JP2023554199A - Method and apparatus for manufacturing filter elements - Google Patents

Abstract

A method of manufacturing a filter element (200) comprising the steps of: longitudinally advancing two or more sheets (102) of filter material; separating and collecting the separated sheets of longitudinally advancing filter material to form a partially collected rod of filter material having a longitudinally extending recess; 204) into the longitudinally extending recess and collecting the filter material around the additive release container to close the recess, thereby forming a longitudinally extending core of the filter material and the one or more additive release containers. forming a rod comprising a container (204).

Description

The present invention relates to a filter element and a filter, a method for manufacturing a filter element, and an apparatus for manufacturing a filter element.

Tobacco filter elements or filters containing frangible capsules are known in the art. Frangible capsules typically contain liquid additives that can modify the characteristics of tobacco smoke passing through the filter or filter element. For example, capsules may contain flavoring agents such as menthol that modify the flavor and other sensory characteristics of tobacco smoke. Typically, the capsule is destroyed by the user prior to smoking so that the contents of the capsule are released into the surrounding filter material.

Tobacco filter elements or filters typically include a core comprising cellulose acetate filter material. Cellulose acetate filter material can slowly degrade under normal environmental conditions. Filter materials made from paper or other nonwoven materials can have improved degradability and other properties.

Methods of manufacturing filter elements including capsules formed from cellulose acetate tow are known in the art. Inserting capsules into filter elements formed from sheet filter materials such as paper or nonwoven materials is more difficult, and problems with capsule placement and filter material homogeneity are common.

New methods and apparatus are needed for manufacturing filter elements that include capsules and are formed from sheet filter materials such as paper or nonwoven materials. There is also a need for new filters or filter elements that include capsules and are formed from sheet filter materials such as paper or nonwoven materials.

In a first aspect of the invention, a method of manufacturing a filter element comprises the steps of: longitudinally advancing two or more sheets of filter material; separating and collecting the separated sheets of longitudinally advancing filter material to form a partially collected rod of filter material having a longitudinally extending recess; inserting the filter material into the longitudinally extending recess and collecting the filter material around the additive release container to close the recess, thereby connecting the longitudinally extending core of the filter material and the one or more additive release containers. forming a rod comprising:

Applicants have disclosed that by using two or more sheets of filter material and separating the two or more sheets before they are collected, the applicant has partially collected the filter material with longitudinally extending recesses. It has been found that a rod can be provided, into which one or more capsules can be inserted. The formation of recesses leads to improved positioning of the capsules in filter elements manufactured from sheet filter materials such as paper or non-woven materials. Applicants have also discovered that the process of the present invention results in filter elements formed from sheet filter materials with improved homogeneity.

The two or more longitudinally advancing sheets of filter material may be longitudinally advancing successively.

The two or more sheets of longitudinally advancing filter material may be separated such that a gap exists between the two or more sheets of longitudinally advancing filter material, the size of the gap being between the two or more sheets of filter material. It may be reduced as more sheets are partially collected. Prior to capsule insertion, the two or more sheets of filter material are not completely collected and the size of the gap between the two sheets is reduced to form a recess in the rod of partially collected filter material. do. When two or more sheets are collected, the two or more sheets may remain substantially vertically aligned. Vertically aligned, as used herein, is perpendicular to the plane in which the sheet of filter material is longitudinally advanced and relative to a plane that is transverse to the plane in which the sheet of filter material is longitudinally advanced. Means to be aligned in a plane that is perpendicular.

Preferably, the two or more longitudinally advancing sheets of filter material are separated by a separator. Preferably, collecting the two or more separated sheets of longitudinally advancing filter material comprises drawing the two or more separated longitudinally advancing sheets of filter material into a collection chamber. .

Applicants have discovered that the separator keeps the folds of the sheet material apart to allow the capsules to be centered in the partially collected filter material, thereby improving the positioning of the capsules. I found it.

Preferably, the collection chamber is a hollow element configured to collect or condense filter material.

Preferably, the separator is coupled to the collection chamber such that two or more longitudinally advancing sheets of filter material are separated before entering the collection chamber, and the separator is coupled to the collection chamber such that two or more sheets of longitudinally advancing filter material are separated before entering the collection chamber. complete collection of the sheets thereby forming a longitudinally extending recess in the partially collected filter material.

The collection chamber may include an inlet for receiving separated sheets of filter material and an outlet for exiting collected or partially collected filter material.

Preferably, the collection chamber tapers longitudinally from the inlet such that the inlet has a larger internal diameter than the outlet. The collection chamber is operative to collect (eg, condense) two or more sheets of filter material into a partially collected rod of filter material having a longitudinally extending recess. The collection chamber may include an opening for receiving an inserter for inserting one or more additive release containers into the longitudinally extending recess. The opening may be positioned between the inlet and the outlet.

Following the insertion of the or each additive release container, the collection chamber further collects the partially collected filter material around the additive release container to close the recess, thereby extending the longitudinal direction of the filter material. A rod can be formed with an elongated core and one or more additive release containers. The collection chamber may taper after or from the opening, thereby further collecting partially collected filter material. Alternatively, further collection may be performed by a further collection chamber joined to the first collection chamber.

