U.S. patent application number 10/725355 was filed with the patent office on 2005-06-02 for cigarette paper testing apparatus and associated method.
Invention is credited to Ademe, Balager, Henderson, Calvin Wayne, Nelson, John Larkin, Seymour, Sydney Keith.
Application Number | 20050115575 10/725355 |
Document ID | / |
Family ID | 34620289 |
Filed Date | 2005-06-02 |
United States Patent
Application |
20050115575 |
Kind Code |
A1 |
Seymour, Sydney Keith ; et
al. |
June 2, 2005 |
Cigarette paper testing apparatus and associated method
Abstract
An apparatus adapted to examine a length of a cigarette paper is
provided. The paper includes a pattern having a first and a second
band, the pattern repeating along the length thereof. A second
bobbin is configured to have the paper advanced thereto and wound
thereon after the paper is unwound from a first bobbin. A pattern
detection device is disposed between the first and second bobbins,
and is configured to detect at least one of the bands and produce a
signal in response thereto. A testing device is in communication
with the pattern detection device and is disposed between the first
and second bobbins. The testing device is configured to
nondestructively determine a property of at least one of the bands
in response to the signal. An associated apparatus, system, and
method are also provided.
Inventors: |
Seymour, Sydney Keith;
(Clemmons, NC) ; Ademe, Balager; (Winston-Salem,
NC) ; Henderson, Calvin Wayne; (Clemmons, NC)
; Nelson, John Larkin; (Lewisville, NC) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Family ID: |
34620289 |
Appl. No.: |
10/725355 |
Filed: |
December 1, 2003 |
Current U.S.
Class: |
131/280 ;
131/908; 73/865.8 |
Current CPC
Class: |
A24C 5/3412 20130101;
A24C 5/005 20130101; G01N 33/34 20130101 |
Class at
Publication: |
131/280 ;
131/908; 073/865.8 |
International
Class: |
A24C 005/32; A24C
005/34 |
Claims
That which is claimed:
1. An apparatus adapted to examine a length of a cigarette paper
comprising a pattern including a first band and a second band, the
pattern repeating along the length thereof, the apparatus
comprising: a second bobbin configured to be capable of receiving
the cigarette paper and to have the cigarette paper advanced
thereto and wound thereon after the cigarette paper is unwound from
a first bobbin; a pattern detection device disposed between the
first and second bobbins, the pattern detection device being
configured to detect at least one of the bands and produce a signal
in response thereto; and a testing device in communication with the
pattern detection device and disposed between the first and second
bobbins, the testing device being configured to nondestructively
determine a property of at least one of the bands in response to
the signal.
2. An apparatus according to claim 1 wherein the second bobbin is
responsive to the signal to selectively stop advancement of the
cigarette paper to the second bobbin and the testing device is
responsive to the signal to determine the property of the at least
one of the bands when advancement of the cigarette paper is
stopped.
3. An apparatus according to claim 1 wherein the second bobbin is
adapted to be received by a cigarette manufacturing machine such
that the cigarette paper wound thereon can be used to manufacture a
cigarette.
4. An apparatus according to claim 1 wherein the testing device is
configured to measure at least one of a porosity and a basis weight
of at least one of the bands of the cigarette paper.
5. An apparatus according to claim 1 further comprising a drive
system capable of being operably engaged with the second bobbin so
as to wind the cigarette paper thereon, the drive system being
operably engaged with the pattern detection device and responsive
thereto so as to allow selective advancement of the cigarette paper
onto the second bobbin.
6. An apparatus according to claim 1 further comprising a brake
system operably engaged with the first bobbin and configured to
cooperate therewith so as to maintain a tension on the cigarette
paper between the first bobbin and the second bobbin.
7. An apparatus according to claim 1 further comprising a
paper-engaging member configured to operably engage the cigarette
paper between the first and second bobbins so as to maintain a
tension on the cigarette paper.
8. An apparatus according to claim 1 further comprising a
controller in communication with the pattern detection device and
the testing device, the controller being configured to control
advancement of the cigarette paper onto the second bobbin in
response to the pattern detection device and to direct the testing
device to determine the property of the cigarette paper.
9. An apparatus according to claim 1 wherein the first bobbin is
interchangeable with the second bobbin.
10. A system for examining a cigarette paper and manufacturing a
cigarette therefrom, the system comprising: a cigarette
manufacturing device configured to manufacture the cigarette from a
length of the cigarette paper, the cigarette paper having a pattern
including a first band and a second band, with the pattern
repeating along the length thereof; and a cigarette paper testing
apparatus adapted to determine a property of one of the bands of
the cigarette paper before the cigarette paper is used to
manufacture the cigarette, the cigarette paper testing apparatus
comprising: a second bobbin configured to be capable of receiving
the cigarette paper and to have the cigarette paper advanced
thereto and wound thereon after the cigarette paper is unwound from
a first bobbin, the second bobbin being configured to be received
by the cigarette manufacturing apparatus so as to provide the
cigarette paper thereto; a pattern detection device disposed
between the first and second bobbins, the pattern detection device
being configured to detect at least one of the bands and produce a
signal in response thereto; and a testing device in communication
with the pattern detection device and disposed between the first
and second bobbins, the testing device being configured to
nondestructively determine a property of at least one of the bands
in response to the signal.
11. A system according to claim 10 wherein the second bobbin is
responsive to the signal to selectively stop advancement of the
cigarette paper to the second bobbin and the testing device is
responsive to the signal to determine the property of the at least
one of the bands when advancement of the cigarette paper is
stopped.
12. A system according to claim 10 wherein the first bobbin is
interchangeable with the second bobbin.
13. A system according to claim 10 wherein the testing device is
configured to measure at least one of a porosity and a basis weight
of at least one of the bands of the cigarette paper.
14. A system according to claim 10 further comprising a drive
system capable of being operably engaged with the second bobbin so
as to wind the cigarette paper thereon, the drive system being
operably engaged with the pattern detection device and responsive
thereto so as to allow selective advancement of the cigarette paper
onto the second bobbin.
15. A system according to claim 10 further comprising a brake
system operably engaged with the first bobbin and configured to
cooperate therewith so as to maintain a tension on the cigarette
paper between the first bobbin and the second bobbin.
16. A system according to claim 10 further comprising a
paper-engaging member configured to operably engage the cigarette
paper between the first and second bobbins so as to maintain a
tension on the cigarette paper.
17. A system according to claim 10 further comprising a controller
in communication with the pattern detection device and the testing
device, the controller being configured to control advancement of
the cigarette paper onto the second bobbin in response to the
pattern detection device and to direct the testing device to
determine the property of the cigarette paper.
18. A method of examining a length of a cigarette paper having a
pattern including a first band and a second band, the pattern
repeating along the length thereof, said method comprising:
detecting at least one of the bands with a pattern detection device
disposed between the first and second bobbins as the cigarette
paper is advanced to and wound on the second bobbin after being
unwound from the first bobbin; producing a signal in response to
the detection of the at least one of the bands; and
nondestructively determining a property of at least one of the
bands with a testing device in communication with the pattern
detection device and disposed between the first and second bobbins
in response to the signal.
