direction, this allows the vacuum to be applied to both the inner frame and the insert by a single vacuum source.

The inner frame may be substantially planar and arranged for mounting only at the front of the outer packaging. Preferably, the method comprises the step of folding first and second edges of the inner frame to form side walls arranged to extend either side of the insert when the inner frame and the insert are retained together on the transfer wheel. The side walls help to maintain correct positioning of the insert relative to the inner frame on the transfer wheel and during subsequent assembly steps. The step of folding may be carried out prior to, during or after the step of feeding individual inner frames to a transfer wheel and prior to, during or after the step of retaining an inner frame and an insert together on the transfer wheel. The step of folding may be carried out by pre-folding individual inner frames from one or more inner frame blanks before feeding the pre-folded individual inner frames to the transfer wheel. Alternatively, the step of feeding individual inner frames to the transfer wheel may be carried out by feeding individual inner frame blanks to the transfer wheel and folding each inner frame blank on the transfer wheel. In certain preferred embodiments, the step of folding first and second edges of the inner frame is carried out while the inner frame is held on the transfer wheel. In this manner, the step of folding can be carried out by a stationary folding device, such as one or more fixed guide rails, as the inner frame is rotated past the folding device. This removes the need for a separate folding device, reducing process complexity. In preferred embodiments, the step of retaining is carried out by first placing the inner frame on the transfer wheel, then placing the insert on the inner frame and the step of folding first and second ends of the inner frame is carried out before the insert is placed on the inner frame. By folding the inner frame before placing the insert on the inner frame, the side walls of the inner frame can assist with the correct placement of the insert on the inner frame. Thus, the side walls of the inner frame can act as a guide to improve the accuracy of the insert placement.

The step of feeding may comprise providing a continuous web of inserts and cutting individual inserts from the continuous web. Alternatively, the step of feeding may comprise storing a plurality of individual inserts in a hopper and delivering individual inserts from the hopper to the transfer wheel. Preferably, the step of feeding comprises providing one or more cartridges containing a plurality of individual inserts. Such inserts may be arranged within the cartridge in one or more stacks. In any of the above embodiments, the inserts may be preprinted, partially printed, or unprinted when on a continuous web or when stored in a hopper or cartridge. Where the inserts are partially printed or unprinted, the method may comprise printing the inserts with a printing device as the inserts are fed to the transfer wheel. In any of the above embodiments, the inserts may be cut, folded, moved, transferred, or otherwise manipulated during the step of feeding the inserts to the transfer wheel. Preferably, the step of feeding comprises providing one or more cartridges containing a plurality of individual printed inserts. Such inserts may be arranged within the cartridge in one or more stacks. In one such example, the step of feeding comprises providing a cartridge containing a stack of 700 printed inserts, although such cartridges may contain any suitable number of inserts. By providing one or more cartridges containing a plurality of printed inserts, the inserts can be refilled at a remote location before being transferred to the vicinity of the transfer wheel. This allows refilling to be carried out more quickly and cost effectively. In contrast, a hopper will require refilling online. This may be difficult where space or access to the hopper are limited.

The step of feeding may comprise delivering individual inserts to the transfer wheel using a conveyor, or delivering individual inserts to the transfer wheel directly from a cartridge or hopper.

The step of feeding may comprise providing a continuous web of inner frames and cutting individual inner frames from the continuous web. Alternatively, the step of feeding may comprise storing a plurality of individual inner frames in a hopper and delivering individual inner frames from the hopper to the transfer wheel. Preferably, the step of feeding comprises providing one or more cartridges containing a plurality of inner frames. Such inner frames may be arranged within the cartridge in one or more stacks. In one such example, the step of feeding comprises providing a cartridge containing a stack of 700 inner frames, although such cartridges may contain any suitable number of inner frames. By providing one or more cartridges containing a plurality of inner frames, the inner frames can be refilled at a remote location before being transferred to the vicinity of the transfer wheel. This allows refilling to be carried out more quickly and cost effectively. In contrast, a hopper will require refilling online. This may be difficult where space or access to the hopper are limited. The step of feeding may comprise delivering individual inner frames to the transfer wheel using a conveyor, or delivering individual inner frames to the transfer wheel directly from a cartridge or hopper.