The further step of applying an outer wrapper may serve to complete the collection of the partially collected rod of filter material and complete the closure of the longitudinally extending recess.

Preferably, the separator is longitudinally tapered. The separator may have a first end having a first diameter and a second end having a second diameter, the second diameter being smaller than the first diameter. The separator may extend into and along at least a portion of the length of the collection chamber. The first end of the separator may protrude from the collection chamber and the second end of the separator may be positioned inside the collection chamber. The separator may taper in the same direction as the collection chamber. The separator may be substantially conical or frustoconical. The tapered shape of the separator separates two or more sheets of filter material while also facilitating partial collection of the sheets of filter material.

The collection chamber may be tapered in the same direction as the separator, thereby partially collecting two or more sheets of filter material. Applicants have discovered that even at the narrowest point of the separator, the two or more sheets of filter material remain separated, and that after the sheets of filter material advance past the separator, the partially collected rods It has been found that a recess remains in the recess which can receive the or each additive release container.

Applicants have discovered that the separator and collection chamber configuration maintains alignment of two or more sheets of filter material. For example, vertical alignment of two or more sheets of filter material is maintained. Vertical alignment, as used herein, is perpendicular to the plane in which the sheet of filter material is longitudinally advanced and perpendicular to the plane that is transverse to the plane in which the sheet of filter material is longitudinally advanced. It means alignment within a certain plane. Applicants have found that maintaining the alignment of two or more sheets of filter material while the filter material is collected results in a core of filter material with improved homogeneity and aids in capsule placement. Ta.

In one embodiment, two or more separated longitudinally advancing sheets of filter material may be drawn into the prechamber before entering the collection chamber. The prechamber may include an inlet and an outlet. The prechamber may taper longitudinally away from the inlet. The inlet may have a larger inner diameter than the outlet. The outlet of the prechamber may be joined to the inlet of the collection chamber, and the separator may extend into and along at least a portion of the length of the prechamber. The first end of the separator may protrude from the prechamber and the second end of the separator may be positioned inside the prechamber. The prechamber and separator may be configured such that two or more longitudinally advancing sheets of filter material are separated before entering the prechamber, and the separator is configured to separate two or more sheets of longitudinally advancing filter material before entering the prechamber. complete collection of the sheets thereby forming a longitudinally extending recess in the partially collected filter material.

Applicants have found that the presence of a pre-chamber helps to partially collect the filter material before it enters the collection chamber. In the case of the method of the invention utilizing a prechamber, the collection chamber comprises an inlet joined to the outlet of the prechamber, and the collection chamber comprises an opening for receiving the inserter. The collection chamber may taper longitudinally from or after the opening, thereby collecting two or more sheets of filter material around the additive release container to close the recess. , thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release vessels.

The additive release container inserter may include a rotating drum or wheel that rotates to insert the additive release containers into the recesses at regular intervals.

The method may include cutting the rod to form a filter element that includes a longitudinally extending core of filter material and one or more additive release containers.

The method may include longitudinally advancing a sheet of filter material and longitudinally cutting the sheet, thereby forming two or more longitudinally extending sheets of filter material. The two or more sheets of filter material continue to advance longitudinally following cutting. The longitudinally advancing sheet of filter material may be cut to form two, three, four, or more longitudinally extending sheets of filter material. Alternatively, the filter material may be cut by a separate process and wound onto reels for use in the method of the invention.

Two or more sheets of filter material may be embossed. For example, the method may include embossing two or more longitudinally extending sheets of filter material. Embossing imparts an embossed profile onto two or more sheets of filter material. Embossing can be performed by an embossing machine. The embossing machine may include a rotating drum (eg, an embossing roller) with protrusions (eg, spikes) extending away from the surface of the drum (eg, the surface of the embossing roller). Applicants have discovered that embossing two or more sheets provides a filter element with the desired pressure drop and visual appearance of compact or dense ends.

The two or more sheets of filter material may include two, three, or four sheets of filter material.

The two or more sheets of filter material may each have a width of 50-200 mm, such as 75-175 mm, such as 80-150 mm, such as 90-125 mm, such as 100-120 mm, such as 110 mm.

The two or more sheets of filter material may have a thickness of 50 μm to 100 μm, such as 60 μm to 90 μm, such as 70 μm to 90 μm, such as 80 μm to 90 μm, such as 82 μm to 88 μm, such as 83 μm to 87 μm, such as 84 μm to 86 μm, such as 85 μm. May have.

The filter material may be a tobacco filter material. The filter material may include paper or a nonwoven material, such as an air laid nonwoven material such as a McAirlaid material, a melt-spun nonwoven material, and/or a melt-blown nonwoven material.

Preferably, the filter material comprises or is paper.

The paper weighs 25-65 g/m ² , such as 30-60 g/m ² , such as 30-50 g/m ² , such as 30-40 g/ ^{m 2 ,} such as 32-38 g/m ² , such as 33-37 g/m 2 m ² , for example 36 g/m ² .

Preferably, the additive release container may be a capsule, such as a frangible capsule. An additive release container, such as a capsule, such as a frangible capsule, may contain the additive. Additives can include smoke modifiers such as flavorants and/or liquids, solids, or other materials, for example to aid in smoke filtration. Flavoring agents may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, and the like.