19. A method according to claim 18 further comprising selectively
stopping advancement of the cigarette paper to the second bobbin in
response to the signal and determining the property of the at least
one of the bands when advancement of the cigarette paper is
stopped.
20. A method according to claim 18 further comprising installing
the second bobbin on a cigarette manufacturing device such that the
cigarette paper wound thereon can be used to manufacture a
cigarette.
21. A method according to claim 18 wherein nondestructively
determining a property further comprises determining at least one
of a porosity and a basis weight of at least one of the bands of
the cigarette paper with the testing device.
22. A method according to claim 18 further comprising selectively
advancing the cigarette paper onto the second bobbin with a drive
system operably engaged therewith, the drive system being operably
engaged with the pattern detection device and responsive thereto so
as to determine the selective advancement of the cigarette
paper.
23. A method according to claim 18 further comprising maintaining a
tension on the cigarette paper between the first bobbin and the
second bobbin with a brake system operably engaged and cooperable
with the first bobbin.
24. A method according to claim 18 further comprising maintaining a
tension on the cigarette paper with a paper-engaging member
configured to operably engage the cigarette paper between the first
and second bobbins.
25. A method according to claim 18 further comprising controlling
advancement of the cigarette paper onto the second bobbin, in
response to the pattern detection device, with a controller in
communication with the pattern detection device and the testing
device.
26. A method according to claim 18 wherein nondestructively
determining a property further comprises directing the testing
device to nondestructively determine the property of the cigarette
paper with a controller in communication with the pattern detection
device and the testing device.
27. A method according to claim 18 further comprising removing the
second bobbin and replacing the second bobbin with the first
bobbin.
28. An apparatus adapted to examine a length of a cigarette paper
having opposed ends and comprising a pattern including a first band
and a second band, the pattern repeating along the length thereof,
the apparatus comprising: a driven roller device configured to
receive one of the ends and to advance the length of the cigarette
paper in a machine direction; a tension device configured to
operably engage the cigarette paper prior to the driven roller
device, with respect to the machine direction, and to cooperate
with the driven roller device so as to maintain a tension on the
cigarette paper therebetween; a pattern detection device disposed
between the driven roller device and the tension device, the
pattern detection device being configured to detect at least one of
the bands and produce a signal in response thereto; and a testing
device in communication with the pattern detection device and
disposed between the driven roller device and the tension device,
the testing device being configured to nondestructively determine a
property of at least one of the bands in response to the
signal.
29. An apparatus according to claim 28 wherein the driven roller
device is responsive to the signal to selectively stop advancement
of the cigarette paper and the testing device is responsive to the
signal to determine the property of the at least one of the
bands.
30. An apparatus according to claim 28 wherein the testing device
is configured to measure at least one of a porosity and a basis
weight of at least one of the bands of the cigarette paper.
31. An apparatus according to claim 28 further comprising a
controller in communication with the pattern detection device and
the testing device, the controller being configured to control
advancement of the cigarette paper by the driven roller device in
response to the pattern detection device and to direct the testing
device to determine the property of the cigarette paper.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to smoking articles and, more
particularly, to an apparatus for examining a length of a paper
material suitable for use as a component of such a smoking article,
preferably in a nondestructive manner, whereafter the paper
material can be used to manufacture the smoking article.
[0003] 2. Description of Related Art
[0004] Popular smoking articles, such as cigarettes, have a
substantially cylindrical rod shaped structure and include a
charge, roll or column of smokable material such as shredded
tobacco (e.g., in cut filler form) surrounded by a paper wrapper
thereby forming a so-called "tobacco rod." Normally, a cigarette
has a cylindrical filter element aligned in an end-to-end
relationship with the tobacco rod. Typically, a filter element
comprises plasticized cellulose acetate tow circumscribed by a
paper material known as "plug wrap." Certain cigarettes incorporate
a filter element having multiple segments, and one of those
segments can comprise activated charcoal particles. Typically, the
filter element is attached to one end of the tobacco rod using a
circumscribing wrapping material known as "tipping paper." It also
has become desirable to perforate the tipping material and plug
wrap in order to provide dilution of drawn mainstream smoke with
ambient air. A cigarette is employed by a smoker by lighting one
end thereof and burning the tobacco rod. The smoker then receives
mainstream smoke into his/her mouth by drawing on the opposite end
(e.g., the filter end) of the cigarette.
[0005] Numerous references propose various types of cigarettes
possessing various types of paper wrapping materials. See, for
example, U.S. Pat. No. 1,909,924 to Schweitzer; U.S. Pat. No.
4,489,650 to Weinert; U.S. Pat. No. 3,030,963 to Cohn; U.S. Pat.
No. 4,146,040 to Cohn; U.S. Pat. No. 4,489,738 to Simon; U.S. Pat.
No. 4,615,345 to Durocher; U.S. Pat. No. 4,607,647 to Dashley; U.S.
Pat. No. 5,060,675 to Milford et al.; U.S. Pat. No. 4,924,888 to
Perfetti et al.; U.S. Pat. No. 5,143,098 to Rogers et al.; U.S.
Pat. No. 4,998,543 to Goodman; U.S. Pat. No. 5,220,930 to Gentry;
and U.S. Pat. No. 5,271,419 to Arzonico et al. Some paper wrapping
materials are so-called "banded papers" and possess segments
defined by the composition, location and properties of the various
materials within those wrapping materials. Numerous references
contain disclosures suggesting various banded wrapping material
configurations. See, for example, U.S. Pat. No. 1,996,002 to
Seaman; U.S. Pat. No. 2,013,508 to Seaman; U.S. Pat. No. 4,452,259
to Norman et al.; U.S. Pat. No. 5,417,228 to Baldwin et al.; U.S.
Pat. No. 5,878,753 to Peterson et al., U.S. Pat. No. 5,878,754 to
Peterson et al.; and U.S. Pat. No. 6,198,537 to Bokelman et al.;
U.S. Patent Application Publication No. 2003/0131860 to Ashcraft et
al.; and PCT WO 02/37991. Methods for manufacturing banded-type
wrapping materials also have been proposed. See, for example, U.S.
Pat. No. 4,739,775 to Hampl, Jr.; U.S. Pat. No. 5,474,095 to Allen
et al.; and PCT WO 02/44700 and PCT WO 02/055294. Some references
further describe banded papers having segments of paper, fibrous
cellulosic material, or particulate material adhered to a paper
web. See, for example, U.S. Pat. No. 5,191,906 to Myracle, Jr.;
U.S. Pat. No. 5,263,999 to Baldwin et al.; U.S. Pat. No. 5,417,228
to Baldwin et al.; and U.S. Pat. No. 5,450,863 to Collins et al.;
and U.S. Patent Application Publication No. 2002/0092621 to Suzuki.
