U.S. patent application number 11/489334 was filed with the patent office on 2008-01-24 for apparatus and methods for manufacturing cigarette tubes.
Invention is credited to Vernon Brent Barnes, Barry Smith Fagg, Dennis Lee Potter.
Application Number | 20080017203 11/489334 |
Document ID | / |
Family ID | 38970272 |
Filed Date | 2008-01-24 |
United States Patent
Application |
20080017203 |
Kind Code |
A1 |
Fagg; Barry Smith ; et
al. |
January 24, 2008 |
Apparatus and methods for manufacturing cigarette tubes
Abstract
Pre-formed cigarette tubes are provided in an automated fashion.
Cigarettes containing a filler material are manufactured according
to known methods and transferred to an apparatus for removing the
filler material. The filler material within each resulting
cigarette is removed therefrom. Optionally, the filler material may
be recycled to the beginning of the process. The resulting
pre-formed cigarette tubes are collected. At a later time, the
hollow regions of those pre-formed tubes can be filled with tobacco
cut filler in order to provide finished cigarettes.
Inventors: |
Fagg; Barry Smith;
(Winston-Salem, NC) ; Potter; Dennis Lee;
(Kernersville, NC) ; Barnes; Vernon Brent;
(Advance, NC) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Family ID: |
38970272 |
Appl. No.: |
11/489334 |
Filed: |
July 19, 2006 |
Current U.S.
Class: |
131/96 ;
131/191 |
Current CPC
Class: |
A24C 5/36 20130101; A24C
5/42 20130101; A24C 5/46 20130101 |
Class at
Publication: |
131/96 ;
131/191 |
International
Class: |
A24C 1/04 20060101
A24C001/04 |
Claims
1. A method of manufacturing a pre-formed cigarette tube, said
method comprising the steps of: a. manufacturing a cigarette using
a cigarette making machine, the cigarette comprising filler
material; b. transferring the cigarette to an apparatus for
removing the filler material from the cigarette; and, c. removing
the filler material from the cigarette.
2. The method of claim 1, further comprising the steps of: d.
collecting the filler material that is removed from the cigarette;
and e. transporting the filler material collected in step (d) to
the cigarette making machine.
3. The method of claim 2, further comprising the step of: f.
measuring one or more characteristics of the filler material after
the filler material is collected and before it is transported to
the cigarette making machine.
4. The method of claim 3, further comprising the steps of: g.
comparing the one or more characteristics of the filler to a
pre-determined standard; and h. discarding any filler that does not
meet the pre-determined standard.
5. The method of claim 3, wherein the one or more characteristics
of the filler material are selected from the group consisting of:
density, moisture content, temperature and particle size.
6. The method of claim 1, wherein each step of the method is
in-line and machine automated.
7. The method of claim 2, further comprising the step of: f.
screening the recovered filler material that is transported to the
cigarette making machine.
8. The method of claim 1, wherein the filler material comprises a
non-tobacco material.
9. The method of claim 1, wherein the cigarette comprises a
filter.
10. The method of claim 1, wherein the filler material is removed
from the cigarette with a burst of air.
11. A machine for manufacturing pre-formed cigarette tubes, the
machine comprising: a. a cigarette making machine, wherein the
cigarette making machine manufactures cigarettes that include
filler material; b. an apparatus for removing the filler material
from the cigarettes; and, c. an apparatus for transporting the
cigarettes from the cigarette making machine to the apparatus for
removing the filler material.
12. The machine of claim 11, wherein the cigarette making machine
manufactures cigarettes that include filler material and a
filter.
13. The machine of claim 11, wherein the filler material comprises
tobacco.
14. The machine of claim 11, wherein the filler material comprises
a non-tobacco material.
15. The machine of claim 11, wherein the apparatus for removing the
filler material removes filler material from the cigarette with a
burst of air.
16. The machine of claim 11, further comprising: d. an apparatus
for recovering the filler material that is removed from the
cigarettes, and e. an apparatus for transporting the recovered
filler material to the cigarette making machine.
17. The machine of claim 16, further comprising: f. an apparatus
for screening the recovered filler material that is transported to
the cigarette making machine.
18. The machine of claim 16, further comprising: f. an apparatus
for measuring one or more of the following characteristics of the
filler material: density, moisture content, temperature and
particle size.
19. The machine of claim 11 wherein each of the components is
in-line and machine automated so that the machine is capable of the
continuous and automated manufacture of pre-formed cigarette
tubes.
20. The machine of claim 16 wherein each of the components is
in-line and machine automated so that the machine is capable of the
continuous and automated manufacture of pre-formed cigarette tubes.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to smoking articles, and in
particular, to cigarettes. More specifically, the present invention
relates to equipment and methods for manufacturing, in an automated
fashion, filtered cigarette tubes that are later used for cigarette
manufacture.
