U.S. patent application number 13/642457 was filed with the patent office on 2013-05-16 for method for manufacturing smoking articles and smoking articles.
This patent application is currently assigned to BRITISH AMERICAN TOBACCO (INVESTMENTS) LIMITED. The applicant listed for this patent is Richard Fiebelkorn, Karl Kaljura, Leonardo Nappi. Invention is credited to Richard Fiebelkorn, Karl Kaljura, Leonardo Nappi.
Application Number | 20130118510 13/642457 |
Document ID | / |
Family ID | 42270671 |
Filed Date | 2013-05-16 |
United States Patent
Application |
20130118510 |
Kind Code |
A1 |
Kaljura; Karl ; et
al. |
May 16, 2013 |
Method for Manufacturing Smoking Articles and Smoking Articles
Abstract
The present invention relates to a method for making smoking
articles, smoking articles, and more particularly to a method for
manufacturing smoking articles having a reduced ignition
propensity. A method of manufacturing a smoking article includes
the steps of providing a filter element (40) and at least one rod
(30) of smokeable material surrounded by a wrapper, wrapping a
section of tipping paper (12A) around the filter element and a
portion of the at least one wrapped rod and applying one or more
patches (12B1, 12B2) of material to the outer surface of the
wrapper. The patches can be arranged to reduce the ignition
propensity of the smoking article and are applied to the outside of
the wrapper, such that this can occur online during manufacture of
the wrapped rod.
Inventors: |
Kaljura; Karl; (London,
GB) ; Nappi; Leonardo; (London, GB) ;
Fiebelkorn; Richard; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kaljura; Karl
Nappi; Leonardo
Fiebelkorn; Richard |
London
London
London |
|
GB
GB
GB |
|
|
Assignee: |
BRITISH AMERICAN TOBACCO
(INVESTMENTS) LIMITED
London
GB
|
Family ID: |
42270671 |
Appl. No.: |
13/642457 |
Filed: |
March 31, 2011 |
PCT Filed: |
March 31, 2011 |
PCT NO: |
PCT/EP2011/054982 |
371 Date: |
January 16, 2013 |
Current U.S.
Class: |
131/280 ;
131/331 |
Current CPC
Class: |
A24C 5/471 20130101;
A24D 1/025 20130101 |
Class at
Publication: |
131/280 ;
131/331 |
International
Class: |
A24D 1/02 20060101
A24D001/02 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 22, 2010 |
GB |
1006730.4 |
Claims
1. A method of manufacturing a smoking article comprising:
providing a filter element and at least one rod of smokeable
material surrounded by a wrapper; wrapping a section of tipping
paper around the filter element and a portion of the at least one
wrapped rod; and applying one or more patches of material to the
outer surface of the wrapper; wherein applying the one or more
patches of material to the wrapper of the at least one wrapped rod
is performed in association with wrapping the section of tipping
paper around the filter element and an end of the at least one
wrapped rod.
2. (canceled)
3. The method according to claim 1, wherein the one or more patches
comprise one of a low porosity and non porous web material.
4. The method according to claim 1, wherein the one or more patches
comprise a web material having a permeability of about 50 CU or
less.
5. A method of manufacturing a smoking article comprising:
providing a filter element and at least one rod of smokeable
material surrounded by a wrapper; wrapping a section of tipping
paper around the filter element and a portion of the at least one
wrapped rod; and applying one or more patches of material to the
outer surface of the wrapper; wherein the one or more patches are
bands applied around the full circumference of the at least one
wrapped rod; and wherein each band is applied such that the
mouth-end side of the band is within the 50% of the length of the
rod which is closest to the filter element.
6. (canceled)
7. The method according to claim 5, wherein the application
includes applying a second band to each rod simultaneously to the
application of the first band.
8. A method of manufacturing a smoking article comprising:
providing a filter element and at least one rod of smokeable
material surrounded by a wrapper; wrapping a section of tipping
paper around the filter element and a portion of the at least one
wrapped rod; and applying one or more patches of material to the
outer surface of the wrapper; wherein the one or more patches are
bands applied around the full circumference of the at least one
wrapped rod; wherein the application includes applying a second
band to each rod simultaneously to the application of the first
band; and wherein the second band is applied such that the
mouth-end side of the second band is within the 50% of the length
of the rod which is furthest from the filter element.