In addition, some references describe apparatuses and method for
inspecting such papers and wrapping materials, some of which may be
capable of operating in an automated and/or high speed process.
See, for example, U.S. Pat. No. 4,845,374 to White et al.; U.S.
Pat. No. 5,966,218 to Bokelman et al.; U.S. Pat. No. 6,020,969 to
Struckhoff et al.; and U.S. Pat. No. 6,198,537 to Bokelman et al.;
U.S. Patent Application Publication Nos. 2003/0145869 and
2003/0150466 to Kitao et al., and 2003/0197126 to Sato et al.; and
U.S. patent application Ser. Nos. 10/645,996, filed Aug. 22, 2003,
and Ser. No. 10/665,066, filed Sep. 17, 2003.
[0006] Since certain properties are often required to provide the
desired burn characteristics and/or other characteristics of such
wrapping materials and since consistency between individual paper
wrappers for a particular product is also desired, it has been
desirable, if not necessary, to determine certain physical
properties or characteristics of wrapping materials for smoking
articles. For example, techniques for measuring the air
permeability or porosity of such wrapping papers, as well as the
diffusion of gases, such as carbon monoxide, through such wrapping
papers, have been developed. For example, the CORESTA method
(CORESTA Publication ISO/TC0126/SC I Ni 59E (1986)) details a
procedure for measuring air flow through paper with a specified
pressure differential across the paper. Further, for example, Drake
et al. (D. G. Drake, D. S. Riley, R. R. Baker and K. D. Kilburn, On
a Cell to Measure Diffusion Coefficients of Gases Through Cigarette
Papers, Int. J. Heat and Mass Transfer, 23 (1980) 127-134) describe
a procedure for direct measurement of paper diffusion coefficients.
In addition, U.S. Pat. No. 4,615,345 to Durocher proposes an
indirect and destructive sample test producing results asserted to
be proportional to paper diffusion coefficients.
[0007] It would be desirable, therefore, to nondestructively
measure certain physical properties or characteristics of wrapping
papers, such as those used for the manufacture of smoking articles.
It would also be desirable to expeditiously determine the
particular characteristic of the tested sample of the wrapping
paper and, in some instances, to have the capability to perform
regular or random evaluations of the paper wrappers in an automated
fashion. Further, such an apparatus and method should desirably be
nondestructive to the paper wrapper, applicable to a small area of
the paper wrapper (sample), cost and time effective, and capable of
being implemented in an environmentally friendly manner.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention, in one aspect, provides an apparatus
adapted to examine a length of a cigarette paper comprising a first
pattern (e.g. band) and a second pattern (e.g. band), with the
patterns repeating along the length thereof. Such an apparatus
comprises a second bobbin capable of receiving the cigarette paper,
and to have the cigarette paper advanced thereto and wound thereon,
after the cigarette paper is unwound from a first bobbin. A pattern
(e.g. band) detection device is disposed between the first and
second bobbins, wherein the pattern detection device is configured
to detect at least one of the patterns and produce a signal in
response thereto. A testing device is in communication with the
pattern detection device and is disposed between the first and
second bobbins. Preferably, the testing device is configured to
nondestructively determine a property of at least one of the
patterns in response to the signal.
[0009] Another aspect of the present invention relates to a system
for examining a cigarette paper and manufacturing a cigarette
therefrom. Such a system includes a cigarette manufacturing device
configured to manufacture the cigarette from a length of the
cigarette paper. The cigarette paper is patterned, for example,
with a first band and a second band, with the bands repeating along
the length thereof. A cigarette paper testing apparatus is adapted
to determine a property of at least one of the bands of the
cigarette paper before the cigarette paper is used to manufacture
the cigarette, and includes a second bobbin configured to be
capable of receiving the cigarette paper and to have the cigarette
paper advanced thereto and wound thereon after the cigarette paper
is unwound from a first bobbin. The second bobbin is further
configured to be received by the cigarette manufacturing device so
as to provide the cigarette paper thereto. A pattern detection
device is disposed between the first and second bobbins. The
pattern detection device is configured to detect at least one of
the patterns (e.g. bands) and produce a signal in response thereto.
A testing device is in communication with the pattern detection
device and is disposed between the first and second bobbins.
Preferably, the testing device is configured to nondestructively
determine a property of at least one of the bands in response to
the signal.
[0010] Still another aspect of the present invention involves a
method of examining a length of a cigarette paper having a pattern,
for example, a first band and a second band, with the bands
repeating along the length thereof. Such a method first comprises
detecting at least one of the patterns (e.g. bands) with a pattern
detection device disposed between the first and second bobbins as
the cigarette paper is advanced to and wound on the second bobbin
after being unwound from the first bobbin. A signal is then
produced in response to the detection of the at least one of the
bands. A property of at least one of the patterns (e.g. bands) is
thereafter determined, preferably nondestructively, with a testing
device, in communication with the pattern detection device and
disposed between the first and second bobbins, in response to the
signal.
[0011] Yet another aspect of the present invention relates to an
apparatus adapted to examine a length of a cigarette paper having
opposed ends, wherein the cigarette paper comprises pattern, for
example, a first band and a second band, with the bands repeating
along the length thereof. Such an apparatus includes a driven
roller device configured to receive one of the ends of the length
of the cigarette paper and to advance the cigarette paper in a
machine direction. A tension device is configured to operably
engage the cigarette paper, prior to the driven roller device, and
to cooperate with the driven roller device so as to maintain a
tension on the cigarette paper therebetween. A pattern (e.g. band)
detection device is disposed between the driven roller device and
the tension device, and is configured to detect at least one of the
bands and produce a signal in response thereto. A testing device is
in communication with the pattern detection device and is disposed
between the driven roller device and the tension device.
Preferably, the testing device is configured to nondestructively
determine a property of at least one of the bands in response to
the signal.
[0012] Accordingly, aspects and embodiments of the present
invention relate to an apparatus, system, and method for examining
a wrapping material for smoking article manufacture. The system is
particularly well suited for inspection of a web of paper wrapping
material that has a discontinuous nature, such as is provided by,
for example, application of an additive material to at least a
portion of that wrapping material so as to form a pattern, for
example, spaced apart bands along the wrapping material. The system
allows a roll of the wrapping material, or just a relatively small
strip therefrom, to be examined or tested in a nondestructive
manner, for example, to determine the suitability and consistency
of the wrapping material. The roll of wrapping material (or
remainder thereof) can then be used to manufacture a smoking
article.