BACKGROUND OF THE INVENTION
[0002] 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, surrounded
by a paper wrapper, to form a "cigarette rod," "smokable rod" or a
"tobacco rod." Normally, a cigarette has a cylindrical filter
element axially 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 filter elements
comprising, for example, 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." A
ventilated or air diluted smoking article can be provided with an
optional air dilution means, such as a series of perforations, each
of which extend through the tipping material and plug wrap.
[0003] A variety of hand operated devices for manufacturing
individual cigarettes have been proposed. In particular, various
manners and methods for filling paper cigarette tubes with tobacco
have been proposed. See, for example, U.S. Pat. No. 2,633,133 to
Higgins; U.S. Pat. No. 3,124,141 to Seitter; U.S. Pat. No.
3,202,156 to Kappeler et al.; U.S. Pat. No. 3,892,245 to Asbill,
Jr.; U.S. Pat. No. 4,167,948 to Moscovitch; U.S. Pat. No. 4,572,216
to Josuttis et al. and U.S. Pat. No. 5,072,740 to Gatschmann et al.
See, also, U.S. Pat. No. 3,491,768 to Paynter and U.S. Pat. No.
3,693,313 to Sexstone which set forth manners and methods for
manufacturing individual cigarettes by filling a tube or "spill"
with a tobacco charge and a filter plug.
[0004] One type of cigarette making machine for the manufacture of
one cigarette at a time using loose tobacco and a filtered
cigarette tube has been marketed as "Bugler" filter cigarette
making machine by Brown & Williamson Tobacco Corporation.
Another type of automated machine for filling pre-formed cigarette
tubes with loose tobacco filler has been available commercially as
"Cig-a-mat" from Jenkins & Ott, Inc. A device representative of
such a machine is described in U.S. Pat. No. 3,645,272 to Jenkins
et al. Yet another type of automated device for filling pre-formed
cigarette tubes with tobacco filler is an electrically operated
cigarette making machine that has been available commercially as
Easy Roller from C. P. Rolling ApS of Denmark. See, also, the types
of devices set forth in U.S. patent application Ser. No.
11/375,700, filed Mar. 14, 2006, to Thomas et al., which is
incorporated herein by reference.
[0005] A cigarette machine for filling empty pre-formed cigarette
tubes with tobacco filler has been produced commercially by The
Central Tobacco Mfg. Co. Ltd. and marketed as "Premier Supermatic."
Other types of cigarette machines for filing cigarette tubes with
tobacco have been marketed as "Escort" and "Pressta Deluxe" by CTC
Canada Inc. See, for example, the representative types of machines
set forth in U.S. Pat. No. 3,127,900 to Kastner and U.S. Pt. No.
4,771,793 to Kastner. Other types of cigarette machines for filing
cigarette tubes with tobacco are available as "Premier Twin,"
"Filterite Twin" and "Rayo Twin" through American Thrust Tobacco,
LLC.
[0006] U.S. Pat. No. 3,822,710 to Bramhill proposes manufacturing
individual cigarettes by inserting a cartridge of compressed
tobacco into an empty filter tip cigarette tube. Other manners and
methods for manufacturing individual cigarettes are set forth in
U.S. Pat. No. 4,887,617 to Ruppert et al.; U.S. Pat. No. 5,018,536
to Liebich; U.S. Pat. No. 5,105,830 to Brackmann et al.; U.S. Pat.
No. 5,133,366 to Liebich; U.S. Pat. No. 5,141,000 to Ruppert et
al.; U.S. Pat. No. 5,167,241 to Ruppert al.; U.S. Pat. No.
5,197,495 to Ruppert et al.; U.S. Pat. No. 5,615,692 to Ruppert et
al. and U.S. Pat. No. 5,713,377 to Gerding et al.
[0007] As can be seen, many cigarette making machines, such as the
cigarette making machines described above, require a supply of
pre-formed cigarette tubes. Representative pre-formed filtered
cigarette tubes have been available commercially as Premier Filter
Tip Tubes from C.T.C. Canada Inc.; MacDonald Export "A" Express Kit
Medium Regular Size Cigarettes Tubes from RJR-MacDonald Inc.; and
Escort King Size Filter Tip Tubes from C.T.C. Canada Inc. Other
representative pre-formed tubular wrapper portions have been
available under the trade names Excel, Century, Zig-Zag, Bugler,
Twister, Rayo, Gizeh, Vera Cruz, Laramie, The "Three Castles"
Tobacco, and Zen. Representative pre-formed tubular wrapper
portions have been made available through companies such as HBI
International, Clinton Tube Company (USA) and American Thrust
Tobacco, LLC.
[0008] There are a number of manners and methods for manufacturing
cigarettes using pre-formed cigarette tubes. Accordingly, it is
desirable to provide a method and apparatus for making uniform
cigarette tubes in an efficient and cost-effective manner.
SUMMARY OF THE INVENTION
[0009] A method of manufacturing a pre-formed cigarette tube is
provided. The method includes the steps of manufacturing a
cigarette using a cigarette making machine, transferring the
cigarette to an apparatus for removing the filler material from the
cigarette, and removing the filler material from the cigarette. The
method may also include the steps of collecting the filler-material
that is removed from the cigarette and transporting the filler
material back to the cigarette making machine.
