Device and method for manufacturing tobacco products

Abstract

In general, the present invention is directed to the manufacture of tobacco products, and more specifically to a common device and method to manufacture cylindrical tobacco products such as cigarettes, cigars, and therapeutic medical products with varying diameters and geometries.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/797,300 filed Dec. 04, 2012, which hereby is incorporated herein in its entirety by reference thereto.

[0002] This application also claims the benefit of U.S. Provisional Patent Application Ser. No. 61/956,695 filed Jun. 14, 2013, which hereby is incorporated herein in its entirety by reference thereto.

FIELD OF THE INVENTION

[0003] In general, the present invention is directed to the manufacture of tobacco products, and more specifically to a common device and method to manufacture cylindrical tobacco products such as cigarettes and cigars with varying diameters.

BACKGROUND

[0004] 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." A typical cigarette has a cylindrical filter element axially aligned in an end-to-end relationship with the tobacco rod. Typically, the filter element comprises plasticized cellulose acetate 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 extends through the tipping material and plug wrap. Conventional automated machines for making cigarette rods that have been employed for the manufacture of commercially popular packaged cigarettes are of the type commercially available from Molins PLC or Hauni-Werke Korber & Co. KG. For example, a description of a commercially available "Protos" cigarette-making machine is provided in U.S. Pat. No. 4,474,190 to Brand. Other types of equipment suitable for the manufacture of cigarettes are set forth in U.S. Patent Application Publication No. 2004/0129281 to Hancock et al. A cigarette-making machine for making relatively small amounts of cigarettes has been available commercially from Hauni-Werke Korber & Co. KG. Another type of portable cigarette-making machine has been set forth in U.S. Pat. No. 4,164,229 to Hurt.

[0005] Cigarettes are commercially available in a wide variety of types. For example, different brands of cigarettes are available containing different individual types of tobaccos having unique or characteristic flavors and aromas (e.g., Burley, Oriental, and Virginia tobaccos). Cigarettes are also available that contain blends of tobacco types and/or flavoring agents in or on the tobacco. Different colors and flavors of wrappers and different types of filter elements are available providing variety in, for example, flavoring, strength of flavor, and tar yield. Conventionally, consumers obtain commercially available cigarettes in a pack containing a single type of cigarette. Thus, consumers wishing to smoke different types of cigarettes typically have to purchase multiple packs of cigarettes. Some consumers purchase wrapping materials, filters, and loose tobacco for so-called "hand-rolling" of their own cigarettes. While this approach allows a consumer to produce a variety of his own cigarettes, the making process requires a certain degree of skill, time, inconvenience, and/or some specialized equipment. A variety of hand-operated devices for manufacturing individual cigarettes have been proposed. See, for example, U.S. Pat. No. 2,376,103 to Wahl; U.S. Pat. No. 2,425,888 to Matteson et al.; U.S. Pat. No. 2,427,884 to Snodgrass; U.S. Pat. No. 2,427,957 to Getts, Jr.; U.S. Pat. No. 2,496,375 to Carter; U.S. Pat. No. 2,594,747 to Du Laney; U.S. Pat. No. 2,699,788 to Kastner; U.S. Pat. No. 2,714,383 to Gee; U.S. Pat. No. 2,731,971 to Kastner; U.S. Pat. No. 2,850,019 to Sosa; U.S. Pat. No. 2,868,209 to Marcotte; U.S. Pat. No. 3,006,348 to Banning, Jr.; U.S. Pat. No.

[0006] 3,011,498 to Armelin; U.S. Pat. No. 4,832,056 to Bryant et al.; U.S. Pat. No. 4,534,367 to Newsome; International Publication No. WO 2004/110187 to Szabo; and European Publication No. 1177731 to British American Tobacco (Germany) GmbH.

[0007] Various 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. 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.TM." filter cigarette-making machine by Brown &

[0008] 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.

[0009] Another cigarette machine for filling pre-formed cigarette tubes with tobacco filler has been produced commercially by The Central Tobacco Mfg. Co. Ltd. and marketed as "PREMIERE SUPERMATIC.TM." Other types of cigarette machines for filling 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 and U.S. Pat. No. 4,771,793 both to Kastner.

[0010] U.S. Pat. No. 3,822,710 to Bramhill proposes manufacturing individual cigarettes by inserting a cartridge of 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.