[0013] A cigarette paper testing apparatus, as described herein in
one embodiment, can be used in a so-called "off-line" manner in
order to nondestructively examine a roll (e.g., a bobbin) of
wrapping material, or a relatively small strip therefrom. The roll
of the wrapping material (or remainder of the roll after removal of
the strip) can then be used to manufacture a smoking article. That
is, the associated system for examining an entire roll can be used
to first examine properties of a continuous strip of wrapping
material wound on a first bobbin using a first device (e.g., the
cigarette paper testing apparatus) disposed at a first location,
and the wrapping material so examined is then rewound on a second
bobbin and used at a later time to produce a smoking article using
a second device (e.g., an automated cigarette manufacturing device)
disposed at a second location. As such, the cigarette paper testing
apparatus is not necessarily integrally associated or configured to
be "online" with an automated cigarette manufacturing device, but
can be so configured if desired.
[0014] Such an off-line system incorporates a detection system for
detecting a feature of a continuous substrate, such as a band of a
wrapping material for manufacturing a smoking article manufacture,
as the substrate is advanced in the machine direction. In response
to the detection system, a testing apparatus performs an
appropriate nondestructive evaluation of the wrapping material.
Following testing, the wrapping material is rewound on the second
bobbin in such a manner that the second bobbin can be removed and
stored (or the strip is discarded). That second bobbin can then be
used to provide the continuous strip of paper web for the
manufacture of a continuous smokable rod using a conventional type
of cigarette making machine or other appropriate device.
[0015] Accordingly, embodiments of the present invention provide
distinct advantages as further detailed herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0016] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0017] FIGS. 1 and 2 are schematics of a cigarette paper testing
apparatus according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present inventions now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments of the invention are shown. Indeed,
these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0019] FIGS. 1 and 2 illustrates a cigarette paper testing
apparatus according to one embodiment of the present invention, the
apparatus being indicated generally by the numeral 100. Such an
apparatus 100 is configured to removably receive a first bobbin 150
on an unwind spindle assembly 125, the first bobbin 150 having a
continuous length of a wrapping material, such as a paper web 200
of a cigarette paper, wound thereon. The paper web 200 includes a
selected pattern such as, for example, one or more bands (of which
two bands 225, 250 are shown and described for illustrative
purposes), wherein the bands 225, 250 may repeat along the length
of the paper web 200. When the first bobbin 150 is engaged with the
apparatus 100, the paper web 200 is routed from the first bobbin
150 to a second bobbin 300 to be wound thereon. The second bobbin
300 is removably mounted to a rewind spindle assembly 325, wherein
the second bobbin 300 and/or the rewind spindle assembly 325 are
configured to be driven by a drive system 350 for unwinding the web
200 from the first bobbin 150 and winding the web 200 onto the
second bobbin 300. The unwinding of the paper web 200 from the
first bobbin 150 is regulated by a brake system 400 engaged with
the first bobbin 150 and/or unwind spindle assembly 125. A pattern
(e.g. band) detection device 450 is disposed between the first and
second bobbins 150, 300 for detecting one or more of the bands
along the length of the paper web 200.
[0020] Between the first and second bobbins 150, 300, a testing
system 500 is disposed and configured to nondestructively determine
a property of the paper web 200. Such a testing system 500 may
comprise, for example, a first testing device 550 configured to
determine a basis weight of the paper web 200 and a second testing
device 600 configured to determine a porosity of the paper web 200.
Though the first and second testing devices 550, 600 are provided
and described herein for illustrative purposes, one skilled in the
art will appreciate that only one of those devices 550, 600 may be
provided, or many other testing devices, in varying numbers, types,
and/or combinations, may be provided and configured to
nondestructively examine the paper web 200 between the first and
second bobbins 150, 300, when necessary. Further, one skilled in
the art will appreciate that other systems may also be provided for
acting on the web 200, wherein such systems may be configured to,
for example, apply a material such as an adhesive, coating, ink or
the like to the web 200, or to otherwise act on the web 200 such
as, for example, to emboss a pattern thereon or to perforate the
web 200, before the web 200 is rewound on the second bobbin 300.
The drive system 350, the pattern detection device 450, and the
first and second testing devices 550, 600 (and the brake system
400, when appropriate) may, where necessary, be connected to
communicate with a controller 650. In some instances, those
components may be connected to communicate with the controller 650
through a control interface 700. Examples of various techniques and
equipment for handling, unwinding, and rewinding bobbins are set
forth in U.S. Pat. No. 4,619,278 to Smeed et al., U.S. Pat. No.
5,156,169 to Holmes et al., and U.S. Pat. No. 5,966,218 to Bokelman
et al., and U.S. patent application Ser. No. 10/682,570, filed Oct.
9, 2003.
[0021] Certain paper wrapping materials that may be examined by
embodiments of the present invention are useful in the manufacture
of cigarettes designed to exhibit reduced ignition propensity. That
is, cigarettes incorporating certain wrapping materials, when
placed on a flammable substrate, tend to self extinguish before
burning that substrate. Of particular interest are those cigarettes
possessing tobacco rods manufactured using appropriate wrapping
materials having bands comprised of appropriate amounts of suitable
components so as to have the ability to meet certain cigarette
extinction criteria.
[0022] The paper wrapping material that is further processed to
provide the banded, or otherwise patterned, wrapping material can
have a wide range of compositions and properties. The selection of
a particular wrapping material will be readily apparent to those
skilled in the art of cigarette design and manufacture. Typical
paper wrapping materials are manufactured from fibrous materials,
and optional filler materials, to form so-called "base sheets."
Typical wrapping material base sheets suitable for use as the
circumscribing wrappers of tobacco rods for cigarettes have basis
weights that can vary. Typical dry basis weights of base sheets are
at least about 15 g/m.sup.2, while typical dry basis weights do not
exceed about 80 g/m.sup.2.
[0023] Typical wrapping material base sheets suitable for use as
the circumscribing wrappers of tobacco rods for cigarettes have
inherent porosities that can vary. Typical base sheets have
inherent porosities that are at least about 5 CORESTA units and
less than about 200 CORESTA units. A CORESTA unit is a measure of
the linear air velocity that passes through a 1 cm.sup.2 area of
wrapping material at a constant pressure of 1 centibar. See,
CORESTA Publication ISO/TC0126/SC I N159E (1986). The term
"inherent porosity" refers to the porosity of that wrapping
material with respect to the flow of air. A particular paper
wrapping material base sheet, for example, is comprised of wood
pulp and calcium carbonate, and exhibits an inherent porosity of
about 20 to about 50 CORESTA units.
[0024] Typical paper wrapping material base sheets suitable for use
as the circumscribing wrappers of tobacco rods for cigarettes
incorporate at least one type of fibrous material, and can
incorporate at least one filler material, in amounts and type of
material that can vary. Both components may affect the porosity
and/or basis weight of the wrapping material. The fibrous material
can be a cellulosic material, and the cellulosic material can be a
lignocellulosic material. Exemplary cellulosic materials include
flax fibers, hardwood pulp, softwood pulp, hemp fibers, esparto
fibers, kenaf fibers, jute fibers and sisal fibers. Mixtures of two
or more types of cellulosic materials can be employed. For example,
wrapping materials can incorporate mixtures of flax fibers and wood
pulp. The fibers can be bleached or unbleached. Other fibrous
materials that can be incorporated within wrapping materials
include microfibers materials and fibrous synthetic cellulosic
materials. See, for example, U.S. Pat. No. 4,779,631 to Durocher
and U.S. Pat. No. 5,849,153 to Ishino. Representative fibrous
materials, and methods for making wrapping materials therefrom, are
set forth in U.S. Pat. No. 2,754,207 to Schur et al.; and U.S. Pat.