The method may include winding a continuous rod including a longitudinally extending core of filter material and one or more additive release containers before the continuous rod is cut. The wrapping step may include applying an outer wrapper, such as a plug wrap, surrounding the continuous rod.

The method may include applying additive material to two or more sheets of filter material. Additives may be applied after the embossing step. The additive may be a taste modifier and/or a flavoring agent. Flavoring agents may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, and the like.

In a further aspect of the invention there is provided a filter element obtainable according to the method of the invention, for example according to any of the methods described above.

In a further aspect of the invention, a filter element comprising a longitudinally extending core of filter material and an additive release container within the longitudinally extending core of the filter material, the longitudinally extending core of the filtering material comprising: a longitudinally extending core of the filtering material; A filter element is provided that is formed from two or more sheets of filter material.

The additive release container may be a capsule, such as a frangible capsule. An additive release container, such as a capsule, such as a frangible capsule, may contain the additive. Additives can include smoke modifiers such as flavorants and/or liquids, solids, or other materials, for example to aid in smoke filtration. Flavoring agents may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, and the like. The amount of additives, such as flavoring agents, may be less than 35 mg per filter element.

The additive release container, such as a capsule or a frangible capsule, may be spherical. The additive release container (such as a capsule or frangible capsule) may have a width at its widest point of 2.0 to 4 mm, such as 2.8 to 3.5 mm.

The filter element may be formed from two, three, four, or more sheets of filter material.

The two or more sheets of filter material may each have a width of 50-200 mm, such as 75-175 mm, such as 80-150 mm, such as 90-125 mm, such as 100-120 mm, such as 110 mm.

The two or more sheets of filter material may have a thickness of 50 μm to 100 μm, such as 60 μm to 90 μm, such as 70 μm to 90 μm, such as 80 μm to 90 μm, such as 82 μm to 88 μm, such as 83 μm to 87 μm, such as 84 μm to 86 μm, such as 85 μm. May have.

Filter materials may include paper or nonwoven materials. The nonwoven material can be an airlaid nonwoven material, such as a McAirlaid material, a meltspun nonwoven material, and/or a meltblown nonwoven material.

The paper weighs 25-65 g/m ² , such as 30-60 g/m ² , such as 30-50 g/m ² , such as 30-40 g/ ^{m 2 ,} such as 32-38 g/m ² , such as 33-37 g/m 2 m ² , for example 36 g/m ² .

Two or more sheets of filter material may be embossed.

The outer circumference of the filter element may be between 14 mm and 26 mm, for example between 16 mm and 26 mm.

The length of the filter element may be between 4.0 mm and 50 mm, for example between 5 mm and 32 mm. The filter element may be for use as part of a tobacco smoke filter or a filter for non-tobacco smokable materials, such as marijuana. The filter element of the invention may be incorporated into a multi-segment filter as a single segment. This allows an increase in the number of features that can be incorporated into the filter. For example, a filter element according to any of the above descriptions may be joined with further filter elements.

Filter elements of the present invention may be incorporated into smoking articles such as cigarettes, cigarillos, cigars, and the like. Filter elements of the invention may be incorporated into tobacco heating products or electronic cigarettes. The filter element may also be used alone or as part of a filter that is assembled by a user to form a smoking article, such as a hand-rolled smoking article.

In a further aspect of the invention there is provided a filter, for example a tobacco smoke filter, comprising a filter element according to any of the above. The filter, for example a tobacco smoke filter, may further comprise one or more further filter element(s). Such filters that include two or more filter elements are sometimes referred to as multi-segment filters.

The filter may include an outer wrapper, such as a plug wrap, surrounding the filter element or one or more filter elements. The wrapper may be paper, for example air permeable paper. The wrapper may have a basis weight of 20 to 100 grams per square meter, such as 20 to 50 grams per square meter. The wrapper may be coated. The further filter element may be wrapped by an outer wrapper, for example a plug wrap, surrounding the further filter element. A filter element defined according to any of the above descriptions and further filter elements may be wrapped together by an outer wrapper, such as a plug wrap. The outer wrapper may serve to join the filter elements and secure them in place.

In a further aspect of the invention there is provided a smoking article comprising a filter or filter element as described above. The smoking article can include a filter as described above joined to a wrapped rod of smoking material, such as tobacco smoking material. The smoking article may further include a tipping wrapper, such as tipping paper. The tipping wrapper joins the wrapped rod of smoking material to the filter by engaging around adjacent ends of the filter and the wrapped rod of smoking material. The chipping wrapper may be configured to leave a portion of the outer surface of the filter or filter wrapper exposed. Alternatively, the filter may be joined to the wrapped rod of smoking material by a full tipping wrapper that engages around the entire length of the filter or mouthpiece and adjacent ends of the rod of smoking material.