In certain preferred embodiments, the step of feeding comprises providing a continuous web of inner frames, cutting individual inner frames from the continuous web and conveying the individual inner frames to the transfer wheel on a continuous belt.

The step of feeding may comprise feeding one or both of the insert and the inner frame to the transfer wheel when the transfer wheel is in motion, or when the wheel is stationary.

The consumer goods may be arranged in the pack in any suitable configuration. The consumer goods may be loose within the pack. Alternatively, the consumer goods may be individually wrapped within the pack. Preferably, the method comprises grouping the consumer goods for each pack into one or more bundles and pre-wrapping the one or more bundles of consumer goods in one or more inner wrappers. That is, wrapping the one or more bundles in one or more inner wrappers prior to the step of placing the inner frame and the insert on the consumer goods. The one or more inner wrappers may comprise any suitable material. In certain preferred embodiments, the one or more inner wrappers comprise a foil, for example metallised paper or aluminium foil, or combination thereof. In certain embodiments, the consumer goods for each pack are grouped into a single bundle, which may be pre-wrapped in one or more inner wrappers. In alternative embodiments, the consumer goods for each pack are arranged into two or more bundles, which may be pre-wrapped individually or together. Where the consumer goods for each pack comprise two or more pre-wrapped bundles, the two or more bundles may be arranged in the pack in any suitable configuration. For example, end- to-end, side-by-side, or front-to-back.

As used herein, the term 'consumer goods' refers to the consumer goods themselves, as well as to any inner wrapper in which the consumer good or goods is wrapped.

The step of placing the inner frame and the insert together on the one or more consumer goods may be carried out while the inner frame and the insert are retained on the transfer wheel. In such embodiments, the inner frame, the insert and the consumer goods are removed together from the transfer wheel, either before, during or after the step of wrapping the one or more laminar blanks around the consumer goods to form the pack. Preferably, the inner frame and the insert are removed from the transfer wheel prior to or during the step of placing the inner frame and the insert together on the one or more consumer goods. For example by conveying the consumer goods to the transfer wheel, placing the inner frame and the insert over the consumer goods and removing the inner frame and the insert from the transfer wheel as they are placed over the consumer goods. The inner frame and the insert may be transferred from the transfer wheel to a further wheel prior to the step of placing the inner frame and the insert together on the consumer goods. In such embodiments, the step of placing the inner frame and the insert together on the consumer goods may comprise conveying the consumer goods to the further wheel and retaining the consumer goods on the further wheel against the inner frame and the insert. The further wheel may comprise a folding wheel on which one or both of the inner frame and the one or more laminar blanks are folded into its final shape.

The inner frame and the insert may be removed from the transfer wheel by any suitable method, for example by applying an outwardly directed transfer force to the inner frame and the insert using a transfer mechanism. The transfer mechanism may comprise one or more push rods, cams, guides, or air nozzles arranged around the periphery of the transfer wheel to apply the transfer force to the inner frame and the insert. Alternatively, or in addition, the transfer mechanism may comprise one or more vacuum devices arranged outwardly from the inner frame and the insert, wherein the inner frame and the insert are removed from the transfer wheel by a vacuum applied by the one or more vacuum devices. For example, where the inner frame and the insert are transferred from the transfer wheel to a further wheel, the further wheel may comprise one or more vacuum devices arranged to remove the inner frame and the insert from the transfer wheel and to retain the inner frame and the insert together on the further wheel. Alternatively, or in addition, where the step of retaining comprises applying a vacuum to both the inner frame and the insert to retain them on the transfer wheel, the inner frame and the insert may be removed from the transfer wheel by selectively reducing or stopping the vacuum. For example, the vacuum may be reduced or stopped at the vacuum source, by one or more vacuum interrupting devices, such as closure plates, placed between the vacuum source and the inner frame and insert, or by arranging the vacuum conduits from the vacuum source such that the vacuum is reduced or stopped at one or more rotational positions of the transfer wheel as the transfer wheel rotates through those positions.