[0011] 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 et al.; U.S. Pat. No. 5,197,495 to Ruppert et al.; U.S. Pat. No. 5,615,692 to Ruppert et al.; U.S. Pat. No. 5,713,377 to Gerding et al.; and US Patent Publication No. 2006/0021625 to Nyffeler.

[0012] Other methods for manufacturing small quantities of cigarettes, for example 20 cigarettes, in an automated fashion by filling paper cigarette tubes are disclosed in U.S. Pat. No. 7,597,105 to Barnes et al.; and US Publication No. 2007/0107738 to Barnes et al., each of which hereby are incorporated herein in their entirety by reference thereto. A representative device for manufacturing cigarettes disclosed in these applications can include a reservoir for containing loose tobacco filler, a means for delivering a portion of the tobacco filler into pre-formed tubular wrappers, and a means for controlling the portion of the tobacco filler delivered into the wrappers, such as a compression mechanism for arranging tobacco filler into a charge of tobacco filler of pre-determined shape and size or a means for controlling the rate of movement of the wrappers as they are being filled. The device can include a tray or cartridge for containing a plurality of the tubular wrappers, which can be aligned with corresponding receptacles, and an insertion means, such as plunger rods or auger conveyors, for delivering each charge of tobacco filler from a receptacle into a wrapper. The cartridge, filled with manufactured cigarettes, can be removed from the cigarette-making device, excess tobacco can be cut away from the ends of the cigarettes with a cutting device, and the cigarettes can be transferred from the cartridge into a cigarette packaging device. As such, a small lot of cigarettes of consistent quality (for example, in terms of components, dimensions, and weight) are produced. The device can be employed in a commercial setting such that a customer can choose a type or blend of tobacco filler for a package of cigarettes. For other manners and methods of manufacturing small quantities of cigarettes, see U.S. Pat. No. 7,565,818 to Thomas et al.

[0013] As shown above, there is a long and diverse history of prior art devoted to manufacturing tobacco products. However, a common theme among all of the prior art, is that the devices, whether automated or manual, are designed to manufacture a cylindrically shaped tobacco product of a similar or fixed diameter.

[0014] Given this, there is a need for a manufacturing device and method to produce cylindrically shaped tobacco products of varying diameters--thereby allowing the same device to manufacture both relatively "thin" cigarettes and "thicker" cigars.

SUMMARY OF THE INVENTION

[0015] In general, the present invention is directed to the manufacture of tobacco products, and more specifically to a common device and method to manufacture cylindrical tobacco products such as cigarettes and cigars with varying diameters.

[0016] One embodiment of the present invention describes a tobacco manufacturing device comprising a rigid cylindrical shell open on one end, a funneling device tapered to fit into the open end of the cylindrical shell, the lateral surface of cylindrical shell in vertical segmented sections, the vertical segmented sections anchored on the closed end of the cylindrical shell, and the vertical segmented sections separable forming an opened cylinder.

[0017] Another embodiment of the present invention describes a tobacco manufacturing device comprising a rigid cylindrical shell open on one end, a funneling device tapered to fit into the open end of the cylindrical shell, and a tobacco grinder attachable to the said funneling device.

[0018] Another embodiment of the present invention describes a method for manufacturing a tobacco product comprising: first, inserting a thin liner into the open end of a cylindrical shell with a vertically segmented lateral surface; second, inserting a funneling device into the open end of the cylindrical shell; third, inserting tobacco into the funneling device thereby filling the cylindrical shell; fourth, compressing the tobacco in the cylindrical shell; and fifth, removing the compressed tobacco encased in the thin liner by expanding the vertically segmented cylindrical shell.

[0019] Another embodiment of the present invention describes a method for manufacturing a tobacco product comprising: first, inserting a thin liner into the open end of a cylindrical shell; second, inserting a funneling device into the open end of the cylindrical shell; third, inserting tobacco into the funneling device thereby filling the cylindrical shell; fourth, compressing the tobacco in the cylindrical shell; and fifth, removing the compressed tobacco encased in the thin liner.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

[0021] FIG. 1 shows a schematic representation of one embodiment of the present invention depicting the funneling device inserted into the cylindrical shell.

[0022] FIG. 2 shows a schematic representation of the cylindrical shell.

[0023] FIG. 3 shows a schematic representation of the cylindrical shell with the vertical segmented sections in the open configuration.

[0024] FIG. 4 shows a schematic representation of the funneling device depicted in FIG. 1.