Filter elements, filters or smoking articles according to the invention may be unvented or may be pre-perforated or air-permeable filter wrappers (plug wraps) or chipped by methods well known in the art. Venting may be accomplished by the use of laser perforation of the wrapper (tipping paper) and/or filter wrapper and/or tipping wrapper. The mouthpiece, filter, filter element, or smoking article according to the invention comprises a laser in the longitudinally extending core of the filter material (and if present, the wrapper(s) (plug wrap) and the tipping wrapper (tipping paper)). Ventilation may also be provided by perforations. Air permeable full tipping wrappers (tipping papers) may likewise be inherently air permeable or may be equipped with ventilation holes, and are similar to filter wrappers (plug wraps) and tipping wrappers (tipping papers). For breathable products where both are present, venting through the tipping wrapper (tipping paper) usually coincides with venting through the filter wrapper (plug wrap). Vent holes through the filter wrapper (plug wrap) or through the tipping wrapper (tipping paper) or both simultaneously may be created by laser drilling during manufacture of the mouthpiece, filter or filter element.

In a further aspect of the invention there is provided a multiple rod comprising a plurality of filter elements according to the invention arranged end-to-end in mirror image relationship.

In a further aspect of the invention, an apparatus for manufacturing a filter element comprising: a separator for separating two or more longitudinally advancing sheets of filter material; and a separator for separating two or more longitudinally advancing sheets of filter material; a collection chamber configured to collect and form a rod of partially collected filter material, wherein the separator and the collection chamber are arranged longitudinally within the rod of partially collected filter material; a collection chamber coupled to the collection chamber configured to form a recess extending into the longitudinally extending recess; and an inserter configured to insert one or more additive release containers into the longitudinally extending recess; Equipped with

Preferably, the collection chamber is a hollow section configured to collect or condense filter material to form a longitudinally extending rod of filter material.

Preferably, the separator and the collection chamber are coupled such that the two or more longitudinally advancing sheets of filter material are separated before entering the collection chamber, and the separator is coupled so that the two or more sheets of longitudinally advancing filter material are separated before entering the collection chamber. complete collection of the sheets thereby forming a longitudinally extending recess in the partially collected filter material.

The collection chamber may include an inlet for receiving separated sheets of filter material and an outlet for exiting collected or partially collected filter material. Preferably, the collection chamber tapers longitudinally away from the inlet such that the inlet has a larger internal diameter than the outlet. The collection chamber is operative to collect (eg, condense) two or more sheets of filter material into a partially collected rod of filter material having a longitudinally extending recess.

Preferably, the separator may be longitudinally tapered. The separator may have a first end having a first diameter and a second end having a second diameter, the second diameter being smaller than the first diameter. The separator may extend into and along at least a portion of the length of the collection chamber. The first end of the separator may protrude from the collection chamber and the second end of the separator may be positioned inside the collection chamber. The separator may taper in the same direction as the collection chamber.

The separator may be substantially conical or frustoconical. The tapered shape of the separator is configured to separate two or more sheets of filter material while also facilitating partial collection of the sheets of filter material. The collection chamber may be tapered in the same direction as the separator, thereby partially collecting two or more sheets of filter material. Applicants have discovered that even at the narrowest point of the separator, the two or more sheets of filter material remain separated, and that after the sheets of filter material advance past the separator, the partially collected rods It has been found that a recess remains in the recess which can receive the or each additive release container.

Applicants have discovered that the separator and collection chamber configuration maintains alignment of two or more sheets of filter material. For example, vertical alignment of two or more sheets of filter material is maintained. Vertical alignment, as used herein, is perpendicular to the plane in which the sheet of filter material is longitudinally advanced and perpendicular to the plane that is transverse to the plane in which the sheet of filter material is longitudinally advanced. It means alignment within a certain plane. Applicants have discovered that maintaining alignment of two or more sheets of filter material while the filter material is collected results in a core of filter material with improved homogeneity and also aids in capsule placement. I found it. Applicants have discovered that the separator keeps the folds of the sheet material apart to allow the capsules to be centered in the partially collected filter material, thereby improving the positioning of the capsules. I found it.

The collection chamber may include an opening, eg, a longitudinally extending opening, for receiving an inserter. This configuration allows the inserter to insert one or more additive release containers into the recess formed in the partially collected rod of filter material. The collection chamber may be tapered from or after the opening to facilitate further collection of partially collected rods of filter material around the additive release container to create a recess. closed, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

The separator may extend into and along at least a portion of the length of the collection chamber, but the separator does not extend to the longitudinally extending opening. This configuration allows one or more additive release containers to be inserted into the recess.

In one embodiment, the device may include a prechamber including an inlet and an outlet, the prechamber tapering longitudinally away from the inlet. The inlet may have a larger inner diameter than the outlet.

The separator may be longitudinally tapered and extend into and along at least a portion of the length of the prechamber. The first end of the separator may protrude from the prechamber and the second end of the separator may be positioned inside the prechamber. The separator may be tapered in the same direction as the prechamber. The fact that the separator tapers in the same direction as the pre-chamber means that the separator can be placed partially inside the pre-chamber.

Applicant has found that the pre-chamber serves to partially collect the filter material before it enters the collection chamber.

In this embodiment, the collection chamber includes an inlet joined to the outlet of the reserve chamber, and the collection chamber includes an opening for receiving the inserter. The collection chamber may be longitudinally tapered from the end of the opening, thereby collecting two or more sheets of filter material around the additive release container to close the recess, thereby A continuous rod is formed with a longitudinally extending core of filter material and one or more additive release vessels.