[0010] A machine is also provided for manufacturing pre-formed
cigarette tubes. The machine includes a cigarette making machine
for making cigarettes that include a filler material. The machine
also includes an apparatus for removing the filler material from
the cigarettes and an apparatus for transporting the cigarettes
from the cigarette making machine to the apparatus for removing the
filler material. The machine may also include an apparatus for
recovering the filler material that is removed from the cigarettes
and an apparatus for transporting the recovered filler material to
the cigarette making machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross-sectional view of a pre-formed filtered
cigarette tube that may be made in accordance with the methods and
apparatus of the present invention.
[0012] FIG. 2 is a flow-chart of one embodiment of a method of
manufacturing pre-formed cigarette tubes in accordance with the
present invention.
[0013] FIG. 3 is a flow-chart of one embodiment of a machine for
making pre-formed cigarette tubes in accordance with the present
invention.
[0014] FIG. 4 is a flow-chart of one method of screening recycled
filler material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] An example of a preferred cigarette tube that can be
manufactured pursuant to the present invention is shown in FIG. 1.
Referring to FIG. 1, there is shown a longitudinal cross-section of
a pre-formed filtered cigarette tube 21. Such a tube has the
general shape of a cigarette, but is virtually devoid of the
smokable filler material that makes up a finished cigarette. The
cigarette tube 21 includes a hollow generally cylindrical region
1200 defined by cigarette paper wrapping material 1205 into which
tobacco cut filler is intended to be inserted. The tubular wrapper
1205 is configured for receiving tobacco cut filler to provide a
finished cigarette; that is, for providing a wrapped, smokable
tobacco rod. The cigarette tube 21 most preferably also includes a
filter element 1210 positioned at one end thereof. The filter
element 1210 preferably is attached to the wrapping material 1205
using a circumscribing tipping material 1215. The tipping material
most preferably circumscribes the entire length of the filter
element, and an adjacent region of the tubular wrapper (e.g., about
3 mm to about 6 mm of the length of the tubular wrapper). The
filter element 1210 includes filter material 1220 (e.g., cellulose
acetate tow plasticized using triacetin) wrapped in a
circumscribing plug wrap material 1225. The tipping material 1215
and plug wrap 1225 may optionally, though preferably, include a
line of perforations 1230 (e.g., at least one circumscribing ring
of a series of individual perforations), in order that during use
of the cigarette that is manufactured using the cigarette tube,
mainstream smoke drawn through the cigarette can be air diluted.
The perforations 1230 may be provided during or after cigarette
manufacture using on-line laser perforation techniques, or the
relevant wrapping materials may be pre-perforated.
[0016] The dimensions of a representative pre-formed filtered
cigarette tube 21, and hence the finished cigarette manufactured
therefrom, can vary. Preferred representative cigarettes are rod
shaped, and can have circumferences of about 17 mm to about 27 mm,
but most preferably about 22.5 mm to about 25 mm; and can have
total lengths of about 80 mm to about 100 mm. The length of the
filter element can vary. A typical filter element can have a length
of about 20 mm to about 40 mm. In one preferred embodiment, the
cigarette tube has a diameter of about 7.5 mm, the length of the
filter element 1210 is about 27 mm, and the length of the
cylindrical region 1200 that forms the tobacco rod is about 56 mm.
In another preferred embodiment, the cigarette tube has a diameter
of about 7.5 mm, the length of the filter element is about 31 mm,
and the length of the tobacco rod is about 66 mm. For a
representative preferred pre-formed filtered cigarette tube,
tipping paper 1215 can circumscribe the entire filter element and
about 4 mm of the length of the paper wrapping material 1205 in the
region adjacent to the filter element. Furthermore, for a
representative preferred pre-formed filtered cigarette tube, a
circumscribing ring of air-dilution perforations is positioned at
least about 13 mm to about 15 mm from the extreme mouthend of the
filter element.
[0017] The wrapping material 1205 that is used to construct the
hollow tubular portion of the pre-formed cigarette tube 21 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, and can be
a matter of design choice. There is most preferably one layer of
wrapping material. Exemplary types of wrapping materials, wrapping
material components and ingredients, and treated wrapping
materials, are described in U.S. Pat. No. 5,220,930 to Gentry and
U.S. Pat. No. 6,868,855 to Shafer et al.; and U.S. Pat. Pub. Nos.
2004/0134631 to Crooks et al.; 2005/0016556 to Ashcraft et al.;
2005/0076929 to Fitzgerald et al. and 2006/0027243 to Matsufuji et
al.; and EP 1234514 to Grider et al.; which are incorporated herein
by reference. The wrapping materials of the tubular wrapper
portions can be treated with additive materials. For example, those
materials can be treated with formulations incorporating
ethylcellulose, starch, alginate, or the like. Representative
manners and methods for treating such wrapping materials are set
forth in U.S. Pat. No. 5,878,753 to Peterson et al.; U.S. Pat. No.