[0025] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

[0026] In general, the present invention is directed to the manufacture of tobacco products, and more specifically to a common device and method to manufacture cylindrical tobacco products such as cigarettes and cigars with varying diameters.

[0027] One embodiment of the present invention is depicted in FIG. 1 wherein a manual cigarette and/or cigar manufacturing device (hereafter "manufacturing device") is shown schematically. The manufacturing device is comprised of a mechanical integrity element 14 which forms a generally cylindrical surface 16. Prior to inserting tobacco, a thin sleeve of appropriate material may be inserted into the mechanical integrity element 14 which eventually will become the cylindrical surface of the finished cigarette/cigar product.

[0028] Tobacco may be inserted into the thin sleeve encased within the mechanical integrity element 14 by way of input funneling device 12, which may be inserted into the proximal end of the mechanical integrity element 14. Ultimately, the thin sleeve is completely filled with tobacco material, which may be compressed by standard mechanical means.

[0029] The mechanical integrity element 14 may be comprised of a metal, hardened plastic, medical grade plastic, or similar plastic-like material. In addition, the mechanical integrity element 14 may have its lateral surface 16 segmented into discrete vertical elements which may be mechanically separated (see FIGS. 2 and 3, elements 14a thru 14d). In practice, when tobacco has been sufficiently compressed, the discrete vertical elements 14a thru 14d may be opened as shown in FIG. 3 allowing for easy removal of the compressed cylindrical tobacco element.

[0030] In an alternative embodiment of the present invention, the mechanical integrity element 14 may be comprised of a cylindrical shell with a rigid lateral surface 16 (i.e., not vertically segmented as described in the embodiment above).

[0031] In one particular embodiment of the present invention ideally suited for the manufacture of cigarettes, the mechanical integrity element 14 may have a rigid lateral surface 16 as described above with the following physical dimensions. The length and diameter of the rigid lateral surface may be approximately 3 3/16 inch and 7/16 of an inch respectively, consistent with the typical dimensions of cigarettes today. In this embodiment of the invention, the funneling device shown in FIG. 4 may be tapered down to a diameter of 1/4 of an inch for easy insertion into the open end of the mechanical integrity element 14. When this embodiment of the invention is employed for the manufacture of cigarettes, an appropriate material for the thin liner (which eventually will become the cylindrical surface of the finished cigarette) may be chosen from the list of wood pulp, hemp paper, flax, rice straw, natural cellulose, or any similar burnable material with the necessary mechanical integrity to support the encased compressed tobacco material.

[0032] In another particular embodiment of the present invention ideally suited for the manufacture of cigars, the mechanical integrity element 14 may have a rigid lateral surface 16 as described above with the following physical dimensions. The length and diameter of the rigid lateral surface 16 may be approximately 4 9/16 inch and 3/4 of an inch respectively, consistent with the typical dimensions of cigars today. In this embodiment of the invention, the funneling device shown in FIG. 4 may be tapered down to a diameter of 5/8 of an inch for easy insertion into the open end of the mechanical integrity element 14. When this embodiment of the invention is employed for the manufacture of cigars, an appropriate material for the thin liner (which eventually will become the cylindrical surface of the finished cigar) may be comprised of tobacco leaves or tobacco paper, or any similar burnable material with the necessary mechanical integrity to support the encased compressed tobacco material.

[0033] In yet another particular embodiment of the present invention ideally suited for the manufacture of therapeutic devices, such as medical marijuana or herbal remedies, the mechanical integrity element 14 may have a rigid lateral surface 16 as described above with the following physical dimensions. The length and diameter of the rigid lateral surface 16 may be approximately 4 5/16 inch and 9/16 of an inch respectively, consistent with the typical dimensions of medical marijuana products marketed today. In this embodiment of the invention, the funneling device shown in FIG. 4 may be tapered down to a diameter of 7/16 of an inch for easy insertion into the open end of the mechanical integrity element 14. When this embodiment of the invention is employed for the manufacture of therapeutic products, an appropriate material for the thin liner (which eventually will become the cylindrical surface of the finished therapeutic product) may be chosen from the list of wood pulp, hemp paper, flax, rice straw, natural cellulose, or any similar burnable material with the necessary mechanical integrity to support the encased compressed therapeutic material.