The apparatus may include a cutter configured to cut a single sheet of filter material into two or more longitudinally extending sheets of filter material. The cutter may be configured to cut a single sheet of filter material into two, three, four, or more longitudinally extending sheets of filter material.

The inserter may include a rotating drum or wheel configured to insert the or each additive release container into the longitudinally extending recess.

The apparatus may include a rod cutter configured to cut a rod comprising a longitudinally extending core of filter material and one or more additive release containers to form a filter element.

The apparatus may include an embossing machine. The embossing machine may include a rotating drum (eg, an embossing roller) with protrusions (eg, spikes) extending away from the surface of the drum (eg, the surface of the embossing roller). The embossing machine can emboss two or more sheets of filter material. Applicants have discovered that embossing two or more sheets provides a filter element with the desired pressure drop and visual appearance of compact or dense ends.

The device may include a wrapping element for wrapping the advancing rod before it is cut.

The apparatus may include an additive applicator for applying additive to two or more sheets of filter material. The additive may be a taste modifier and/or a flavoring agent. Flavoring agents may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, and the like.

In a further aspect of the invention, there is provided an apparatus for separating and collecting two or more sheets of filter material, the collection chamber comprising an inlet and an outlet, the inlet being such that the collection chamber tapers longitudinally. a collection chamber having a diameter that is larger than the outlet; and a separator extending at least a portion of the path into the collection chamber and projecting from the inlet of the collection chamber, the separator and the collection chamber having a diameter larger than the outlet. Provided is an apparatus configured to separate and partially collect one or more sheets, thereby forming a partially collected longitudinally extending rod of filter material having a longitudinally extending recess. do.

The collection chamber may include an inlet for receiving separated sheets of filter material and an outlet for partially collected filter material to exit. The collection chamber is operative to collect (eg, condense) two or more sheets of filter material into a partially collected rod of filter material having a longitudinally extending recess.

The separator may taper in the same direction as the collection chamber.

The separator may be substantially conical or frustoconical. The tapered shape of the separator separates two or more sheets of filter material while also facilitating partial collection of the sheets of filter material. The collection chamber may be tapered in the same direction as the separator, thereby partially collecting two or more sheets of filter material. Applicants have discovered that even at the narrowest point of the separator, the two or more sheets of filter material remain separated, and that after the sheets of filter material advance past the separator, the partially collected rods It has been found that a recess remains in the recess which can receive the or each additive release container.

Applicants have discovered that the separator and collection chamber configuration maintains alignment of two or more sheets of filter material. For example, vertical alignment of two or more sheets of filter material is maintained. Vertical alignment, as used herein, is perpendicular to the plane in which the sheet of filter material is longitudinally advanced and perpendicular to the plane that is transverse to the plane in which the sheet of filter material is longitudinally advanced. It means alignment within a certain plane. Applicants have discovered that maintaining alignment of two or more sheets of filter material while the filter material is collected results in a core of filter material with improved homogeneity and also aids in capsule placement. I found it. Applicants have discovered that the separator keeps the folds of the sheet material apart to allow the capsules to be centered in the partially collected filter material, thereby improving the positioning of the capsules. I found it.

The collection chamber may include an opening, eg, a longitudinally extending opening, for receiving an inserter for inserting one or more additive release containers. This configuration allows the inserter to insert one or more additive release containers into the recess formed in the partially collected rod of filter material. The collection chamber may be tapered from or after the opening to facilitate further collection of partially collected rods of filter material around the additive release container to create a recess. closed, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

The separator may extend into and along at least a portion of the length of the collection chamber, but the separator does not extend to the longitudinally extending opening. This configuration allows one or more additive release containers to be inserted into the recess.

In one embodiment, the device may include a prechamber including an inlet and an outlet, the prechamber tapering longitudinally away from the inlet. The inlet may have a larger inner diameter than the outlet.

The separator may be longitudinally tapered and extend into and along at least a portion of the length of the prechamber. The first end of the separator may protrude from the prechamber and the second end of the separator may be positioned inside the prechamber. The separator may be tapered in the same direction as the prechamber. The fact that the separator tapers in the same direction as the pre-chamber means that the separator can be placed partially inside the pre-chamber.

Applicant has found that the pre-chamber serves to partially collect the filter material before it enters the collection chamber.

In this embodiment, the collection chamber includes an inlet joined to the outlet of the reserve chamber, and the collection chamber includes an opening for receiving the inserter. The collection chamber may taper longitudinally from or after the end of the opening, thereby allowing two or more sheets of filter material to be placed around the additive release container. The collection closes the recess, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

Apparatus for separating and collecting two or more sheets of filter material may be included as part of the apparatus for manufacturing filter elements.

The collection chamber is sometimes referred to as a collection shoe. The reserve chamber is sometimes referred to as a support shoe.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

1 is a schematic diagram of the method of the invention; FIG. 1 is a perspective view of a part of a device according to the invention; FIG. 1 is a side view of a part of the device according to the invention in use; FIG. 1 is a rear view of a part of the device according to the invention in use; FIG. FIG. 2 is a side view of a separator according to the invention. 1 is a perspective view of a filter element according to the invention; FIG. 1 is a cross-sectional view of a filter element according to the invention; FIG. 1 is a perspective view of an apparatus for separating and collecting two or more sheets of filter material; FIG.