No. 5,474,095 to Allen et al.; and PCT WO 01/48318.
[0025] The wrapping material may also normally incorporate a filler
material such as, for example, those set forth in PCT WO 03/043450.
The filler material may have the form of essentially water
insoluble particles and may normally incorporate inorganic
components such as calcium salts or calcium carbonate, wherein
calcium carbonate is typically used in particulate form. See, for
example, U.S. Pat. No. 4,805,644 to Hampl; U.S. Pat. No. 5,161,551
to Sanders; and U.S. Pat. No. 5,263,500 to Baldwin et al.; and PCT
WO 01/48,316. Other filler materials include, for example,
agglomerated calcium carbonate particles, calcium tartrate
particles, magnesium oxide particles, magnesium hydroxide gels;
magnesium carbonate-type materials, clays, diatomaceous earth
materials, titanium dioxide particles, gamma alumina materials and
calcium sulfate particles. See, for example, U.S. Pat. No.
3,049,449 to Allegrini; U.S. Pat. No. 4,108,151 to Martin; U.S.
Pat. No. 4,231,377 to Cline; U.S. Pat. No. 4,450,847 to Owens; U.S.
Pat. No. 4,779,631 to Durocher; U.S. Pat. No. 4,915,118 to Kaufman;
U.S. Pat. No. 5,092,306 to Bokelman; U.S. Pat. No. 5,109,876 to
Hayden; U.S. Pat. No. 5,699,811 to Paine; U.S. Pat. No. 5,927,288
to Bensalem; U.S. Pat. No. 5,979,461 to Bensalem; and U.S. Pat. No.
6,138,684 to Yamazaki; and European Patent Application 357359.
Certain filler-type materials that can be incorporated into the
wrapping materials can have fibrous forms, having components which
may include materials such as glass fibers, ceramic fibers, carbon
fibers and calcium sulfate fibers. See, for example, U.S. Pat. No.
2,998,012 to Lamm; U.S. Pat. No. 4,433,679 to Cline; and U.S. Pat.
No. 5,103,844 to Hayden et al.; PCT WO 01/41590; and European
Patent Application 1,084,629. Mixtures of filler materials can also
be used.
[0026] There are various ways by which the various additive
components can be added to, or otherwise incorporated into, the
base sheet. Certain additives can be incorporated into the wrapping
material as part of the paper manufacturing process associated with
the production of that wrapping material. Alternatively, additives
can be incorporated into the wrapping material using size press
techniques, spraying techniques, printing techniques, or the like.
Such techniques, known as "off-line" techniques, are used to apply
additives to wrapping materials after those wrapping materials have
been manufactured. Various additives can be added to, or otherwise
incorporated into, the wrapping material simultaneously or at
different stages during or after the paper manufacturing
process.
[0027] The base sheets can be treated further, and those base
sheets can be treated so as to impart a change to the overall
physical characteristics thereof and/or so as to introduce a change
in the overall chemical compositions thereof. For example, the base
sheet can be electrostatically perforated (see, for example, U.S.
Pat. No. 4,924,888 to Perfetti et al.) or embossed to provide
texture to a surface thereof. Additives can be incorporated into
the wrapping material, with representative additives, and methods
for incorporating those additives to wrapping materials, being set
forth in, for example, U.S. Pat. No. 5,220,930 to Gentry and U.S.
Pat. No. 5,168,884 to Baldwin et al. Certain components, such as
alkali metal salts, can act as burn control additives and include,
for example, alkali metal succinates, citrates, acetates, malates,
carbonates, chlorides, tartrates, propionates, nitrates and
glycolates; including sodium succinate, potassium succinate, sodium
citrate, potassium citrate, sodium acetate, potassium acetate,
sodium malate, potassium malate, sodium carbonate, potassium
carbonate, sodium chloride, potassium chloride, sodium tartrate,
potassium tartrate, sodium propionate, potassium propionate, sodium
nitrate, potassium nitrate, sodium glycolate and potassium
glycolate; and other salts such as monoammonium phosphate. Certain
alkali earth metal salts also can be used. See, for example, U.S.
Pat. No. 2,580,568 to Matthews; U.S. Pat. No. 4,461,311 to
Matthews; U.S. Pat. No. 4,622,983 to Matthews; U.S. Pat. No.
4,941,485 to Perfetti et al.; U.S. Pat. No. 4,998,541 to Perfetti
et al.; and PCT WO 01/08514. Certain components, such as metal
citrates, can act as ash conditioners or ash sealers. See, for
example, European Patent Application 1,084,630.
[0028] Other representative components include organic and
inorganic acids, such as malic, levulinic, boric and lactic acids
(see, for example, U.S. Pat. No. 4,230,131 to Simon) or catalytic
materials (see, for example, U.S. Pat. No. 2,755,207 to
Frankenburg). Typically, the amount of chemical additive does not
exceed about 3 percent, based on the dry weight of the wrapping
material to which the chemical additive is applied. For certain
wrapping materials, the amount of certain additive salts, such as
burn chemicals such as potassium citrate and monoammonium
phosphate, preferably are in the range of about 0.5 to about 0.8
percent, based on the dry weight of the wrapping material to which
those additive salts are applied. Relatively high levels of such
additive salts can be used on certain types of wrapping materials
printed with printed regions that are very effective at causing
extinction of cigarettes manufactured from those wrapping
materials.
[0029] Flavoring agents and/or flavor and aroma precursors (e.g.,
vanillin glucoside and/or ethyl vanillin glucoside) also can be
incorporated into the paper wrapping material (see, for example,
U.S. Pat. No. 4,804,002 to Herron; and U.S. Pat. No. 4,941,486 to
Dube et al.) or printed onto cigarette papers. Some types of
flavoring agents used in cigarette manufacture that are set forth
in, for example, Gutcho, Tobacco Flavoring Substances and Methods,
Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring
for Smoking Products (1972). Films can be applied to the paper
(see, for example, U.S. Pat. No. 4,889,145 to Adams; U.S. Pat. No.
5,060,675 to Milford et al., and PCT WO 02/43513 and PCT WO
02/055294), while catalytic materials can be incorporated into the
paper. See, for example, PCT WO 02/435134.