9. A method of manufacturing a smoking article comprising:
providing a filter element and at least one rod of smokeable
material surrounded by a wrapper; wrapping a section of tipping
paper around the filter element and a portion of the at least one
wrapped rod; and applying at least one patch of material to the
outer surface of the wrapper; wherein the at least one patch
comprises a patch having a window which exposes a region of the
outer surface of the wrapper.
10. The method according to claim 9, wherein said at least one
patch comprises a plurality of said windows.
11. The method according to claim 9, wherein said patch extends
substantially from an edge of the tipping paper to an end of the
rod of smokeable material which is furthest from the filter.
12. The method according to claim 1, wherein the providing
comprises first and second rods of smokeable material surrounded by
wrappers, and the filter element interposed between the first and
second rods, and wherein the method further comprises cutting the
filter element to form two smoking articles after application of
the one or more patches.
13. A method of manufacturing a smoking article comprising:
providing a filter element and at least one rod of smokeable
material surrounded by a wrapper; splitting tipping paper from a
roll to form patches, and a section to be applied to around the
filter element and a portion of the at least one wrapped rod;
wrapping the section of tipping paper around the filter element and
the portion of the at least one wrapped rod; and applying one or
more patches of material to the outer surface of the wrapper.
14. A smoking article comprising: a rod of smokeable material
surrounded by a wrapper; a filter element at one end of the wrapped
rod; a tipping paper surrounding the filter element and a portion
of the wrapped rod; and a patch of material applied to the outer
surface of the wrapper; wherein the patch comprises a window which
exposes a region of the outer surface of the wrapper.
15. The smoking article according to claim 14, wherein the patch
comprises one of a low porosity and non porous web material.
16. The smoking article according to claim 15, wherein the patch
comprises a web material having a permeability of about 50 CU or
less.
17. The smoking article according to claim 14, wherein the patch is
a band applied around the full circumference of the wrapped
rod.
18. The smoking article according to claim 17, wherein the band is
spaced from an edge of the tipping paper.
19. The smoking article according to claim 17, wherein the band is
at least 4 mm wide.
20. The smoking article according to claim 19, wherein the band is
at least 6 mm wide.
21. (canceled)
22. The smoking article according to claim 14, wherein the patch
comprises a plurality of said windows.
23. A smoking article comprising: a rod of smokeable material
surrounded by a wrapper; a filter element at one end of the wrapped
rod; a tipping paper surrounding the filter element and a portion
of the wrapped rod; and a patch of material applied to the outer
surface of the wrapper; wherein the patch is a band at least 4 mm
wide applied around the full circumference of the wrapped rod; and
wherein the patch extends substantially from an edge of the tipping
paper to an end of the rod of smokeable material which is furthest
from the filter.
24. A smoking article comprising: a rod of smokeable material
surrounded by a wrapper; a filter element at one end of the wrapped
rod; a tipping paper surrounding the filter element and a portion
of the wrapped rod; and a patch of material applied to the outer
surface of the wrapper; wherein the material is the same as the
tipping paper.
Description
FIELD OF INVENTION
[0001] The present invention relates to a method for making smoking
articles, smoking articles, and more particularly to a method for
manufacturing smoking articles having a reduced ignition
propensity.
BACKGROUND TO THE INVENTION
[0002] Many different methods have been suggested for manufacturing
smoking articles such as cigarettes having a reduced ignition
propensity i.e. a tendency to self-extinguish when not drawn on by
a smoker. Such smoking articles are generally referred to as having
a low ignition propensity (LIP). It has been recognised that the
constitution of the wrapper has a significant effect on the burn
rate of a cigarette and by modifying the wrapper by various
methods, a self-extinguishing cigarette can be produced.