5,5,878,754 to Peterson et al. and U.S. Pat. No. 6,779,530 to
Kraker; U.S. Pat. Pub. Nos. 2005/0016556 to Ashcraft et al.;
2005/0076929 to Fitzgerald et al.; 2006/0021625 to Nyffeler; and
U.S. patent application Ser. No. 11/251,632, filed Oct. 14, 2005 to
Oglesby; which are incorporated herein by reference.
[0018] A preferred method of making cigarette tubes, particularly
pre-formed filtered cigarette tubes of the type set forth
hereinbefore, will now be described. In general, pre-formed
cigarette tubes are made by manufacturing finished cigarettes and
removing the filler therefrom. More particularly, in the preferred
embodiment, a continuous cigarette rod is provided, using a
conventional type of cigarette making equipment. The continuous
cigarette rod, which possesses a filler material circumscribed by
wrapping material, is cut at pre-determined intervals in order to
provide a plurality of cigarette rods, each of a pre-determined
length. The individual cigarette rods are transported to a tipping
region, where a filter element segment is attached to one end of
each tobacco rod. Optionally, each cigarette can be air diluted
(e.g., using laser perforation techniques). Then, the filler
material within each resulting filtered cigarette is removed
therefrom. The resulting pre-formed tubular wrapping portions are
collected. In an alternative embodiment, the filler material that
is removed from the each cigarette is collected, and put through a
recycling process for use in the further manufacture of future
cigarette tubes. A flow-chart of one embodiment of a method of
making pre-formed cigarette tubes in accordance with the present
invention is provided as FIG. 2. Similarly, a flow-chart of one
embodiment of a machine for making pre-formed cigarette tubes in
accordance with the present invention is provided as FIG. 3
[0019] An automated cigarette tube making system can be used for
the manufacture of cigarette tubes for personal use (e.g., for use
at home, whereby a consumer fills the tubes with his/her choice of
tobacco), for the manufacture of specialty type cigarettes within
tobacco products retail establishments (e.g., for the production of
individual packages of cigarettes at tobacco shops, such as can be
produced using the types of devices set forth in U.S. patent
application Ser. No. 11/375,700, filed Mar. 14, 2006, to Thomas et
al.), for the manufacture of small lots of cigarettes for quality
control or regulatory related activities, or for research and
development purposes. That is, the pre-formed cigarette tubes are
useful for the manufacture of finished cigarettes using a wide
variety of manual and automated cigarette making devices.
[0020] The preferred method of manufacturing cigarette tubes will
now be described in greater detail. First, numerous individual
cigarette rods are manufactured using a cigarette making machine. A
conventional automated cigarette rod making machine useful in
carrying out the present invention is of the type commercially
available from Molins PLC or Hauni-Werke Korber & Co. KG. For
example, cigarette rod making machines of the type known as Mk8
(commercially available from Molins PLC) or PROTOS (commercially
available from Hauni-Werke Korber & Co. KG) can be employed,
and can be suitably modified in accordance with the present
invention. A description of a PROTOS cigarette making machine is
provided in U.S. Pat. No. 4,474,190 to Brand, at col. 5, line 48
through col. 8, line 3, which is incorporated herein by reference.
Types of equipment suitable for the manufacture of cigarettes also
are set forth in U.S. Pat. No. 4,781,203 to La Hue; U.S. Pat. No.
4,844,100 to Holznagel; U.S. Pat. No. 5,156,169 to Holmes et al.;
U.S. Pat. No. 5,191,906 to Myracle, Jr. et al.; U.S. Pat. No.
6,647,870 to Blau et al.; U.S. Pat. No. 6,848,449 to Kitao et al.;
and U.S. Pat. No. 6,904,917 to Kitao et al.; and U.S. Pat. Pub.
Nos. 2003/0145866 to Hartman and 2005/1094014 to Read, Jr.; which
are incorporated herein by reference. The preferred cigarette
making machines manufacture cigarettes at a high speed.
[0021] The components and operation of conventional automated
cigarette making machines will be readily apparent to those skilled
in the art of cigarette making machinery design and operation. For
example, descriptions of the components and operation of several
types of chimneys, tobacco filler supply equipment, suction
conveyor systems and garniture systems are set forth in U.S. Pat.
No. 3,288,147 to Molins et al.; U.S. Pat. No. 3,915,176 to Heitmann
et al; U.S. Pat. No. 4,291,713 to Frank; U.S. Pat. No. 4,574,816 to
Rudszinat; U.S. Pat. No. 4,736,754 to Heitmann et al. U.S. Pat. No.
4,878,506 to Pinck et al.; U.S. Pat. No. 5,060,665 to Heitmann;
U.S. Pat. No. 5,012,823 to Keritsis et al. and U.S. Pat. No.
6,360,751 to Fagg et al.; and U.S. Pat. Pub. No. 2003/0136419 to
Muller; which are incorporated herein by reference. The automated
cigarette making machines of the type set forth herein provide a
formed continuous cigarette rod or smokable rod that can be
subdivided into formed smokable rods of desired lengths.