FIG. 1 shows a schematic diagram of the process of the invention.

Filter material 104 is unwound from reel 102 and advanced in longitudinal direction L. The filter material is a pre-cut sheet of paper filter material that includes two individual sheets of paper filter material wound on the same reel 102. Each sheet has a width of 110 mm, a thickness of 85 μm, and a basis weight of 36 g/m ² . The two sheets 104 advance longitudinally in parallel together. The longitudinal edge of one sheet abuts the longitudinal edge of the other sheet. It will be appreciated that more than two sheets of filter material may be used, for example three or four or more longitudinally advancing sheets of filter material. It will be appreciated that more than one sheet of filter material may be formed as part of the method of the invention. For example, a single sheet of filter material may be longitudinally advanced and longitudinally cut into multiple sheets. It will be appreciated that non-woven sheet materials may also be used.

The advancing sheet of filter material 104 is embossed by an embossing machine 106. Embossing machine 106 includes a rotating roller with spikes projecting from the outer surface of the roller. The advancing sheet of filter material is drawn between a roller and a flat surface, or between a roller and a second smooth roller (shown in FIG. 1), and an embossing roller embosses the sheet of filter material. . Applicants have discovered that embossing sheets of filter material provides the desired pressure drop and provides a dense or compact visual edge appearance.

The embossed sheet of filter material is then advanced and flattened by wire 108. The flattened sheets of filter material are then separated by separators in the form of separator cones 110. The separated sheets of filter material pass through a pre-chamber 116 which collects the two sheets together so that when a recess is formed in the partially collected rod of filter material, the sheets remain separated. There is even. The partially collected rod of filter material is then passed through the collection chamber 122 and one or more capsules are inserted into the partially collected rod of filter material by a capsule inserter 130 comprising a rotating wheel. Insert into the recess. The rod is then further collected and condensed by the collection chamber 122, thereby closing the recess and forming the rod with a longitudinally extending core of the filter material and one or more additive release containers within the core of the filter material. Form.

The rod is advanced longitudinally and wrapped with an outer wrapper, such as plug wrap, to form a wrapped rod. The rod is wrapped with an outer wrapper using techniques known in the art. Finally, the wrapped rod is cut by a rod cutter 140 to form a filter element that includes a longitudinally extending core of filter material that includes one or more additive release containers disposed within the core of the filter material. do. The rod cutter is a standard rod cutter known in the art.

The collection and capsule insertion steps and apparatus will now be described in more detail with reference to FIGS. 2-4 and 8.

The two sheets are separated by a cone 110 before advancing the flattened tow 104 and entering the prechamber 116. Cone 110 includes a first end 112 and a second end 114. The first end has a wider diameter than the second end such that the cone tapers longitudinally from the first end to the second end. The cone is formed from metal.

As shown in FIGS. 3 and 4, cone 110 separates two sheets of filter material as they enter prechamber 116. As shown in FIGS.

Pre-chamber 116 includes an inlet 118 and an outlet 120. Inlet 118 has a larger diameter than outlet 120 such that prechamber 116 tapers longitudinally from inlet 118 to outlet 120. Cone 110 is partially positioned within prechamber 116 such that a portion of cone 110 protrudes from and away from an inlet 118 of prechamber 116. Pre-chamber 116 is made of metal.

Cone 110 is secured within prechamber 116 by mechanical supports. Before the sheets of filter material are drawn into prechamber 116, the sheets are separated by cone 110. As the sheets of filter material are drawn into the prechamber 116, the sheets remain separated by the cone 110, but as the filter material advances longitudinally, the gap between the sheets decreases as the diameter of the cone 110 decreases. . At the same time, the filter material is partially collected by the inner surface of the prechamber 116. As the diameter of prechamber 116 decreases, filter material collects and condenses to form a partially collected rod of filter material. Cone 110 prevents complete collection of filter material and forms a recess in the rod that is partially collected from filter material. Applicants have determined that the cone 110 holds the folds of the sheet material apart to allow the capsule to be centered in the partially collected filter material, thereby improving capsule positioning. I found out.

The partially collected rod of filter material is drawn into a collection chamber in the form of a collection shoe 122. Collection shoe 122 includes an inlet 124 and an outlet (not shown). The collection shoe inlet has a larger diameter than the collection shoe outlet. The cross-sectional diameter of the collection shoe initially remains constant in the first section 126. In the second section 127 of the collection shoe, the cross-sectional diameter decreases such that the second section 127 tapers longitudinally. Third section 128 has a constant cross-sectional diameter. It will be appreciated that the collection shoe may not include the third section 128. A longitudinally extending opening is positioned in the upper surface of the collection shoe that extends partially along the first section 126 and the second section 127 of the collection shoe. The opening is configured to receive a capsule inserter wheel 130.

Capsule inserter wheel 130 is fed by a hopper (not shown).

Capsule inserter wheels are known in the art. The capsule inserter wheel utilizes a vacuum and air jet system to collect and insert the capsules into the longitudinally extending recess. In such systems, a first wheel (not shown) includes a plurality of equally spaced grooves around its cylindrical surface. A hopper containing capsules discharges the capsules, which are collected by a groove in the first wheel. A vacuum pump applies suction to the grooves so that each groove collects a single capsule.

