Apparatus and method for forming hinged top cigarette box

An apparatus for forming a hinged top cigarette box from a one-piece blank, the one piece blank having first and second edges and located therebetween, cut-out and hinge features, the apparatus comprising:

• a. a frame;
• b. a hopper connected to said frame for holding a supply of one piece blanks;
• c. a mandrel rotatably mounted on said frame for wrapping said one piece blank around itself to form a plural layered shell;
• d. a pusher bar and a stop disposed adjacent said mandrel, said pusher bar pushing said one piece blank and said stop engaging said cut-out feature to align said first edge of said one piece blank, so that said cut-out and hinge features register with each other when said one piece blank is wrapped around itself;
• e. transferring means adjacent to said hopper for transferring a one piece blank from said hopper to said mandrel;
• and
• f. means for applying glue to said one piece blank in a region adjacent to said second edge to secure said second edge to said one piece blank after said one piece blank has been wrapped around itself.

A method of forming a hinged top cigarette box having dual layers and an arcuate surface from a one piece blank, the one piece blank having first and second edges and located therebetween, cut-out and hinge features, the method comprising the steps of:

• engaging said first edge of said one piece blank to a mandrel while aligning said one piece blank by abutting a portion of said one piece blank to a stop located near said mandrel;
• aligning said cut-out and hinge features by rotating said mandrel to wind said one piece blank around itself to form a dual layered shell having inner and outer sleeves and having an arcuate surface;
• and
• securing said second edge of said one piece blank to said outer sleeve of said dual layered shell.

A method of forming a hinged top cigarettes box having dual layers and an arcuate surface from a one piece blank, said one piece blank having first and second edges and located therebetween, a first portion serving as an inner sleeve and a second portion serving as an outer sleeve, the method comprising the steps of:

• engaging said first edge of said one piece blank with a mandrel while aligning said one piece blank by abutting a portion of said one piece blank to a stop located near said mandrel;
• aligning said second portion of said one piece blank with said first portion of said one piece blank by rotating said mandrel to wind said one piece blank around itself to form a dual layered shell having an arcuate surface so that said first and second portions of said one piece blank define inner and outer sleeves, respectively;
• and
• securing said second edge of said one piece blank to said outer sleeve of said dual layered shell.

Apparatus for forming a hinged top cigarette box from a one-piece blank, the one piece blank having first and second edges and located therebetween, cut-out and hinge features, the apparatus comprising:

• a. a frame;
• b. a mandrel rotatably mounted on said frame for wrapping said one piece blank around itself to form a dual layered shell so that the cut-out and hinge features register;
• c. a stop disposed adjacent said mandrel for engaging said cut-out feature, so that said first edge of said one piece blank is aligned on said blank when said cut-out feature engages said stop;
• d. means for urging said one piece blank into engagement with said stop;
• e. an ultrasonic sealing device disposed adjacent said mandrel and having an acoustical horn for engaging said one piece blank disposed on said mandrel, said ultrasonic sealing device sealing said one piece blank after said one piece blank has been wrapped so that its cut-out and hinge features register.