[0022] The filler material can be any material that can be used in
the cigarette making process, and subsequently can be removed from
the cigarette to yield an empty cigarette tube. Filler materials
employed for manufacture of the continuous cigarette rod typically
have forms, and are used in manners, that are traditional for the
manufacture of smoking articles, such as cigarettes.
[0023] The filler material most preferably includes a tobacco
material, and in certain circumstances the filler material is
composed entirely of tobacco material. Preferably, the filler
material is can be characteristic of the so-called "cut filler"
material traditionally employed in the operation of conventional
automated cigarette making machines (e.g., shreds or strands of
tobacco filler shredded or cut into widths of about 1/20 inch to
about 1/60 inch, often about 1/25 inch to about 1/50 inch,
frequently about 1/30 inch to about 1/45 inch, and in lengths of
about 1/4 inch to about 1 inch). Additionally, the filler material
can be composed of pieces of tobacco lamina, parts of tobacco
stems, pieces of processed tobacco (e.g., reconstituted tobacco,
processed tobacco stems, expanded tobacco, or the like), or
mixtures or blends thereof. In certain circumstances, tobacco
filler materials can be straight grade materials; that is, only one
type of tobacco (e.g., flue-cured tobacco or burley tobacco) is
used for cigarette rod manufacture. Preferred tobacco filler
materials are materials that exhibit good integrity, and have a
propensity not to degrade into fines during successive cigarette
rod manufacturing operations. Most preferably, the tobacco filler
materials do not incorporate, or have not been treated with,
additives (e.g., processing aids, flavoring agents, top dressing
components, non-aqueous casing components, and the like). In
certain circumstances, the tobacco filler materials can be absent
of additives, and can be grown under conditions specified by the
U.S. Department of Agriculture as being required for the production
of crops that might be designated as "organic." Filler materials
are most preferably tobacco materials not possessing additive
materials or substantial amounts of additive materials, or
materials used for the manufacture of cigarettes (e.g., paper
materials) in order that any residual filler material that is not
removed from the cigarette tube so formed does not have the
propensity to introduce any significant degree of contamination to
the finished cigarette that is subsequently manufactured from that
cigarette tube.
[0024] The filler material can be a material other than tobacco, or
the filler material can be a mixture of tobacco material and
another filler material. Such other materials preferably have
general physical characteristics (e.g., size, shape, weight,
density, and the like) that are similar to tobacco cut filler
traditionally used for cigarette rod manufacture. For example, in
addition to standard cut tobacco, tobacco substitute materials can
be employed as some or all of the filler material used for the
manufacture of pre-formed tubes. The filler material may comprise
shredded tobacco stem, paper, pulp, wood, plastic, plants, and
mixtures thereof. The filler material may be woven or nonwoven,
particulate, shredded, or granular. Exemplary plastics include
polymers such as polyethylene and polystyrene. Preferably, the
filler material has a density and consistency that is approximately
the same as tobacco filler.
[0025] Various tobacco substitute materials have been proposed.
Substantial listings of various types of tobacco substitute
materials can be found in U.S. Pat. No. 4,079,742 to Rainer et al.
and U.S. Pat. No. 4,771,795 to White et al. Certain cigarette-type
products that employ non-tobacco materials (e.g., dried vegetable
leaves, such as lettuce leaves) as filler that is burned to produce
smoke that resembles tobacco smoke have been marketed under the
trade names "CUBEBS," "TRIUMPH," "JAZZ," and "BRAVO." For example,
such materials are described in U.S. Pat. No. 4,700,727 to
Torigian. Furthermore, tobacco substitute materials having the
trade names "CYTREL" and "NSM" were introduced in Europe during the
1970s.
[0026] Representative types of proposed synthetic tobacco
substitute materials, smokable materials incorporating tobacco and
other components, and cigarettes incorporating those materials, are
described in British Pat. No. 1,431,045; and U.S. Pat. No.
3,738,374 to Bennett; U.S. Pat. No. 3,844,294 to Webster; U.S. Pat.
No. 3,878,850 to Gibson et al.; U.S. Pat. NO. 3,931,824 to Miano et
al.; U.S. Pat. No. 3,943,941 to Boyd et al.; U.S. Pat. No.
4,044,777 to Boyd et al.; U.S. Pat. No. 4,233,993 to Miano et al.;
U.S. Pat. No. 4,286,604 to Ehretsmann et al.; U.S. Pat. No.
4,326,544 to Hardwick et al.; U.S. Pat. No. 4,920,990 to Lawrence
et al.; U.S. Pat. No. 5,046,514 to Bolt; U.S. Pat. No. 5,074,321 to
Gentry et al.; U.S. Pat. No. 5,092,353 to Montoya et al.; U.S. Pat.