[0003] One method for making wrappers for smoking articles having
reduced ignition propensity is to add bands of paper to the
wrapping paper, wherein the composition of the wrapper and the band
paper are selected to yield a composite paper having the desired
burn rate, as disclosed in EP 0 483998 and EP 0 262550. The bands
are typically applied to the paper before it is wrapped around a
tobacco core, and when the paper is wrapped around the tobacco the
bands are on the inside of the paper, facing the tobacco. When the
paper is used to manufacture the cigarettes, the bands are randomly
situated along the length of the cigarette.
[0004] To ensure that cigarettes meet the requirements for
self-extinguishment which exist in various counties, the accurate
positioning of the bands along the length of the cigarette can be
important. However, when using banded papers, ensuring that the
bands are positioned in the correct positions along the cigarette
is not straightforward and requires longitudinal registration of
the paper, adding complexity to the cigarette manufacturing
machinery.
[0005] Another method for making smoking articles having reduced
ignition propensity is to apply a burn retardant additive to the
smoking article wrapper, for instance cigarette paper. The burn
retardant additive is typically applied as a solution in a pattern
such as bands which, in the final assembled cigarette, extend
around the circumference of the cigarette. A method for
manufacturing a suitable such banded paper is disclosed in W
098/01233.
[0006] Attempts have been made to apply burn retardant additive
banding during the cigarette making process. This allows the bands
to be positioned at desired locations by synchronising the
application of the bands with cutting of the rod formed when the
tobacco is wrapped in the banded paper. This overcomes the problem
of positioning of the bands found with the pre-manufactured banded
papers. This on line application of banding is disclosed in WO
2004/057986 and US 2004/0261805. However, these processes have
additional drawbacks. One problem is in the drying of the paper
once the burn retardant solution has been applied. Firstly, this
must be dried before the garniture section of the machine where the
tobacco is wrapped in the paper, because if the paper is damp at
this stage when it comes into contact with the tobacco then
discolouration of the paper may occur. Furthermore, the machines
used for wrapping cigarettes, which may be modified to include a
section for applying a burn retardant solution, apply significant
tension to the paper and when the paper is damp its tensile
strength is significantly reduced so that tearing of the paper
easily occurs. Various heaters can be included in the machine to
assist in drying the paper but to allow time for these to properly
dry the paper, the machine must be slowed. The slowing of the
machine may also alleviate problems with tearing, but this
decreases production efficiency.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method of manufacturing a
smoking article comprising providing a filter element and at least
one rod of smokeable material surrounded by a wrapper, wrapping a
section of tipping paper around the filter element and a portion of
the at least one wrapped rod and applying one or more patches of
material to the outer surface of the wrapper.
[0008] The present invention also provides a smoking article
comprising a rod of smokeable material surrounded by a wrapper, a
filter element at one end of the wrapped rod, a tipping paper
surrounding the filter element and a portion of the wrapped rod and
a patch of material applied to the outer surface of the
wrapper.
[0009] Therefore, one or more patches are applied to the outside of
the wrapper, such that this can occur online during manufacture of
the wrapped rod. This allows the position of the patches relative
to the filter in the final smoking article to be determined.
[0010] The step of applying the one or more patches of material to
the wrapper of the at least one wrapped rod can be performed in
association with the step of wrapping the section of tipping paper
around the filter element and an end of the at least one wrapped
rod. In this way, modification to existing cigarette manufacturing
processes in order to apply the additional patches can be minimised
and production rates are not limited by the modification.
[0011] The one or more patches can comprise a low porosity or non
porous web material and/or can comprise a web material having a
permeability of approximately 50 CU or less, preferably
approximately 10 CU or less. The one or more patches can be bands
applied around the full circumference of the at least one wrapped
rod, and/or applied such that the mouth-end side of the band is
within the 50% of the length of the rod which is closest to the
filter element.
[0012] The application of the bands can include applying a second
band to each rod simultaneously to the application of the first
band. The second band can be applied such that the mouth-end side
of the second band is within the 50% of the length of the rod which
is furthest from the filter element.