According to a second aspect of the invention, there is provided a method of providing a printed insert for a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, and an inner frame mounted in the outer package, the method comprising the steps of: feeding individual inner frames and individual inserts to a transfer wheel; retaining an inner frame and an insert together on the transfer wheel; and placing the inner frame and the insert together on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods.

According to a third aspect of the invention, there is provided an apparatus for making a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, an inner frame mounted in the outer package and a printed insert between the inner frame and the consumer goods, the apparatus comprising: a transfer wheel indexable between a number of stations; a first station at which an inner frame feeder is arranged to supply individual inner frames to the transfer wheel; a second station at which an insert feeder is arranged to supply individual printed inserts to the transfer wheel; a retention means for retaining an inner frame and an insert together on the wheel; a third station at which the inner frame and the insert are removed from the transfer wheel and placed on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods; and means for wrapping one or more laminar blanks for forming the outer package around the consumer goods, the insert and the inner frame to form the pack.

The first, second and third stations and the means for wrapping may be arranged in any suitable order. Preferably, the second station is positioned downstream of the first station, the third station is positioned downstream of the second station, and the means for wrapping one or more laminar blanks is positioned downstream of the third station.

As used herein, the term 'indexable' means that the wheel is arranged to rotate intermittently between stations, such that the wheel is stationary at one or more of the stations.

The retention means may comprise any suitable means for retaining the inner frame and the insert together on the transfer wheel. For example, the retention means may comprise a tacky surface on one or more of the transfer wheel, the insert and the inner frame. For example, a low tack adhesive could be used. Preferably, the retention means comprises one or more vacuum devices arranged around the periphery of the wheel.

The insert feeder may comprise a cutting blade for cutting individual inserts from a continuous web. Alternatively, the insert feeder may comprise a hopper for storing a plurality of individual inserts. Preferably, the insert feeder comprises one or more cartridges containing a plurality of inserts. The plurality of inserts may be arranged within the cartridge in one or more stacks. Where the insert feeder comprises a hopper or a cartridge for storing a plurality of individual inserts, the insert feeder may be arranged to supply individual inserts directly to the transfer wheel. Alternatively, the insert feeder may comprise a wheel, belt, or other conveying means for supplying individual inserts to the transfer wheel. In any of the above embodiments, the inserts may be pre-printed, partially printed, or unprinted when on a continuous web or when stored in a hopper or cartridge. Consequently, the insert feeder may further comprise a printing device arranged to print the inserts as the inserts are fed to the transfer wheel. Preferably, the insert feeder comprises one or more cartridges containing a plurality of printed inserts. Such printed inserts may be arranged within the cartridge in one or more stacks. In one such example, the insert feeder comprises a cartridge containing a stack of 700 printed inserts, although such cartridges may contain any suitable number of inserts. By providing one or more cartridges containing a plurality of printed inserts, the inserts can be refilled at a remote location before being transferred to the vicinity of the transfer wheel. This allows refilling to be carried out more quickly and cost effectively. In contrast, a hopper will require refilling online. This may be difficult where space or access to the hopper are limited.

The insert feeder may further comprise a folding device for folding individual inserts as the inserts are fed to the transfer wheel.

The inner frame feeder may comprise a cutting blade for cutting individual inner frames from a continuous web. Alternatively, the inner frame feeder may comprise a hopper for storing a plurality of individual inner frames. In certain embodiments, the inner frame feeder comprises one or more cartridges containing a plurality of inner frames. The plurality of inner frames may be arranged in one or more stacks. Where the inner frame feeder comprises a hopper or a cartridge for storing a plurality of individual inner frames, the inner frame feeder may be arranged to supply individual inner frames directly to the transfer wheel. Alternatively, the inner frame feeder may comprise a wheel, belt, or other conveying means for supplying individual inner frames to the transfer wheel. In certain preferred embodiments, the inner frame feeder comprises a cutting blade for cutting individual inner frames from a continuous web and a continuous belt for conveying individual inner frames to the transfer wheel.