No. 5,778,899 to Saito et al.; U.S. Pat. No. 6,397,852 to McAdam;
and U.S. Pat. No. 6,408,856 to McAdam. Furthermore, various types
of highly processed smokable materials incorporating tobacco and
other ingredients are set forth in U.S. Pat. No. 4,823,817 to Luke;
U.S. Pat. No. 4,874,000 to Tamol et al.; U.S. Pat. No. 4,977,908 to
Luke; U.S. Pat. No. 5,072,744 to Luke et al.; U.S. Pat. No.
5,829,453 to White et al. and U.S. Pat. No. 6,182,670 to White et
al.
[0027] Filler material can be provided using techniques familiar in
the art of tobacco blend formulation and preparation. Filler
material can be provided using blending drums, air transport
devices, or other suitable means that provides adequate physical
mixing of pieces of filler material. It is highly desirable that
the filler material, whether as single strain or blended form, have
the form of a consistent mixture in terms of distribution of
particle size, density of components and composition of components.
The amount of filler material normally used within each formed
tobacco rod ranges from about 0.6 g to about 1 g. The tobacco
filler normally is employed so as to fill each tobacco rod at a
packing density of about 100 mg/cm3 to about 300 mg/cm3, and often
about 150 mg/cm3 to about 275 mg/cm3.
[0028] It is desirable that the moisture content of the filler
material, and in particular tobacco filler material, be
sufficiently high so that the filler does not undergo an
undesirable degree of degradation during handling and processing
associated with the process steps of the present invention. It also
is desirable that the moisture content of the filler material not
be so high that the filler material clumps during handling and
processing. Preferably, cigarette rods are manufactured using
tobacco filler material having a moisture content of about 12
weight percent to about 13 weight percent.
[0029] The individual formed tobacco rods most preferably have
filter elements attached thereto, typically using known types of
components, techniques and equipment. For example, the cigarette
rod making machine can be suitably coupled to filter tipping
machine, such as a machine available as a MAX, MAX S or MAX 80
Hauni-Werke Korber & Co. KG. See, also, for example, U.S. Pat.
No. 3,308,600 to Erdmann et al. and U.S. Pat. No. 4,280,187 to
Reuland et al; which are incorporated herein by reference. Various
manners and methods for attaching filter elements to cigarette rods
are set forth in U.S. Pat. No. 2,809,640 to Oldenkamp; U.S. Pat.
No. 4,077,415 to Preston et al.; U.S. Pat. No. 4,236,535 to Schmidt
et al.; U.S. Pat. No. 4,237,907 to Pawelko et al.; U.S. Pat. No.
4,340,074 to Tudor; U.S. Pat. No. 4,361,156 to Hall; U.S. Pat. No.
4,431,010 to Seragnoli; U.S. Pat. No. 4,583,558 to Luke; U.S. Pat.
No. 4,841,993 to Hinz et al; and U.S. Pat. No. 5,228,462 to Osmalov
et al.; and U.S. Patent Application Pub. Nos. 2003/0172942 to
Schlisio and 2003/0205235 to Draghetti; which are incorporated
herein by reference. For example, there are provided representative
manners or methods for supplying a series of two-up filtered
cigarette rods, each having two smokable rods and filter element of
double length therebetween. Typically, a web of tipping paper is
supplied, adhesive is applied to one side of the paper web, the web
is cut to provide a segment of desired size, the segment is applied
to the aligned dual filter and tobacco rods, and rotation of the
components causes the paper segment to wrap around the filter and
tobacco rod components.
[0030] The selection of a particular filter element or mouth-end
piece of the filtered cigarette tube can vary, and will be readily
apparent to those skilled in the art of cigarette design and
manufacture. The composition, size, format and configuration of the
filter element can be a matter of design choice. Preferred filter
elements are composed of plasticized cellulose acetate tow. Filter
elements also can be composed of materials such as polypropylene
tow, gathered polypropylene web, gathered cellulose acetate web or
gathered paper. Representative filter elements can incorporate
flavors, flavored threads, flavored pellets, breakable capsules,
catalytic materials, interactive resin particles, activated carbon
particles, and the like. Exemplary filter elements, including
multi-segment filter elements, are set forth in U.S. patent
application Ser. No. 11/377,630 to Crooks et al.; which is
incorporated herein by reference.
[0031] The cigarette tubes can be provided with perforations in
order to provide for air-dilution of finished cigarettes produced
therefrom. Representative manners and methods for perforating
manufactured cigarettes using laser systems are set forth in U.S.
Pat. Nos. 4,281,670 to Heitmann et al.; U.S. Pat. No. 4,500,770 to
Vock et al.; U.S. Pat. No. 4,565,202 to Seragnoli et al; U.S. Pat.
No. 4,600,027 to Houck et al.; U.S. Pat. No. 4,825,883 to Hinz et
al.; U.S. Pat. No. 4,889,140 to Lorenzen et al.; U.S. Pat. No.
5,060,668 to Weinhold and U.S. Pat. No. 6,675,811 to Dombeck; U.S.