[0030] The composition of the additive material or coating
formulation can vary, and is generally determined by the
ingredients of the coating formulation. Preferably, the coating
formulation has an overall composition, and is applied in a manner
and in an amount, such that the physical integrity of the wrapping
material is not adversely affected when the coating formulation is
applied to selected regions of the wrapping material. It also is
desirable that components of the coating formulation not introduce
undesirable sensory characteristics to the smoke generated by a
smoke article incorporating a wrapping material treated with that
coating formulation. Thus, suitable combinations of various
components can act to reduce the effect of coatings on sensory
characteristics of smoke generated by the smoking article during
use. Some coatings also provide desirable physical characteristics
to cigarettes manufactured from wrapping materials incorporating
those coatings, and can be considered as adhesives since those
coatings typically remain in contact with (e.g., to adhere to or
otherwise remain secured to) desired locations on the wrapping
material. Some examples of coating formulations and components
thereof are set forth in U.S. Pat. No. 4,889,145 to Adams; and U.S.
Pat. No. 5,060,675 to Milford et al.; U.S. Patent Application
Publication Nos. 2003/0145869 to Kitao et al., 2003/0150466 to
Kitao et al., and 2003/0131860 to Ashcraft et al.; U.S. patent
application Ser. No. 09/892,834, filed Jun. 27, 2001, and Ser. No.
10/682,570, filed Oct. 9, 2003; PCT WO 02/043513; PCT WO 02/055294;
and European Patent Application 1,234,514.
[0031] The coating formulation may include a film-forming agent,
such as a polymeric material or resin. Exemplary film-forming
agents include alginates (e.g., sodium alginate or ammonium
alginate), pectins, derivatives of cellulose (e.g.,
carboxymethylcellulose and other polymeric materials such as
hydroxypropylcellulose and hydroxyethylcellulose), ethylene vinyl
acetate copolymers, guar gum, xanthan gum, starch (e.g., corn
starch, rice starch and dextrin), modified starch (e.g., oxidized
tapioca starch and oxidized corn starch), polyvinyl acetate,
polyvinyl alcohol, and combinations thereof. Exemplary blends
include water-based blends of an ethylene vinyl acetate copolymer
emulsion and polyvinyl alcohol, or water-based blends provided by
mixing starches or modified starches with emulsion polymers or
copolymers. The solvent or liquid carrier for the coating
formulation can vary, and can be a liquid having an aqueous
character, such as relatively pure water, or a non-aqueous solvent,
such as ethanol, n-propyl alcohol, iso-propyl alcohol, ethyl
acetate, n-propyl acetate, iso-propyl acetate, toluene, and the
like.
[0032] The coating formulation also can include a filler material
such as, for example, the essentially water insoluble types of
filler materials previously described, preferably with a finely
divided (e.g., particulate) form. Typical fillers are those that
have particle sizes that are less than about 3 microns in diameter
and suitably range from about 0.3 micron to 2 microns in diameter.
Exemplary filler materials may comprise inorganic materials
including metal particles and filings, calcium carbonate (e.g.,
precipitated-type fillers, including those having a prismatic
form), calcium phosphate, clays (e.g., attapulgite clay), talc,
aluminum oxide, mica, magnesium oxide, calcium sulfate, magnesium
carbonate, magnesium hydroxide, aluminum oxide and titanium
dioxide. See, for example, the types of filler materials set forth
in U.S. Pat. No. 5,878,753 to Peterson et al. Exemplary filler
materials also can be composed of organic materials including
starches, modified starches and flours (e.g., rice flour),
particles of polyvinyl alcohol, particles of tobacco (e.g., tobacco
dust), fibrous cellulosic materials, and other like materials. See,
for example, U.S. Pat. No. 5,417,228 to Baldwin et al. Alternate
fillers can include carbon-based materials (e.g., graphite-type
materials, carbon fiber materials and ceramics), metallic materials
(e.g., particles of iron), and the like. The filler material also
can be a water soluble salt (e.g., potassium chloride, sodium
chloride, potassium citrate, sodium citrate, calcium chloride or
magnesium chloride).
[0033] The coating formulations can incorporate other ingredients
that may be dispersed or suspended therein so as to provide
specific properties or characteristics to the wrapping material.
Those ingredients can be, for example, preservatives (e.g.,
potassium sorbate), humectants (e.g., ethylene glycol and propylene
glycol), pigments, dyes, colorants, burn promoters and enhancers,
burn retardants and inhibitors, plasticers (e.g., dibutyl
phthalate, polyethylene glycol, polypropylene glycol and
triacetin), sizing agents, syrups (e.g., high fructose corn syrup),
flavoring agents (e.g., ethyl vanillin and caryophyllene oxide),
sugars (e.g., rhamnose), flavor precursors, hydrate materials, such
as metal hydrates (e.g., borax, magnesium sulfate decahydrate,
sodium silicate pentahydrate and sodium sulfate decahydrate),
viscosity reducing agents (e.g., urea), and the like.
[0034] The amount of coating formulation that is applied to the
paper wrapping material can vary, but typically provides a coated
wrapping material having an overall dry basis weight (i.e., the
basis weight of the whole wrapping material, including coated and
uncoated regions) of at least about 1.05 times that of the dry
basis weight of that wrapping material prior to the application of
coating thereto, and an overall dry basis weight of not more about
1.4 times that of the dry basis weight of the wrapping material
that has the coating applied thereto. Typical overall dry basis
weights of those wrapping materials are between about 20 g/m.sup.2
to about 40 g/m.sup.2.
[0035] The dry weights of the coated regions of wrapping material
of the present invention can vary. For wrapping materials that are
used for the manufacture of cigarettes designed to meet certain
cigarette extinction test criteria, it is generally desirable that
the wrapping materials have sufficient coating formulation applied
thereto in the form of appropriately shaped and spaced bands in
order that the dry weight of additive material applied to those
wrapping materials totals at least about 1 pound/ream, while the
total dry weight of that applied additive material normally does
not exceed about 10 pounds/ream. As such, typical coated regions of
paper wrapping materials suitable for use as the circumscribing
wrappers of tobacco rods for cigarettes have inherent porosities
that can vary. Typically, the inherent porosities of the coated
regions of the wrapping materials are less than about 8.5 CORESTA
units, and at least about 0.1 CORESTA unit. Preferably, the
inherent porosities of the coated regions of the wrapping
materials, particularly those wrapping materials that are used for
the manufacture of cigarettes designed to meet certain cigarette
extinction test criteria, are between about 0.1 CORESTA unit and
about 4 CORESTA units.
[0036] Certain wrapping materials possess coatings in the form of
patterns (e.g. bands) that extend across the wrapping material,
generally perpendicular to the longitudinal axis of the wrapping
material. The widths of the individual bands can vary, as well as
the spacings between those bands. Typically, those bands have
widths of between at least about 0.5 mm and about 8 mm. Such bands
can be spaced apart such that the spacing between the bands is at
least about 10 mm, but usually no more than about 50 mm.