The apparatus may comprise a fourth station, positioned upstream of the third station, at which consumer goods for each pack are grouped into one or more bundles and pre-wrapped in one or more inner wrappers. The fourth station may be arranged to group the consumer goods for each pack into two or more bundles and to individually pre-wrap the two or more bundles of consumer goods in one or more inner wrappers.

The third station may comprise a further wheel downstream of the transfer wheel to which the insert and the inner frame are transferred together. The further wheel may comprise a folding wheel that is arranged to wrap the one or more laminar blanks around the consumer goods to form the pack. The folding wheel may be indexable between a number of stations at which the one or more laminar blanks are wrapped around the consumer goods to form the pack.

The apparatus may comprise a transfer mechanism for removing the insert and inner frame from the transfer wheel. The transfer mechanism may comprise one or more push rods, cams, guides, or air nozzles arranged around the periphery of the transfer wheel to apply a transfer force to the inner frame and the insert. Alternatively, or in addition, the transfer mechanism may comprise one or more vacuum devices arranged outwardly from the inner frame and the insert, wherein the inner frame and the insert are removed from the transfer wheel by a vacuum applied by the one or more vacuum devices. For example, where the third station comprises a further wheel to which the inner frame and the insert are transferred, the one or more vacuum devices may be arranged around the periphery of the further wheel. Where the retention means comprises one or more vacuum devices, the transfer mechanism may comprise one or more vacuum interruption devices for reducing or substantially preventing the application of a vacuum to the insert and the inner frame by the one or more vacuum devices. For example, the one or more vacuum interruption devices may comprise one or more closure plates arranged to at least partially close a vacuum conduit or outlet between a vacuum source and the inner frame and insert. Alternatively, or in addition, the transfer wheel may comprise vacuum conduits between a vacuum source and the inner frame and insert, the vacuum conduits being arranged such that the vacuum is reduced or stopped at one or more rotational positions of the transfer wheel when the transfer wheel is rotated through those positions.

According to a fourth aspect of the invention, there is provided an apparatus for providing a printed insert for a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, and an inner frame mounted in the outer package, the apparatus comprising: a transfer wheel indexable between a number of stations; a first station at which an inner frame feeder is arranged to supply individual inner frames to the transfer wheel; a second station at which an insert feeder is arranged to supply individual printed inserts to the transfer wheel; a retention means for retaining an inner frame and an insert together on the wheel; and a third station at which the inner frame and the insert are removed from the wheel and placed on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods.

The stations may be arranged in any suitable order. Preferably, the second station is positioned downstream of the first station, and the third station is positioned downstream of the second station.

In any of the embodiments described above, the one or more consumer goods may comprise one or more aerosol-generating articles, such as smoking articles. In any of the embodiments described above, the transfer wheel may be arranged to retain more than one inner frame, more than one insert, or more than one inner frame and more than one insert at each station. In such embodiments, the transfer wheel preferably comprises a plurality of holders arranged around its periphery. One or more of the holders may be arranged to retain more than one inner frame, more than one insert, or more than one inner frame and more than one insert, for example by retaining them side-by-side in the axial direct. Alternatively, or in addition, two or more of the holders may be arranged side-by-side in the axial direct with each of these holders arranged to retain one or more inner frame and insert. Such a 'double track' arrangement allows simultaneous production of multiple packs using a single wheel. It also allows more than one insert or inner frame, or insert and inner frame, to be placed over the consumer goods for each pack. Alternatively, such arrangement allows a single inner frame to be placed over two bundles of consumer goods. This is advantageous in a configuration that is known as "princess pack", where two bundles of smoking articles are arranged side by side within the same outer package.

Although the disclosure has been described by reference to different aspects, it should be clear that features described in relation to one aspect of the disclosure may be applied to the other aspects of the disclosure.