Pub. No. 2005/0103355 to Holmes; and EP 1072200 to Dombeck; which
are incorporated herein by reference. Methods for rolling
cigarettes in controlled manners (e.g., providing controlled
rotation) in order that regions of those cigarettes can be
appropriately treated (e.g., using laser systems) are set forth in
U.S. Pat. No. 4,781,204 to Barbe et al.; U.S. Pat. No. 4,827,947 to
Hinz; U.S. Pat. No. 5,690,125 to Niemann et al.; U.S. Pat. No.
6,526,985 to Bombeck and U.S. Pat. No. 6,532,966 to Dombeck; which
are incorporated herein by reference.
[0032] Finished cigarettes that are air-diluted or ventilated can
possess an amount or degree of air dilution or ventilation that can
vary. Frequently, the amount of air dilution for an air-diluted
finished cigarette is greater than about 10 percent, generally is
greater than about 20 percent, often is greater than about 30
percent, and sometimes is greater than about 40 percent. Typically,
the upper level for air dilution for such an air-diluted cigarette
is less than about 80 percent, and often is less than about 70
percent. As used herein, the term "air dilution" is the ratio
(expressed as a percentage) of the volume of air drawn through the
air dilution means to the total volume of air and smoke drawn
through the cigarette and exiting the mouth end portion of the
cigarette.
[0033] Preferably, the finished cigarettes are conveyed directly to
an apparatus for removing the filler material so that cigarettes
can be manufactured and converted to empty, pre-formed cigarette
tubes in an automated, in-line manufacturing process. Such a
process would enable mass production of a large number of
consistent and uniform pre-formed cigarette tubes.
[0034] Accordingly, the apparatus for removing the filler material
is preferably attached in-line with the cigarette making machine.
Finished cigarettes may be transferred from the tipping device by a
rotating drum. Those cigarettes can be transferred to a conveyor
belt to a suitable reservoir for transfer to a device for removing
the filler material therefrom. Alternatively, those cigarettes can
be transferred to another series of transfer drums equipped with
components designed to reciprocate and hence encapsulate the filter
section or region of each cigarette. Preferably, care is taken to
ensure that the non-filter end of each cigarette is not deformed,
blocked or undesirably squeezed together. Then, at an appropriate
time and location, a burst or pulse of high velocity air into the
filter end of the cigarette can cause the filler material to be
blown from the cigarette.
[0035] In a preferred embodiment of the present invention, the
filler material is ejected from the cigarette using an apparatus
for ejecting filler that is similar to the apparatus described in
U.S. Pat. No. 4,763,673 to Barnes, which is incorporated herein by
reference, or other suitable apparatus. If desired, vacuum devices
that are commonly employed during indexing to check the quality of
air-diluted filtered cigarettes (e.g., the types of technologies
provided by sources such as Carrier and Key Technologies) may be
suitably modified so as to supply air to blow out filler material,
rather than apply vacuum to the cigarette. Alternatively, the
filler material may be sucked out of the cigarette using a vacuum
device or the filler material may be removed from the cigarette by
any other means that suitably removes the filler material from the
cigarette to yield a pre-formed cigarette tube that is
substantially devoid of filler material.
[0036] Each pre-formed tube so provided then continues movement
until it is transported to an appropriate location. For example,
the tubes can be transported to a conveyor belt (e.g., mass flow
conveyor belt). The tubes can be examined visually and by weight in
order to confirm that those tubes are of desired quality and then
packaged.
[0037] The filler material that is ejected from the cigarettes may
be collected and recycled to the cigarette making machine for use
in making new cigarettes. An exemplary method of recovering filler
material that is ejected from the finished cigarettes is described
at column 5, lines 54-63 of U.S. Pat. No. 4,763,673 to Barnes. The
collected filler may be transferred to the cigarette making machine
using a conveyer system, rollers, automated mass flow, or the like.
The recycled filler may be the sole source of filler for the
cigarette making machine or it may be combined with fresh filler
before being conveyed to the cigarette making machine.
[0038] The filler material removed from the cigarettes may be
screened, or otherwise processed in order ensure that a continuous
supply of filler of consistent quality is provided. An example of a
process for screening the recycled filler materials is described in
FIG. 4. For example, the filler material can be conveyed on a
vibratory conveyor using a "two stage" screening process. That is,
the filler material can be grossly screened to collect large size
materials, such as large pieces of wrapping material or pieces of
filter material; then, the filler material can be screened on a
fine screen in order to sieve out or otherwise remove dust and
fines. Suitable vibratory conveyor systems for tobacco filler are
commercially available, and an example of a suitable device is
available from Decouffle. In addition, suitably modified "on
machine tobacco reclamation devices," such as Decouffle Model DWR,
can be employed. The filler material then can be stored in a
suitable reservoir, or returned directly to the filler input region
of the cigarette making machine. Techniques for movement of that
filler material typically involve the use of pneumatic conveyor
systems, and if desired, cyclone separators can be used in order to
further ensure the consistency of the make up of the filler
material. The filler material so provided then can be returned to
the cigarette making machine. For example, the filler material may
be returned to the cigarette making machine through the trim return
conveyor of a Protos cigarette making machine that is operated in
an essentially traditional manner). Additionally, the filler
material may be aerated, humidified, cooled, or warmed in order to
obtain the desired density, moisture content or temperature.