A second smaller wheel 130 is positioned below the first wheel. The second wheel 130 includes a plurality of equally spaced grooves around its cylindrical surface. The capsules collected by the first wheel are transferred to the second wheel 130. At the bottom of the travel path of a given groove on the first wheel, the suction applied to that groove stops and the capsule is transferred by gravity to the corresponding groove on the second wheel. The capsule is held within the groove of the second wheel 130 by suction applied by the vacuum pump. The bottom of second wheel 130 is positioned within the opening of collection shoe 122. At the bottom of the travel path of a given groove, the suction applied to that particular groove is stopped and replaced by a jet of air directed at the capsule, thereby ejecting the capsule into a longitudinally extending recess. .

Alternative capsule inserter wheels may be used, and alternative capsule inserter wheel configurations are described herein. The capsule inserter wheel has radially extending cylindrical recesses equally spaced around its cylindrical surface. The base of each recess is formed by the free end of the plunger or piston. Each piston is elastically biased radially toward the center of the wheel by a spring, but is movable radially outward against this spring bias, sweeping through the recess and thus its Make sure to drain the contents. Continuous movement of the piston or plunger as the wheel rotates clockwise is effected by a stationary cam surface that engages the radially inner end of the piston or plunger over a portion of its path of travel.

As the inserter wheel rotates, each recess is filled with individual frangible capsules from the hopper as the recesses pass around the top of their path of travel. A piston or plunger is actuated by a cam surface to empty the capsule from the inserter wheel recess into the longitudinally extending recess of the advancing rod of partially collected filter material at the bottom of the travel path of the recess. put in.

An opening in collection shoe 122 allows a capsule inserter wheel to extend into collection shoe 122, thereby inserting one or more capsules into a recess in the rod of partially collected filter material. . Since the rotational speed of the capsule inserter 130 and the longitudinal speed of the advancing rod of partially collected filter material are constant, the capsules are inserted into the rod of partially collected filter material at regular intervals. and positioned at regular intervals within the core of filter material. The presence of recesses in the partially collected rod of filter material aids in the placement of one or more capsules and improves their positioning within the finished filter element.

Following capsule insertion, the partially collected rod continues to advance longitudinally and is further collected by the wall of the collection shoe. As the inner diameter of the collection shoe decreases, the partially collected rod closes the recess, providing a longitudinally advancing rod comprising a longitudinally extending core of filter material and one or more capsules. further collected and condensed.

Further process steps are performed on the rod as described above with reference to FIG.

FIG. 8 shows an apparatus for separating and collecting two or more sheets of filter material. The device includes the same structure and components as described above with reference to FIGS. 2-4, but the device does not include a capsule inserter.

FIG. 5 shows a side view of cone 110. As shown in FIG. 5, the cone has a first end 112 having a larger diameter than a second end 114. As shown in FIG. A first section of the cone extending from the cone first end 112 has a constant diameter. A second section of the cone extends from the first section and decreases from a first end of the second section to a second end of the second section such that the second section tapers. It has a diameter. A final third section extends from the second end of the second section and includes a narrower, constant diameter.

FIG. 6 is a perspective view of a filter element according to the invention.

The filter element 200 shown in FIG. 6 comprises a longitudinally extending core 202 of filter material formed from two sheets of paper filter material having a basis weight of 36 g/m ² and a thickness of 85 μm, with each sheet has a width of 110 mm. Core 202 includes a capsule 204 centrally positioned within the core. The capsules are frangible capsules containing 2.5 g of menthol in an oil carrier. The diameter of the capsule is 3.35 mm. Filter element 200 also includes a paper plug wrap 206 that surrounds the core and is secured by overlapping and affixed seams, as is known in the art. The filter element has a circumference of 24 mm and a length of 27 mm.

FIG. 6 shows a perspective cross-sectional view of the filter element 200 shown in FIG. FIG. 6 shows the structure of a capsule 204 that includes a capsule shell 208 that includes gelatin and a liquid menthol flavoring solution 210 within the capsule shell. It will be appreciated that other flavoring agents may be included in capsule 204.

The filter elements shown in FIGS. 5 and 6 can be manufactured according to the method described above with reference to FIGS. 1-4.

The filter element 200 shown in FIGS. 5 and 6 can be joined to a wrapped tobacco rod (not shown) to form a filtered smoking article, such as a filtered cigarette. The filter element 200 may be joined to the wrapped tobacco rod by ring tipping paper, the tipping paper engaging only around the adjacent ends of the filter element and the wrapped tobacco rod, thereby Leave a portion of plug wrap 206 exposed. Alternatively, the filter may be joined by a full tipping overlap that engages around the entire length of the filter element and adjacent ends of the wrapped tobacco rod.