The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 shows a perspective view of a pack of smoking articles manufactured in accordance with the present invention;

Figure 2 shows a schematic front view of an apparatus for making a pack of smoking articles in accordance with the present invention; and

Figure 3 shows a schematic front view of a transfer wheel for the apparatus of Figure 2.

Figure 1 shows a hinge-lid pack 10 of smoking articles manufactured in accordance with the present invention. The pack 10 comprises an outer package 12 formed from a folded laminar blank and having a lower box portion 14 and an upper lid portion 16 hinged to the rear wall of the box portion 14. In use, the front of the lid 16 is pivoted up and to the rear by the consumer to open the pack 10 and thereby allow access to its contents, as shown in Figure 1 . The pack 10 also includes an inner frame 18 inside the front and sides of the box portion 14, at least a portion of the inner frame 18 extending above the box portion 14 into the space covered by the lid 16 in the closed position.

The inner frame 18 is formed from a folded laminar blank and has a front wall 20 and side walls 22 extending rearwardly from the side edges of the front wall 20. Standing in the box portion 14 and between the side walls 22 of the inner frame 18 are two individually foil wrapped bundles 24 of smoking articles. A central cut-out 26 is provided in the front wall 20 of the inner frame to allow the consumer to remove smoking articles from the pack 10 in the open position. As well as reinforcing the front and sides of the pack 10, the inner frame 18 provides some interference or frictional engagement with the lid 16 as it opens and closes, thereby helping to prevent accidental opening of the pack 10 and to retain the lid 16 in the closed position when desired.

Between the front wall 20 of the inner frame 18 and the front of the wrapped bundles 24 is a printed insert 28. In this example, an upper portion of the printed insert 28 extends above the inner frame 18 in the region of the central cut-out 26 such that it is visible to the consumer when the pack 10 is in the open position. However, the insert 28 could be in any suitable position between the inner frame 18 and the bundles 24.

Figure 2 shows an apparatus 100 for making a pack of smoking articles in accordance with the present invention. The apparatus 100 includes a transfer wheel 1 10 that is indexable between a number of stations, an inner frame feeder assembly 120, an insert feeder assembly 130, and a folding wheel 140.

The transfer wheel 1 10 has four radially extending arms 1 12 that are rotatable around a horizontal axis to index the transfer wheel 1 10 between a first station 102, an intermediate station 104, a second station 106 and a third station 108 of the apparatus 100. At the end of each arm 1 12 of the transfer wheel 1 10 is an axially extending and substantially planar holder 1 14, as discussed below in relation to Figure 3.

The inner frame feeder assembly 120 includes a continuous belt 122 extending around a wheel 124 and an inner frame supply (not shown) for supplying individual inner frame blanks 126 to the continuous belt 122. The inner frame supply may be of any suitable type, such as a cartridge containing a stack of inner frame blanks, or a hopper containing a plurality of inner frame blanks. The continuous belt 122 runs between the individual inner frame supply and the transfer wheel 1 10 to feed individual inner frame blanks 126 to the transfer wheel at the first station 102.

The insert feeder assembly 130 includes a continuous belt 132 extending around a wheel 134 and an insert supply (not shown) for supplying individual inserts 28 to the continuous belt 132. The insert supply may be of any suitable type, such as a cartridge containing a stack of inserts, or a hopper containing a plurality of inserts. The continuous belt 132 runs between the insert supply and the transfer wheel 1 10 to feed individual inserts 28 to the transfer wheel at the second station 106.

The folding wheel 140 is positioned adjacent to the transfer wheel 1 10 at the third station 108 and is rotatable about a horizontal axis. A plurality of pockets 142 of substantially the same cross section as the pack to be made are equally spaced around the circumference of the folding wheel 140 with their longitudinal axes parallel to the axis of rotation of the folding wheel 140. Figure 3 shows the transfer wheel 1 10 in more detail. As shown, each holder 1 14 comprises a plurality of vacuum devices in the form of vacuum nozzles 1 16 fed by a vacuum supply (not shown) via vacuum conduits 1 18.