[0034] The procedure for manufacturing a tobacco product with a cylindrically rigid (i.e., non-segmented) mechanical integrity element 14 follows a somewhat similar procedure--prior to inserting tobacco, a thin sleeve of appropriate material may be inserted into the mechanical integrity element 14 which eventually will become the cylindrical surface of the finished cigarette/cigar/medical product.

[0035] Tobacco may be inserted into the thin sleeve encased within the mechanical integrity element 14 by way of input funneling device 12, which may be inserted into the proximal end of the mechanical integrity element 14. Ultimately, the thin sleeve is completely filled with tobacco material, which may be compressed by standard mechanical means. The thin liner may be manufactured from a material with a sufficiently smooth surface and a diameter slightly smaller than the cylinder within which it is encased, that the finished tobacco product may easily be extracted from the mechanical integrity element 14 by a variety of means known to those with skill in the art.

[0036] The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification. The claims are intended to cover such modifications and devices.

Claims

1. A tobacco manufacturing device comprising; a rigid cylindrical shell open on one end; a funneling device tapered to fit into the open end of the cylindrical shell; the lateral surface of said cylindrical shell in vertically segmented sections; said vertically segmented sections anchored on the closed end of the cylindrical shell; and said vertically segmented sections separable forming an opened cylinder.

2. The device of claim 1 wherein a thin liner may be inserted into the cylindrical shell prior to inserting the funneling device.

3. The device of claim 2 wherein tobacco may be inserted into the thin liner by way of the funneling device.

4. The device of claim 1 wherein the compacted tobacco encased in the thin liner may be easily removed from the cylinder with the vertically segmented sections in the separated configuration.

5. The device of claim 1 wherein the rigid cylindrical shell has a length of approximately 3 3/16 of an inch and a diameter of approximately 7/16 of an inch, and the funneling device is tapered down to a diameter of approximately 1/4 of an inch for insertion into the open end of the cylindrical shell.

6. The device of claim 1 wherein the rigid cylindrical shell has a length of approximately 4 9/16 of an inch and a diameter of approximately 3/4 of an inch, and the funneling device is tapered down to a diameter of approximately 5/8 of an inch for insertion into the open end of the cylindrical shell.

7. The device of claim 1 wherein the rigid cylindrical shell has a length of approximately 4 5/16 of an inch and a diameter of approximately 9/16 of an inch, and the funneling device is tapered down to a diameter approximately 7/16 of an inch for insertion into the open end of the cylindrical shell.

8. A tobacco manufacturing device comprising; a rigid cylindrical shell open on one end; a funneling device tapered to fit into the open end of the cylindrical shell; and a tobacco grinder attachable to the said funneling device,

9. The device of claim 8 wherein a thin liner may be inserted into the cylindrical shell prior to inserting the funneling device.

10. The device of claim 8 wherein the tobacco grinder and funneling device may be in permanent mechanical communication.

11. The device of claim 8 wherein the rigid cylindrical shell has a length of approximately 3 3/16 of an inch and a diameter of approximately 7/16 of an inch, and the funneling device is tapered down to a diameter of approximately 1/4 of an inch for insertion into the open end of the cylindrical shell.

12. The device of claim 8 wherein the rigid cylindrical shell has a length of approximately 4 9/16 of an inch and a diameter of approximately 3/4 of an inch, and the funneling device is tapered down to a diameter of approximately 5/8 of an inch for insertion into the open end of the cylindrical shell.

13. The device of claim 8 wherein the rigid cylindrical shell has a length of approximately 4 5/16 of an inch and a diameter of approximately 9/16 of an inch, and the funneling device is tapered down to a diameter approximately 7/16 of an inch for insertion into the open end of the cylindrical shell.

14. A method for manufacturing a tobacco product comprising; first, inserting a thin liner into the open end of a cylindrical shell with a vertically segmented lateral surface; second, inserting a funneling device into the open end of the said cylindrical shell; third, inserting tobacco into the funneling device thereby filling the thin liner; fourth, compressing the tobacco in the thin liner; and fifth, removing the compressed tobacco encased in the thin liner by expanding the vertically segmented cylindrical shell.

15. A method for manufacturing a tobacco product comprising; first, inserting a thin liner into the open end of a cylindrical shell; second, inserting a funneling device into the open end of the said cylindrical shell; third, inserting tobacco into the funneling device thereby filling the thin liner; fourth, compressing the tobacco in the thin liner; and fifth, removing the compressed tobacco encased in the thin liner.