Claims (33)

A method of manufacturing a filter element, the method comprising:
longitudinally advancing two or more sheets of filter material;
separating said two or more longitudinally advancing sheets of filter material;
collecting the longitudinally advancing separated sheets of filter material to form a partially collected rod of filter material having a longitudinally extending recess;
inserting an additive release container into the longitudinally extending recess;
collecting the filter material around the additive release container to close the recess, thereby forming a rod comprising a longitudinally extending core of filter material and one or more additive release containers;
including methods. 2. The method of claim 1, wherein the two or more longitudinally advancing sheets of filter material are separated by a separator. The step of collecting the two or more separated longitudinally advancing sheets of filter material includes drawing the two or more separated longitudinally advancing sheets of filter material into a collection chamber. , the method according to claim 2. the separator is coupled to the collection chamber such that the two or more sheets of longitudinally advancing filter material are separated before entering the collection chamber; 4. The method of claim 3, wherein complete collection of the two or more sheets is prevented thereby forming a longitudinally extending recess in the partially collected filter material. The collection chamber comprises an inlet for receiving the separated sheets of filter material and an outlet for exiting the partially collected filter material, the collection chamber being elongated away from the inlet. 5. A method according to claim 3 or 4, tapering in the direction. A method according to any one of claims 3 to 5, wherein the separator is longitudinally tapered and/or extends into and along at least part of the length of the collection chamber. . A method according to any one of claims 4 to 6, wherein the separator is tapered in the same direction as the collection chamber. A method according to any one of claims 4 to 7, wherein the separated two or more longitudinally advancing sheets of filter material are drawn into a preliminary chamber before entering the collection chamber. The prechamber has an inlet and an outlet, the outlet of the prechamber is joined to the inlet of the collection chamber, and the separator is within and along at least a portion of the length of the prechamber. 9. The method of claim 8, further comprising: 10. A method according to claim 8 or 9, wherein the pre-chamber is longitudinally tapered away from the pre-chamber inlet. A method according to any preceding claim, wherein the additive release container is inserted into the longitudinally extending recess by an additive release container inserter. 12. The method of claim 11, wherein the additive release container inserter comprises a rotating drum or wheel. A method according to any preceding claim, wherein the two or more sheets of filter material are embossed. A method according to any one of claims 1 to 13, wherein the filter material comprises a non-woven material or paper. 15. The method according to any one of claims 1 to 14, comprising cutting the rod to form a filter element comprising a longitudinally extending core of filter material and one or more additive release containers. Method. 16. According to any one of claims 1 to 15, wherein the two or more sheets of longitudinally advancing filter material include two, three or four longitudinally advancing sheets of filter material. the method of. Filter element obtainable by the method according to any one of claims 1 to 16. A filter element comprising a longitudinally extending core of filter material and an additive release container enclosed within the longitudinally extending core of filter material, the filter element comprising:
A filter element, wherein the longitudinally extending core of filter material is formed from two or more sheets of filter material. 19. The filter element of claim 18, wherein the filter material comprises paper or nonwoven material. 19. A filter element according to claim 17 or 18, wherein the additive release container is a capsule. A filter comprising a filter element according to any one of claims 17 to 20. A smoking article comprising a filter element according to any one of claims 17 to 20 or a filter according to claim 21. An apparatus for manufacturing a filter element, comprising:
a separator for separating two or more longitudinally advancing sheets of filter material;
a collection chamber configured to collect the separated longitudinally advancing sheets of filter material to form a partially collected rod of filter material;
The separator is coupled to the collection chamber such that the separator and the collection chamber are configured to form a longitudinally extending recess within the rod of partially collected filter material. a chamber;
an inserter configured to insert one or more additive release containers into the longitudinally extending recess;
A device comprising: The collection chamber comprises an inlet for receiving the separated sheets of filter material and an outlet for exiting the partially collected filter material, the collection chamber being elongated away from the inlet. 24. The device of claim 23, tapering in the direction. 25. The apparatus of claim 23 or 24, wherein the separator is longitudinally tapered and extends into and along at least part of the length of the collection chamber. Apparatus according to any one of claims 23 to 25, wherein the separator is tapered in the same direction as the collection chamber. a prechamber including an inlet and an outlet, the outlet of the prechamber being joined to the inlet of the collection chamber, and the separator extending into and along a portion of the length of the prechamber; , a device according to any one of claims 23 to 26. 28. The apparatus of claim 27, wherein the prechamber is longitudinally tapered away from the inlet. Apparatus according to any one of claims 23 to 28, wherein the collection chamber comprises a longitudinally extending opening for receiving the inserter. the collection chamber collects the filter material around the additive release container to close the recess, thereby comprising a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers; 30. Apparatus according to any one of claims 23 to 29, configured to form a . Any one of claims 23 to 30, comprising a rod cutter configured to cut a rod comprising a longitudinally extending core of filter material and one or more additive release containers to form a filter element. Equipment described in Section. Apparatus according to any one of claims 23 to 31, wherein the inserter comprises a rotating drum or wheel configured to insert the or each additive release container into the longitudinally extending recess. An apparatus for separating and collecting two or more sheets of filter material, the apparatus comprising:
a collection chamber comprising an inlet and an outlet, the inlet having a larger diameter than the outlet such that the collection chamber tapers longitudinally;
a separator extending at least a portion of the path into the collection chamber and projecting from the inlet of the collection chamber;
The separator and the collection chamber separate and partially collect two or more sheets of filter material, thereby forming a partially collected longitudinal rod of filter material with a longitudinally extending recess. configured to form a
Device.