[0037] Cigarettes designed to meet certain cigarette extinction
test criteria can be produced from such wrapping materials, wherein
the banded regions are produced using additive materials that are
effective in reducing the inherent porosity of the wrapping
material in those regions. Film-forming materials and fillers
applied to the wrapping material in those banded regions are
effective in increasing the weight of the wrapping material in
those regions. Filler materials that are applied to the wrapping
material in those banded regions are effective in decreasing the
burn rate of the wrapping materials in those regions. Typically,
when wrapping materials of relatively high inherent porosity are
used to manufacture cigarettes, those wrapping materials possess
relatively high weight bands that introduce a relatively low
inherent porosity to the banded regions. Film-forming materials
have a tendency to reduce the porosity of the wrapping material,
whether or not those materials are used in conjunction with
fillers. However, coatings that combine porosity reduction with
added coating weight to wrapping materials also are effective in
facilitating extinction of cigarettes manufactured from those
wrapping materials. Low porosity in selected regions of a wrapping
material tends to cause a lit cigarette to extinguish due to the
decrease in access to oxygen for combustion for the smokable
material within that wrapping material. Increased weight of the
wrapping material also tends to cause lit cigarette incorporating
that wrapping material to extinguish. As the inherent porosity of
the wrapping material increases, it also is desirable to (a) select
a film-forming material so as to cause a decrease the inherent
porosity of the coated region of the wrapping material and/or (b)
provide a coating that provides a relatively large amount of added
weight to the coated region of the wrapping material.
[0038] The basis weight and porosity effects resulting from
treatment of the wrapping material base sheet are indicators of the
characteristics of the smoking article produced therefrom.
Accordingly, before such wrapping material is used to produce the
smoking article, significant time and cost saving may be realized
by first analyzing such factors of the wrapping material in order
to determine that the characteristics of the wrapping material are
within desired specifications and that the treatment of the
wrapping material is consistent along the length of the wrapping
material used in an automated cigarette manufacturing device.
[0039] As such, as the paper web 200 is unwound from the first
bobbin 150, the paper web 200 is directed around an arrangement of
rollers (shown as rollers 160, 165, 170), otherwise referred to
herein as a paper-engaging member or dancer assembly 175. The brake
system 400 comprising, for example, a magnetic brake 405, is
configured to cooperate with the first bobbin 150 such that the
magnetic brake 405, in cooperation with the dancer assembly 175,
takes up slack in the paper web 200 and maintains a certain amount
of tension on the paper web 200 as the web 200 is unwound from the
first bobbin 150 and wound onto the second bobbin 300 by the drive
system 350. The magnetic brake 405/dancer assembly 175 may be, for
example, a Model DDC (Digital Dancer Controller) System
manufactured by Magpower. A tension sensor 180 may, in some
instances, be configured to cooperate with the brake system 400
and/or the dancer assembly 175 in order to provide the selected
tension on the paper web 200.
[0040] The drive system 350 operably engaged with the second bobbin
300 may comprise, for example, a stepper motor 355, configured to
cooperate with the second bobbin 300 to wind the paper web 200 onto
the second bobbin 300 while cooperating with the first bobbin
150/magnetic brake 405/dancer assembly 175 to maintain a certain
amount of tension on the paper web 200 between the first and second
bobbins 150, 300. The drive system 350 may particularly comprise,
for example, a Model 583-135-MO stepper motor 355 and a Model 6104
stepper driver 360, both manufactured by Compumotor. One skilled in
the art will appreciate that, between the first and second bobbins
150, 300, the paper web 200 may be supported, routed, and/or guided
by a suitably aligned series of any number of, for example, idler
rollers, guideposts, air bars, turning bars, guides, tracks,
tunnels, or the like, for directing the paper web 200 along the
desired path. Typical bobbins used by conventional automated
cigarette making apparatuses often contain a continuous strip of
wrapping material 200 that is on the order of about 6,500 meters in
length, though the length of the web 200 may vary. As such, the
apparatus 100 described herein is appropriately configured so as to
handle bobbins of that type and size.
[0041] According to one embodiment of the present invention, the
apparatus 100 may be configured to handle and examine a relatively
small strip of the web 200, instead of an entire bobbin, as being
representative of the remainder of the web 200 wound on that
bobbin. For example, in some instances, it may be desirable to test
only a small length of the web 200 unwound from the first bobbin
150. In such instances, a pair of counter-rotating rollers
(otherwise referred to herein as a driven roller device or capstan
drive 295) comprising, for example, a drive pressure roller 285 and
a capstan roller 290, is disposed downstream of the first and
second testing devices 550, 600 and is configured to receive the
leading edge of the small strip (not shown) of the paper web 200
and to advance the strip downstream in the machine direction. The
capstan roller 290 is engaged with an indexer/driver system 275
comprising, for example, a Model M2-2240 stepper motor and a Model
IM4831 indexer/driver control, both manufactured by IMS. The drive
pressure roller 285 may be mounted on a free end of a pivoting arm
so as to be pivotable away from the capstan roller 290 when the
apparatus 100 is not testing a strip or the capstan drive 295 is
otherwise not needed.
[0042] A tension device comprising, for example, a tension roller
190 in cooperation with a guide post 195, is disposed upstream of
the pattern detection device 450 and the first and second testing
devices 550, 600, and cooperates with the capstan drive 295 to
maintain a tension in the strip of the web 200 therebetween as the
strip is tested. More particularly, the tension roller 190 may be
weighted and attached to the free end of a pivoting arm such that
the tension roller 190 may be pivoted toward the guide post 195 so
as to engage the strip of the web 200 therebetween. The leading
edge of the strip of the web 200 is then extended past the pattern
detection device 450 and the first and second testing devices 550,
600 and into engagement with the capstan drive 295 for advancing
the strip in the machine direction. In one advantageous embodiment,
the capstan roller 290 is separated from the guide post 195 by a
center-to-center distance of about 350 mm and configured such that
a strip of at least about 500 mm in length can be tested by the
apparatus 100, though one skilled in the art will appreciate that
the center-to center distance, as well as the minimum strip length,
may vary considerably.
[0043] Accordingly, the first and second testing devices 550, 600,
as well as the pattern detection device 450, are generally disposed
between the first and second bobbins 150, 300, preferably between
the dancer assembly 175 and the second bobbin 300 and, in one
embodiment, between the tension device, comprising the tension
roller 190 and guide post 195, and the capstan drive 295. The first
testing device 550 may comprise, for example, a Beta gauge
manufactured by Pettit Applied Technology, configured to determine
a basis weight of a measured sample area (not shown) of the web
200. Such a Beta gauge may use, for example, a Kr-85 radioactive
source and may be configured to take the appropriate nondestructive
measurement of the paper web 200 using a measurement time, for
instance, on the order of about 4 seconds over a sampling area of
the web 200 of about 2 mm (length) by about 15 mm (width). One
skilled in the art will appreciate, however, that the first testing
device 550 described herein is provided for exemplary purposes and
that the measurement parameters may vary considerably.
