II.1a. The blank of the box interior ( flaps) –technical description – a blank

The blank of the flaps is app. twice bigger than the previously produce standard stiff cigarette boxes and has been produced of the same paper type. 

The technical drawings disclose actual dimensions. The model samples have been based on these.

The innovative elements in the construction of the box, which are incorporated in the folding system of the out shell, are as follows:

- The separation and magnification of the inside wall (flaps)

the separation of the inside wall into an independent, supporting, separate and completely usable box element enables to design the model of the box with a hinged lid and justifies such a solution. As the wall features comparatively large plane it reinforces the box by conjoining all side walls with the bottom wall. 

- Additional bottom wall, flaps’ mapped

the bottom mapped wall stiffens and completes the box as well as keeps steady constantly used hinged lid. Said wall when glued, prevents inside lower part deflection and allows the footing ledge to receive the hinged lid. 

- creasing lines of side and bottom walls

the creasing along said lines has been performed only after the inside wall has been extruded due to paper shifts and strains as well as set dimensions shift. Therefore, the side walls, on the side of the creasing, are protracted by app. 1,3- 1,5 mm while they achieve correct size only after the extrusion and paper contraction. This enables appropriate positioning of the side walls within the box making allowances for the collar. In the production stage the processes mentioned above can be performed automatically and simultaneously allowing for paper contraction.

- bottom extrusion of the flaps –the depth

the bottom extrusion enables additional storage pace formation and is optimized in dimensions to app. 2,5-2,8 mm due to paper stretch-resistance, minimum pack expansion, minimum paper use in production and the possibility to attach matches of 1mm breadth + sulfur brim  as well as to opportunity to gain maximum space for commercials and gadgets. The depth is app. 2,5-2,8 mm and enables to achieve appropriate stiffness of the interior and the footing ledge around it including the upper ridge. 
The extrusion depth range of 0 – 1,8 mm in test conditions proved neither sufficiency of pay-load capacity nor stiffness. The overall design was not attractive enough, either. The extrusion depth range above 3,5 mm posed further creasing problems. The box was too thick and there were problems with easy access to the box when taking out cigarettes or a gadget.

- bottom extrusion of the flaps – the ledge and extrusion angles

the bottom extrusion ridge of app. 2,5-2,8 mm together with the creasing lines enable erection of  the footing ledge ( useful for the hinged lid for proper footing) which is needed for gaining appropriate stiffness, tightness and an attractive design of the box. The minimum set press angles are 78,5 degrees in the upper part and on the sides, and 67,5 degrees on the ledge walls in the bottom sections, which enables easy realization as well as appropriate use and visual effect. The bottom extrusion ridge was made based on maximum overall dimensions. Possible ledge narrowing, which is app. 2,5 mm at the moment, might have caused visual decrepitude and loss of both stiffness of the construction and tightness of the box. 

- the footing ledge

constituted as a result of both upper and lower extrusions, it serves the role of a stiffening- footing ledge as well as a dividing component. It separates the additional storage space from the cigarette compartment.  The central function of the ledge resides in making the side walls stiff enough and precluding possible hinged lid or flaps’ diffraction. 

- upper extrusion of the flaps – the depth

the extrusion ridge app. 2,5 mm deep was performed in order to contain the tip of the hinged lid and to hold the cigarettes in their original position, making allowance for their volume.  The width of stamping is the achievable maximum, which enables unobstructed cigarette access and the gives rise to erection of the footing ledge. 

- upper extrusion of the flaps – the ledge and extrusion angles

the extrusion ridge thus created enables proper footing for the lid and appropriate guidance of the hinged upper cap as well as correct location of incisions required for locking purposes. The lateral angles hereto applied are 67,5 degrees for compactness and stiffness reasons, such as in the lower extrusion ridge. The extrusion featuring said angles prevents straightening of the flaps either as a result of the force of the cigarettes or as a result of daily use.    

- upper extrusion of the flaps, ledge arrangement and undercutting

a small undercutting in the upper section of the flaps enables easy opening of the hinged lid, however, precludes accidental opening when taking out a cigarette if the bottom hinged lid remains closed.   The decent of ledges is justified for maximum stiffening of the box in this spot as well as to hide 3 layers of paper i.e. 1 layer of the top cap and 2 layers of the hinged lid tips overlapping when the lid remains in the closed position. The bottommost ledge, an extrusion ridge in actuality, enables one-handed opening of the hinged lid. A gap between the bottom of the extrusion ridge and the hinged lid’s tip prevents accidental opening of the lid with a cigarette when it is being removed from the box, if it is our wish to keep the lid closed. 

- the depth of extrusion ridges in proportion to the box

the proportion of the depth of the extrusion ridges to the box can be presented by the following algorithm:  B:A=B:(C-X) and has been optimally set on the following value: x = app. 2,5 – 2,8 mm when the lid closed.  

- stamping method

in sample models, the extrusions of the flaps were made before the creasing stage and after the flaps were cut out of slightly damp paper, with the stamping die set to the following parameters: 67,5 and 78,5 mm. 
The dimensions and the depth are presented in the technical description for the herby specified box size.
The matrix and patrix are dissimilar in dimensions by app. 0,10 mm along all vertical walls.  

In case there are any problems or difficulties in the stamping process for the producer the utilisation of alternative stamping systems is advisable, i.e. infusing nalewowy
The main characteristic of the system is that paper manufacturer produces given element with infusion or other according to his proprietary technology.

- the location of the matches

the most advantageous solution applicable here is crosswise positioning of the matches in the box. Maximum size of the matches is thus achieved (width and length), and the matches are similar to standard matches. Such a positioning is the most effective and functional for the user as far as match utilization is concerned. The crosswise positioning enables the use of sulfur overhang, which appropriates the breadth of the co-lateral match in the neighbouring row. Such solution also provides that the totality of matches is covered completely by a hinged lid. The tests proved that the easiest way of breaking off a match is in the crosswise direction of the box i.e. towards oneself, starting from the top of the box.
The crosswise positioning of the matches in the process of their gradual use provides proportionate and optimal exposal of the commercial situated under the matches, with regard to transparent glasses also. The crosswise positioning of the matches in the process of their use has also been chosen in respect of the commercial printing applied on alongside a single match or the totality of them, said inscription being legible with any amount of matches unused and remaining in the box. The last, but not least argument pro crosswise positioning resides in the lack necessity of application of an additional strip used for fixing said matches in a paper row.   

- A commercial brochure

a commercial brochure, any folding system applicable, is glue-bonded to the ledge linearly or spot-welded. The linear glue-bonding technique, apart from ordinary commercial brochure function, additionally provides tight-locking of the additional storage space until it is removed. The brochure can be produced of any material type – paper, parchment, metal foil, or PCV foil depending on the intended effect. The maximum brochure width, in the footing position on the ledge, for this type of box is app. 0,20 mm.   

- assemblage and glue-bonding system

the flaps, after die-stamping, creasing and extruding process, together with the matches already fixed in place or a gadget and a commercial brochure also located properly, said flaps are inserted in the box in the traditional way, i.e. as in hitherto existing stiff cigarette boxes. The flaps, in such type of boxes, appear as autonomous elements cementing all walls, if said walls are glue-bonded to the box along all 3 sidewalls linearly, along the edges of the ledge and spot-welded in their lower sections.

Special Project for Tobacco Industries. Copyright 2004 - 2012. Mazur Office. All rights reserved.
Patented by Mazur

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