[0039] Optionally, the system may include an apparatus for
monitoring the quality and characteristics of the filler material
that is ejected from the finished cigarettes. The quality and
consistency of the filler material may affect the quality and
consistency of the pre-formed tubes. For example, if the density
and moisture content of the filler material changes over time, the
shape and quality of the empty tubes may also change over time.
Accordingly, it is sometimes desirable to monitor and control the
quality of the recycled filler. In this regard, an apparatus may be
used to monitor the quality of the filler material. The
characteristics of the filler material that may be monitored
typically include, but are not limited to, density and particle
size. Density and/or particle size may be monitored according to
the screening techniques described above. Filler material that does
not meet a pre-determined standard for some or all of these
characteristics may be discarded, in whole or in part.
Alternatively, the recycled filler material may be mixed with a
sufficient amount of new filler to bring the overall quality of the
filler material up to the pre-determined standard.
[0040] The resulting pre-formed filtered cigarette tubes can be
collected and packaged for distribution to consumers or retailers.
Preferably, the capture of the cigarette tubes is accomplished by
automated mass flow and then packaged.
[0041] The pre-formed cigarette tubes may be used by consumers to
make their cigarettes using hand operated cigarette making
machines. Alternatively, the tubes may be used in commercial,
mass-production cigarette making operations.
[0042] The pre-formed cigarette tubes are used for the manufacture
of cigarettes. Various representative types of cigarette components
are set forth in U.S. Pat. No. 5,220,930 to Gentry; U.S. Pat. Pub.
Nos. 2004/0255965 to Perfetti et al.; 2004/0261807 to Dube et al.;
2005/0066982 to Clark et al. and 2005/0066986 to Nestor et al.; and
U.S. patent application Ser. No. 11/375,700, filed Mar. 14, 2006,
to Thomas et al.; which are incorporated herein by reference. See,
also, Johnson, Development of Cigarette Components to Meet Industry
Needs, 52nd T.S.R.C. (September, 1998).
[0043] The pre-formed cigarette tubes may also be used in retail
establishments that provide for the custom manufacture of
cigarettes according to the personal choices and preferences of
retails customers. Such a retail establishment is operating as
Marshall McGearty Tobacco Lounge at 1553 North Milwaukee Avenue,
Chicago, Ill., USA.
[0044] Certain embodiments of the present invention may provide
various advantages over known techniques for the manufacture of
certain traditional types of pre-formed tubes. Certain traditional
types of pre-formed filtered tubes are manufactured by inserting
filter segments at predetermined locations within a continuous web
of cigarette wrapping material, and forming a continuous series of
pre-formed tubes that are sub-divided at desired locations to
provide segments of the desired length; and those segments then are
tipped with a type of tipping material in order to provide the look
of traditional filtered cigarettes. Typically, those types of
pre-formed tubes are limited in selection filter length (e.g.,
typical filter lengths are selected at about 15 mm to about 20 mm),
rod circumference, draw or draft, "tar" removal efficiency, air
dilution levels, and the like. Pre-formed filtered tubes of the
present invention may be produced so that the components (e.g.,
selection, design and format of wrapping materials and filter
materials), air dilution levels, rod dimensions, filter dimensions,
and the like, can be selected and controlled. Furthermore, the
pre-formed filtered tubes of the present invention may not require
that the wrapping material of the smokable rod portion extend over
the entire length of the cigarette, as is necessarily required for
certain traditional types of pre-formed tubes that are manufactured
using certain other types of techniques. In addition, the
pre-formed tubes of the present invention can be produced so as to
be virtually identical to the relevant components of cigarettes
manufactured commercially using automated cigarette making
machines.
[0045] The present invention provides a cigarette manufacturer with
the ability to become highly versatile when manufacturing
pre-formed filtered cigarette tubes. A wide variety of designs,
formats and configurations can be incorporated into pre-formed
filter cigarette tubes. As such, there is provided an ability to
produce quality cigarettes at a later time by stuffing those
cigarettes with tobacco filler, tobacco filler cartridges, or the
like, which cigarettes are comparable in many respects to
commercially manufactured cigarettes. Thus, a manufacturer of
commercially manufactured finished cigarettes can provide
pre-formed filtered tubes identical to the relevant components of
those commercially manufactured cigarettes, and provide a blended
tobacco cut filler identical to that of the commercially
manufactured cigarettes; and hence, there can be constructed
finished cigarettes from those tubes and tobacco cut filler that
can match or approach the performance (e.g., yields, draw, flavor,
and the like) of the commercially manufactured cigarettes.
[0046] It is intended that the foregoing detailed description be
regarded as illustrative rather than limiting, and that it be
understood that it is the following claims, including all
equivalents, that are intended to define the spirit and scope of
this invention.
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