[0013] The step of providing a filter element and at least one rod
of smokeable material surrounded by a wrapper can comprise
providing first and second rods of smokeable material surrounded by
wrappers, and a filter element interposed between the first and
second rods, and the method can further comprise cutting the filter
element to form two smoking articles after application of the one
or more patches.
[0014] The method can also comprise splitting tipping paper from a
roll to form both the patches and the section to be applied to the
filter element and the ends of the wrapped rods.
[0015] The one or more bands can be spaced from an edge of the
tipping paper and/or have a width of at least 4 mm. The material
for the patches can be the same as the tipping paper material,
although additional printing may be used on the section of material
used on the tipping paper or bands.
[0016] The invention is defined in the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Preferred embodiments of the present invention will now be
described with reference to the accompanying drawings, in
which:
[0018] FIG. 1 is a schematic illustration of a method of
manufacturing a smoking article according to an embodiment of the
present invention;
[0019] FIG. 2 shows a smoking article according to an embodiment of
the present invention;
[0020] FIG. 3 shows a smoking article in which a window in a patch
exposes a region of underlying wrapper;
[0021] FIG. 4 shows another smoking article in which a window in a
patch exposes a region of underlying wrapper.
DETAILED DESCRIPTION
[0022] FIG. 1 illustrates a method and apparatus for manufacturing
smoking articles in the form of cigarettes, according to an
embodiment of the invention.
[0023] In accordance with standard cigarette manufacturing
processes, a continuous wrapped rod of tobacco 20 is supplied from
a garniture region of a cigarette making machine to cutting means
21A and 21B which cut the rod 20 into lengths required for a single
cigarette. The first cutting means 21A cuts the rod 20 into double
length rods, each having a length required to make two cigarettes,
and then second cutting means 21B cuts the double length rods into
single length rods 30. Each pair of single length rods 30 is
separated and a double length filter 40 is positioned between the
ends of the two wrapped rods 30 such that each end of the double
length filter 40 abuts an end of one of the single length rods
30.
[0024] Tipping paper is supplied from a reel 13 of tipping paper
mounted on a bobbin. In FIG. 1, the tipping paper is split
longitudinally into three sections, comprising a wider central
section 12A and two narrower edge sections 12B.sub.1, 12B.sub.2 and
adhesive 14 is applied to the tipping paper. Alternatively, the
adhesive could be applied before splitting with dry lines provided
on the gummer roller positioned to allow a clean cut to take place
after application of adhesive. The sections 12A, 12B.sub.1,
12B.sub.2 are then cut laterally into individual segments, each of
which is applied to a double cigarette assembly. The wider central
section 12A is wrapped around the centre of the double cigarette
assembly such that it covers the entire double length filter 40 and
overlaps an end of each of the wrapped rods 30. Thus the central
section 12A forms a tipping paper section 12A which attaches the
double length filter to the pair of wrapped rods 30. Each of the
edge sections 12B.sub.1, 12B.sub.2 comprises a patch which is
wrapped around a respective one of the wrapped rods 30, spaced from
a respective edge of the central section 12A to form a
circumferential band. The patches 12B.sub.1, 12B.sub.2 may
alternatively be applied so that they only partially circumscribe
the wrapped rod 30, thereby forming a partial band.
[0025] The double length cigarette assembly is subsequently cut by
third cutting means 50 at the centre of the double length filter 40
to form a cigarette pair.
[0026] In the method illustrated in FIG. 1, the patch sections
12B.sub.1 and 12B.sub.2 form an LIP band on each wrapped rod 30 and
are applied to the wrapped rods 30 online during cigarette
manufacture, in a process step associated with the step of applying
the tipping paper section 12A to connect the filter to the wrapped
rods 30. For instance, the patch sections 12B.sub.1 and 12B.sub.2
can be applied simultaneously to applying the tipping paper section
12A or can be otherwise applied in the same phase of manufacture as
that in which the tipping paper section 12A is applied, for
instance after formation of the wrapped rods 30.