Referring to Figures 1 to 3, a method of making a pack of smoking articles in accordance with the invention is described. At the first station 102, an individual inner frame blank 126 is fed as a laminar board by the inner frame feeder 120 to one of the holders 1 14 of the transfer wheel 1 10, as indicated by arrow A in Figure 3. The inner frame blank 126 is retained on the transfer wheel 1 10 by the vacuum nozzles 1 16 of the holder 1 14. The transfer wheel 1 10 then rotates in an anti-clockwise direction to move the holder 1 14 to the intermediate station 104. At the intermediate station 104, the inner frame 18 is formed from the inner frame blank 126 by folding the lateral edges of the inner frame blank 126 radially outwardly about an axis parallel to the axis of rotation of the transfer wheel 1 10 to form the side walls 22 of the inner frame 18, as indicated by arrows B in Figure 3. The folding of the inner frame blank 126 is carried out in a conventional manner, for example by using a static folding bar that folds the inner frame blank 126 as it rotates on the transfer wheel 1 10. The transfer wheel 1 10 then rotates in an anticlockwise direction to move the holder 1 14 to the second station 106. At the second station 106, an individual printed insert 28 is fed by the insert feeder 130 to the holder 1 14, as indicated by arrow C in Figure 3, and is placed against the front wall 20 and between the side walls 22 of the inner frame 18. The side walls 22 of the inner frame thus act as a guide to improve the accuracy of the insert placement. When placed against the inner frame 18, the upper portion of the insert 28 extends above the inner frame 18 in the region of the central cut-out (as shown in Figure 1 ). As a result, the vacuum nozzles 1 16 apply a vacuum simultaneously to the inner frame 18 and to the upper portion of the insert 28 to retain the inner frame 18 and the insert 28 together on the transfer wheel 1 10. The transfer wheel 1 10 then rotates in an anti-clockwise direction to move the holder 1 14 to the third station 108.

As the transfer wheel 1 10 rotates in an anti-clockwise direction to index the holder 1 14 between the first station 102, intermediate station 104, second station 106 and third station 108, the folding wheel 140 rotates in a clockwise direction to index the folding wheel between a plurality of folding wheel stations. As the transfer wheel 1 10 and the folding wheel 140 rotate in opposite directions, their peripheries move in the same direction at the third station 108. This can make it easier to transfer the inner frame 18 and the insert 28 from the transfer wheel 1 10 to the folding wheel 140. In alternative embodiments, the transfer wheel 1 10 could rotate in a clockwise direction and the folding wheel 140 rotate in an anti-clockwise direction. However, the transfer wheel 1 10 and the folding wheel 140 could rotate in the same direction, if both are indexed such that they are stationary at the third station 108.

Upstream of the third station 108, smoking articles are grouped and wrapped in, for example, metallised or waxed paper or a polymeric film, to form the bundles 24, which are supplied in a conventional manner to the folding wheel 140 and a pair of bundles 24 is pushed into each of the pockets 142 on top of a card blank (not shown) contained in the pocket 142. The card blank is inserted into the pocket 142 in a known manner. The folding wheel 140 indexes the card blank and the pair of bundles 24 to the third station 108 at which the pocket 142 of the folding wheel is in close proximity with the holder 1 16 of the transfer wheel 1 10 on which the inner frame 18 and the insert 28 are retained.

At the third station 108, the vacuum supply to the vacuum nozzles 1 16 is reduced or prevented and the inner frame 18 and the insert 28 are held by the folding wheel 140 to transfer the inner frame 18 and the insert 28 from the transfer wheel 1 10 to the folding wheel 140, as indicated by arrow D in Figure 4. In this manner, the inner frame 18 and the insert 28 are placed over the pair of bundles 24 on the adjacent pocket 142 such that the insert 28 is positioned between the bundles 24 and the inner frame 18.. The inner frame 18 and the insert 28 may be retained on the folding wheel 140 in a conventional manner, for example using one or more guide plates, clamps, clips, or vacuum nozzles (not shown) arranged around the periphery of the folding wheel 140. The folding wheel 140 indexes the card blank, the pair of bundles 24, the inner frame 18 and the insert 28 between a number of folding stations at which a known folding mechanism (not shown) folds the card blank around the pair of bundles 24, the inner frame 18 and the insert 28 to form the pack.