[0044] The pattern detection device 450 is configured to detect at
least one of the bands 225, 250 (or other pattern) of the web 200
as the web 200 is routed past the pattern detection device 450. The
pattern detection device 450 may comprise, for example, an optical
sensor using, for instance, a Model E3X-NL11 sensor and a Model
ES32-S15-1 fiber optic element, both manufactured by OMRON. One
skilled in the art will appreciate, however, that many other
detection methods, schemes, and devices may be used to detect the
bands 225, 250 (as well as other patterns) of the web 200. For
example, the pattern detection device 450 may, in some instances
comprise a non-optical spectroscopic system, such as a non-contact
ultrasonic transmission system or a near infrared (NIR) absorption
system.
[0045] The second testing device 600 may comprise, for example, a
CES Model 477LF porosity measuring system configured to test a
sampling area of the web 200 of about 2 mm (length) by about 15 mm
(width), and may be disposed either upstream or downstream of the
first testing device 550, as will be appreciated by one skilled in
the art. The pattern detection device 450 is preferably disposed in
a known spaced relation with the first and second testing devices
550, 600 with respect to the route traveled by the web 200 though,
in some instances, the pattern detection device 450 and the first
and second testing devices 550, 600 may be configured so as to be
movable with respect to each other along the route traveled by the
web 200 such that the spacing between respective components is
adjustable.
[0046] As previously described, the length of the web 200 wound on
the first bobbin 150 (or the small strip therefrom) may include a
pattern such as, for example, adjacent bands 225, 250, with the
bands regularly repeating along the length of the web 200. The
characteristics of such bands 225, 250 are generally determined by
the treatment (or lack thereof) of the wrapping material base sheet
in any of the manners previously described. Accordingly, for a band
of particular interest to be tested along the length of the web
200, the distance between successive occurrences of that band (the
band pitch) is determined and the appropriate distance is set
between the pattern detection device 450 and each of the first and
second testing devices 550, 600, and/or between the first and
second testing devices 550, 600. This spacing may be set manually
or, in some instances, may be entered into the controller 650,
along with the desired measurement scheme, such that the testing
parameters are automatically determined and set by the apparatus
100. In some instances, for example, the width of the web 200 may
be about 27 mm with a particular band extending for between about 5
mm and about 6 mm, and repeating at an interval of between about 25
mm and about 60 mm. In the alternative, the apparatus 100 may
implement a search algorithm using any combination of the pattern
detection device 450, the first and second testing devices 550,
600, and/or other components in order to locate the band or pattern
of interest and determine the pitch between successive occurrences
thereof.
[0047] One skilled in the art will appreciate that both testing
devices 550, 600 may be configured to test the same band of
particular interest or each testing device may be configured to
test different bands. Further, the apparatus 100 may, in some
instances, be configured so as to allow either of the testing
devices 550, 600, or both, to examine the web 200 as the web 200 is
advanced to the second bobbin 300 from the first bobbin 150 or to
the capstan drive 295 from the tension device, comprising the
tension roller 190 and guide post 195. In some instances, the
apparatus 100 may include multiples of each of the testing devices
so as to allow similar measurements of different bands to occur
concurrently.
[0048] The pattern detection device 450 is configured to detect the
band or pattern of particular interest as the web 200 is advanced
by the capstan drive 295 or the drive system 350/second bobbin 300.
Accordingly, in order for one or more of the testing devices 550,
600 to examine the web 200, the pattern detection device 450
communicates with the capstan roller 290 or the drive system 350
through the controller 650 and/or the control interface 700, and
cooperates therewith to stop the advancement of the web 200 when a
particular band is detected and a measurement is to be made. In
addition, the pattern detection device 450 concurrently
communicates with either or both of the testing devices 500, 600
through the controller 650 and/or the control interface 700, and
cooperates therewith to direct the appropriate testing device to
perform the desired measurement on the web 200 once advancement of
the web 200 is stopped. However, in some instances, the testing
devices 550, 600 may be configured to perform the appropriate
examination of the web 200 without requiring the advancement of the
web 200 to be stopped by the apparatus 100.
[0049] One skilled in the art will also appreciate that the
measurements along the web 200 may occur in many different manners.
For example, the apparatus 100 may be configured to measure every
occurrence of a particular band or other pattern. In other
instances, the apparatus 100 may be configured to perform the
measurements at a particular interval along the length of the web
200, or at randomly selected points, so as to form a data profile
of the web 200. In other instances, when considering the entire
length of the strip of the web 200 (or an entire bobbin), the
testing or sampling scheme may divide the web 200 into sections
where, for example, the apparatus 100 may perform and average a
certain number of measurements per section using parameters such
as, for instance, distance between points in a section and distance
between sections. Thus, the apparatus 100 may be configured to
analyze the web 200 using many different measurement schemes. In
any instance, the data collected by the first and/or second testing
device(s) 550, 600, as well as other components of the apparatus
100, can be stored by the controller 650 or other storage device
(not shown) for further analysis.
[0050] Once the web 200 has been examined by the first and/or
second testing devices 550, 600, the strip can be removed and
discarded, or the second bobbin 300 can be removed from the
apparatus 100 and stored as necessary. In other instances, the
second bobbin 300 can be mounted onto a conventional type of
automated cigarette making apparatus (not shown) in order to
manufacture cigarettes using the examined web 200. In other
instances, the apparatus 100 may also include an automatic bobbin
changer device (not shown) configured to automatically move the
second bobbin 300 to the automated cigarette making apparatus (not
shown) once the desired length of the web 200 has been examined. If
desired, the apparatus 100 can be operated so as to provide one
examined second bobbin 300 at a time. Alternatively, the apparatus
100 can be adapted so as to provide a examined master roll or
bobbin of the web 200, which then can be divided one or more times
across the width of the roll to provide a plurality of bobbins,
each of the desired width and having the desired length of the web
200 wound thereon. Alternatively, the apparatus 100 can be suitably
adapted to simultaneously examine several strips or produce several
examined second bobbins 300 at a time. Preferably, the second
bobbin 300 can be transferred to a cigarette manufacturing device
and the web 200 subsequently used to produce cigarettes. In
addition, it may also be preferable for the first and second
bobbins 150, 300 to be interchangeable such that, once the first
bobbin 150 is emptied by the apparatus 100, the first bobbin 150
can then be moved to replace the removed full second bobbin 300
such that the first bobbin 150 essentially becomes a new second
bobbin 300.
[0051] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, the apparatus 100 may also be configured to
measure or otherwise determine that the appropriate amount of the
paper web 200 is wound on either of the first and second bobbins
150, 300. In such instances, the apparatus 100 may also include
components capable of allowing for automatic bobbin changing of the
first bobbin 150 and splicing of the web 200, as well as an
automatic rewind bobbin changer for changing the second bobbin 300
when the second bobbin 300 is full. Therefore, it is to be
understood that the inventions are not to be limited to the
specific embodiments disclosed and that modifications and other
embodiments are intended to be included within the scope of the
appended claims. Although specific terms are employed herein, they
are used in a generic and descriptive sense only and not for
purposes of limitation.
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