[0027] The cigarettes manufactured by the method illustrated in
FIG. 1 include only a single LIP patch spaced from an edge of the
tipping paper. Preferably the patch is positioned in the first 50%
of the exposed length (i.e. the 50% closest to the filter end) of
the wrapped rod. This is because it is desirable that the cigarette
self extinguish towards the end of the smoking. However, it may
also be desirable to provide further patches at different positions
along the wrapped rod to provide the cigarette with the potential
to self extinguish at different points during smoking. To provide
further patches, for one or more additional bands, a wider reel 13
of tipping paper may be provided, wherein the paper is split into
further longitudinal ribbons. For example, if two bands are
required, the paper may be split into five ribbons.
[0028] FIG. 2 shows a smoking article in the form of a cigarette,
in accordance with an embodiment of the present invention, having
two LIP bands A, B. The cigarette comprises a wrapped rod 30 and a
filter attached to the wrapped rod 30 by tipping paper 2 which
covers the filter and overlaps the wrapped rod 30. The wrapped rod
30 comprises a tobacco core surrounded by a paper wrapper. The
length of the tipping paper 2 is L.sub.T and the exposed length of
the wrapped rod 1 (before the LIP bands A, B are applied) is
L.sub.W. A first LIP band A has a first width W.sub.A and is
positioned spaced from an edge of the tipping paper 2 by a first
distance a. A second LIP band B has a second width W.sub.B and is
spaced from an edge of the tipping paper 2 by a second distance b,
which is longer than the first distance a. The tipping paper 2 is
formed from the half of the central tipping section 12A shown in
FIG. 1, and the first band A is formed from one of the edge patch
sections 12B.sub.1, 12B.sub.2. The second band B can be formed from
a further patch section of tipping paper split from the reel
13.
[0029] Preferably, the first band A is positioned within the first
50% of the exposed length of the wrapped rod 1 ie (W.sub.A+a)/
L.sub.W.ltoreq.0.5. Preferably, the second band B is spaced from
the first band A and positioned within the last 50% of the exposed
length of the wrapped rod 1 ie (L.sub.W-b)/ L.sub.W.ltoreq.0.5.
Preferably the width of the bands are approximately the same, i.e.
W.sub.A=W.sub.B.
[0030] In the preferred example, given a cigarette of 83 mm length,
wherein the length L.sub.T of the tipping paper 2 is 32 mm and the
exposed length of the wrapped rod 1 L.sub.W is 51 mm, a=11 mm, b=31
mm and W.sub.A=W.sub.B=6 mm. The base material used for the LIP
bands is the same as that used for the tipping paper (although
different printing may be used on each section) and preferably has
a porosity of approximately 5 Coresta Units (CU).
[0031] In an alternative to the embodiment shown in FIG. 1, rather
than splitting the sections 12A, 12B.sub.1, 12B.sub.2, from a
single reel 13 of tipping paper, each section may be provided from
a separate reel. In this case, the outer patch sections 12B.sub.1,
12B.sub.2 need not be formed from the same material as the central
tipping section 12A. For example, the outer patch sections
12B.sub.1, 12B.sub.2 may be formed from the same material as the
wrapper of the wrapped rods 30. Alternatively, the outer patch
sections 12B.sub.1, 12B.sub.2 may be formed from an alternative
material, such as a plugwrap paper or a cigarette paper having a
different weight or permeability to the cigarette paper forming the
wrapping of the wrapped rods 30. An example porosity is
approximately 5 CU.
[0032] As would be appreciated by those skilled in the art, the
specific values chosen for the widths W.sub.A, W.sub.B and sizes of
the LIP patches, for the porosity of the LIP patches and for their
position on the wrapped rod can be adjusted as appropriate to
achieve a required reduction in ignition propensity and the
location at which this will be effective. For example, LIP band
widths above approximately 4 mm could be used, preferably between 4
mm and 25 mm and more preferably between approximately 4 mm and 10
mm. The porosity of the paper can be less than approximately 50 CU,
preferably less than 10 CU and more preferably less than or equal
to 5 CU.
[0033] In a particular example, based on LIP performance measured
according to the ASTM E2187-04 method, LIP-compliant cigarettes
were manufactured having a single 5 CU porosity LIP band applied
per cigarette in a 6 mm or 8 mm width and with the mouth-end edge
of the band being 50 mm from the mouth end of the cigarette. The
banding material was adhered to the tobacco rod with water-based
glue.