The exemplary embodiments described above illustrate but are not limiting. In view of the above discussed exemplary embodiments, other embodiments consistent with the above exemplary embodiments will now be apparent to one of ordinary skill in the art. For example, in the embodiment described above, making of the pack of consumer goods is carried out using indexing wheels mounted for rotation about a horizontal axis. However, one or both of the indexing wheels could be mounted for rotation about a vertical axis.

Claims

1 . A method of making a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, an inner frame mounted in the outer package, and a printed insert between the inner frame and the consumer goods, the method comprising the steps of:

feeding individual inner frames and individual printed inserts to a transfer wheel;

retaining an inner frame and a printed insert together on the transfer wheel;

placing the inner frame and the insert together on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods;

providing one or more laminar blanks for forming the outer package; and

wrapping the one or more laminar blanks around the consumer goods and over the inner frame and the insert to form the pack.

2. A method according to claim 1 , wherein the step of retaining is carried out by first placing the inner frame on the transfer wheel, then placing the insert on the inner frame.

3. A method according to claim 1 or 2, wherein the step of retaining comprises applying a vacuum to both the inner frame and the insert to retain them on the wheel.

4. A method according to claim 3, wherein the insert extends beyond the inner frame in at least one direction.

5. A method according to claim 3 or claim 4, wherein the inner frame comprises one or more holes through which the vacuum is applied to the insert.

6. A method according to any preceding claim, further comprising the step of folding first and second edges of the inner frame to form side walls, the side walls being arranged to extend either side of the insert when the inner frame and the insert are retained together on the transfer wheel.

7. A method according to any preceding claim, wherein the step of feeding comprises providing one or more cartridges containing a plurality of printed inserts and feeding individual inserts from the cartridge to the transfer wheel.

8. A method of providing a printed insert for a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, and an inner frame mounted in the outer package, the method comprising the steps of:

feeding individual inner frames and individual inserts to a transfer wheel;

retaining an inner frame and an insert together on the transfer wheel; and

placing the inner frame and the insert together on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods.

9. A method according to any of claims 1 to 8, wherein the one or more consumer goods comprises one or more aerosol-generating articles.

10. An apparatus for making a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, an inner frame mounted in the outer package and a printed insert between the inner frame and the consumer goods, the apparatus comprising:

a transfer wheel indexable between a number of stations;

a first station at which an inner frame feeder is arranged to supply individual inner frames to the transfer wheel;

a second station at which an insert feeder is arranged to supply individual preprinted inserts to the transfer wheel;

a retention means for retaining an inner frame and an insert together on the wheel;

a third station at which the inner frame and the insert are removed from the transfer wheel and placed on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods; and

means for wrapping one or more laminar blanks for forming the outer package around the consumer goods, the insert and the inner frame to form the pack.

1 1 . An apparatus according to claim 10, wherein the retention means comprises one or more vacuum devices arranged around the periphery of the transfer wheel.

12. An apparatus according to any preceding claim, wherein the insert feeder comprises one or more cartridges containing a plurality of printed inserts.

13. An apparatus for providing a printed insert for a pack of consumer goods, the pack comprising an outer package, one or more consumer goods within the outer package, and an inner frame mounted in the outer package, the apparatus comprising:

a transfer wheel indexable between a number of stations; a first station at which an inner frame feeder is arranged to supply individual inner frames to the transfer wheel;

a second station at which an insert feeder is arranged to supply individual printed inserts to the transfer wheel;

a retention means for retaining an inner frame and an insert together on the wheel; and a third station at which the inner frame and the insert are removed from the wheel and placed on the one or more consumer goods such that the insert is positioned between the inner frame and the consumer goods.

14. An apparatus according to any of claims 10 to 13, wherein the one or more consumer goods comprises one or more aerosol-generating articles.