[0034] The width of the LIP patch 12B.sub.1, 12B.sub.2 may
optionally be substantially equal to the length L.sub.W of the
region of wrapped tobacco rod 30 which is not covered by the sheet
of tipping paper 2 connecting the wrapped rod 30 to the filter. For
example, FIG. 3 shows an LIP patch C which extends substantially
from the edge of the tipping paper 2 which is furthest from the
mouth end of the smoking article to the opposite end of the wrapped
tobacco rod 30. As can be seen, the LIP patch C comprises one or
more windows 3 which expose the underlying wrapped tobacco rod 30
to the surrounding atmosphere. Each window 3 comprises a hole in
the patch C of LIP material. The windows 3 may be cut-out from the
LIP sheet material before the material is applied to the wrapped
rod 30. For example, the windows 3 can be cut-out from the material
before the material is wound onto the bobbin or reel 13.
[0035] The regions of the patch C between the windows 3 fully
circumscribe the wrapped tobacco rod 30. Therefore, the regions of
the patch which do not align with a window 3 can be considered as
corresponding to the LIP bands A, B described above. The patch C
thus provides the same LIP effect as the LIP patches A, B
previously referred to. Specifically, burning of the wrapped
tobacco rod 30 is hindered in the regions of the rod 30 which are
covered by the LIP patch A, B, C whilst burning of the rod 30 is
less hindered in the regions of the rod 30 which are not covered by
the patch A, B, C. The rate of gaseous transfer between the tobacco
and the surrounding environment, for example the surrounding air,
through the windows 3 in the patch C mirrors the rate of gaseous
transfer through the un-banded regions of the wrapped rod 30 shown
in FIG. 2 and as previously described.
[0036] The location of the windows 3 may be opposite to the
location of the LIP bands A, B described above. For example, as
shown in FIG. 3, a first window 3 in the LIP patch C may extend
between a location which is a distance of (a+W.sub.A) from the edge
of the tipping paper 2 and a location which is a distance b from
the edge of the tipping paper 2. The width of the first window is
therefore (b-(a+W.sub.A)). Additionally or alternatively, a second
window 3 may extend between a location which is a distance of
(b+W.sub.B) from the edge of the tipping paper 2 and a location
which is a distance of L.sub.W from the edge of the tipping paper
2. The width of the second window 3 is therefore
(L.sub.W-(b+W.sub.B)). This is also shown in FIG. 3.
[0037] FIG. 4 shows another example, in which a window 3 extends
between a location which is a distance of (a+W.sub.A) from the edge
of the tipping paper 2 and a location which is a distance of
L.sub.W from the edge of the tipping paper 2. The width of the
window 3 is therefore (L.sub.W-(a+W.sub.A)).
[0038] Therefore, circumferential regions of LIP material are
provided around the same regions of the wrapped tobacco rod 30 in
both the embodiment shown in FIG. 2 and the embodiments shown in
FIGS. 3 and 4. Similarly, the wrapped tobacco rod 30 in between the
circumferential regions of LIP material is largely exposed.
[0039] The location, number and size of the windows in the patch C
can be chosen in accordance with the desired LIP effect.
Optionally, windows 3 may be provided in a circumferential band
around the tobacco rod 30 so that two or more windows 3 are
provided at the same longitudinal location on the rod 30. The
windows 3 can be of any suitable shape.
[0040] If the LIP patch material comprises the same material that
is used for the tipping paper 2, a sheet of the material can
optionally be applied over the whole length of a double length
cigarette of the type shown in FIG. 1 before cutting the double
length filter in half. The windows 3 should be cut-out from the LIP
material beforehand.
[0041] In FIGS. 3 and 4, the tipping paper 2 and patch C are shown
using a different pattern in order to allow the reader to clearly
distinguish between the two. However, as has been explained, the
tipping paper 2 and patch C may in practice be made of the same
type of material.
* * * * *