WO2012025723A1

WO2012025723A1 - Apparatus for making tobacco smoke filters and filter rods

Info

Publication number: WO2012025723A1
Application number: PCT/GB2011/001268
Authority: WO
Inventors: Ahmad Fashihul Lisan; Dyah Pp Wardhana
Original assignee: Filtrona International Limited
Priority date: 2010-08-26
Filing date: 2011-08-24
Publication date: 2012-03-01
Also published as: GB201014290D0; TW201215337A

Abstract

An apparatus for making tobacco smoke filter rods which include a continuous element (22) extending longitudinally of the rod, the apparatus comprising: a delivery device (24) for advancing a continuous element (22); and a gathering device (15) for gathering a longitudinally advancing filtering material (10) and condensing the gathering filtering material into rod form around the advancing continuous element (22); wherein the delivery device (24) comprises a delivery channel (26) through which the element (22) advances for delivery to the gathering device (15); and a smoke modifying agent applicator (41) for applying smoke modifying agent to the element (22) as it advances through the delivery channel (26) prior to delivery to the gathering device (15), the smoke modifying agent applicator (41) being oriented (e.g. substantially perpendicularly to the direction in which the filtering material is longitudinally advancing) to apply the smoke modifying agent substantially vertically to the element (22) as it advances through the channel (26).

Description

Apparatus for making tobacco smoke filters and filter rods

The present invention relates to apparatus and methods of making tobacco smoke filters and filter rods, in particular filters and filter rods which include a continuous element, for example a thread, tape or extruded element, for example a flavourant bearing element, extending longitudinally of a rod of tobacco smoke filtering material.

'Flavour Thread' cigarette filters are well known in the prior art. Such filters incorporate a thread or tape element, typically longitudinally aligned therein, the element carrying a smoke modifying agent such as a flavourant. These were originally proposed in US 4281671 , in which a cotton sewing thread was the preferred element. This document also disclosed how the thread could be coloured, e.g. with different colours denoting different flavours.

In recent years, there has been a growing commercial interest in the use of flavour thread filters with coloured threads. When a coloured thread is used, there is a greater need for the thread element to be precisely located in the centre of the (white) filter fibrous matrix. Various improvements have been suggested to the process of manufacturing flavour thread filters to try and ensure such central alignment, see for examples WO 03/082558, WO 09/127711 , WO 07/085830 and WO 08/016839. However, these apparatus have drawbacks. In WO 03/082558, for example, the flavour element delivery device is in a rather constricted position and must be oriented to achieve clearance from the rest of the machine, and that adjustment of the centering during a machine run may be difficult. In WO09/127711 , the flavour element delivery device may be positioned with reference to the tobacco smoke filtering material using a sliding plate. However, the sliding plate is inclined and true vertical adjustment of the thread, especially "in-line", during filter manufacture, is difficult. WO 07/085830 and WO 08/016839 do not provide high loading of flavour on the flavour element because the flavour is applied to the tobacco smoke filtering material (not the element) in a separate operation to introduction of the element. There is therefore a need for an apparatus and method which allows introduction of a flavour bearing element which allows ready and effective positioning and centralisation (especially vertically or substantially vertically) of the flavour bearing element, in real time during (for example in-line) production of tobacco smoke filter rods.

According to the present invention there is provided an apparatus for making tobacco smoke filter rods which include a continuous (e.g. smoke modifying agent bearing e.g. flavourant bearing) element extending longitudinally of the rod, the apparatus comprising:

a delivery device for advancing (e.g. delivering) a continuous element; and a gathering device for gathering a longitudinally advancing filtering material and condensing the gathering filtering material into rod form around the advancing continuous element;

wherein the delivery device comprises a delivery channel through which the element advances for delivery to the gathering device; and

a smoke modifying agent applicator for applying a smoke modifying agent (e.g. a flavourant) to the element as it advances through the delivery channel prior to delivery to the gathering device, the smoke modifying agent (e.g. flavourant) applicator being oriented (e.g. substantially perpendicularly to the direction in which the filtering material is longitudinally advancing) to apply the smoke modifying agent (e.g. flavourant) substantially vertically (for example, substantially vertically downwards) to the element as it advances through the channel. Preferably the smoke modifying agent is a flavourant.

The delivery device may further comprise an adjuster (e.g. adjuster mechanism) for adjusting the position of the delivery device and the element advancing there-through up and/or down, for example substantially vertically up and/or down, a substantially vertical axis with reference to the longitudinally advancing filtering material. For example, the adjuster (e.g. adjuster mechanism, e.g. vertical adjuster) may be for adjusting the position of the delivery device and the element advancing there-through up and/or down a substantially vertical axis in a plane which is substantially perpendicular to the direction in which the filtering material is longitudinally advancing. In a preferred example, the adjuster is engaged with or around the smoke modifying agent (e.g. flavourant) applicator so that the position of the delivery device and the element advancing there-through is adjusted (with reference to the longitudinally advancing filtering material) up and/or down, for example substantially vertically up and/or down, the substantially vertical axis of the smoke modifying agent (e.g. flavourant) applicator. Thus, the apparatus may provide adjustment of the position of the element within the product rod in the x axis, as discussed below.

The apparatus may include a lateral adjuster for adjusting the position of the delivery device and the element advancing there-through, with reference to the

longitudinally advancing filtering material, rotationally about the substantially vertical axis of the smoke modifying agent applicator. The lateral adjuster may be the same mechanism as the vertical adjuster, or different. Thus, the apparatus may provide adjustment of the position of the element within the product rod in the y axis, as discussed below.

The apparatus may provide introduction of a smoke modifying agent (e.g.

flavourant) bearing element with ready and effective positioning and centralisation

(especially vertically or substantially vertically) of the element. The apparatus may provide effective adjustment of positioning of the element in real time during (for example in-line) production of tobacco smoke filter rods (e.g. in the x and/or y axis of the cross section of the product filter rod). This provides a significant advantage (e.g. over known techniques) in that centering of the element in the product rod may be adjusted and therefore maintained during rod manufacture at high machine speeds, thereby reducing or removing the requirement to stop the manufacturing process to correct the fault if the element in the product rod moves off centre.

Herein, the term filter rod includes individual filters and individual filter elements, which are well known in the art. The term also includes double or higher multiple (usually quadruple or sextuple) length filters or double or higher multiple (usually quadruple or sextuple) length filter elements, as are also well known.

The (product) filter rod may be of circumference 14 to 28 mm, for example 16 to 26 mm, for example 16 to 19 mm (e.g. 17.5mm) or 16 to 17mm or 24 to 25 mm.

The filtering material [e.g. included in, for example, forming, the rod (for example substantially cylindrical rod)] may be for example any of those materials (usually

filamentary, fibrous, web or extruded) conventionally employed for tobacco smoke filter manufacture. The filtering material may be natural or synthetic filamentary tow, e.g. of cotton or plastics such as polyethylene or polypropylene, or cellulose acetate filamentary tow. It may be, for example, natural or synthetic staple fibres, cotton wool, web material such as paper (usually creped) and synthetic non-wovens, and extruded material (e.g. starch, synthetic foams). The tobacco smoke filtering material (e.g. cellulose acetate filamentary tow) may further comprise a plasticiser (e.g. triacetin). The amount of plasticiser may be from 4 to 15% by weight of the filtering material.

The continuous element extending longitudinally of the (product) rod may be cotton, rayon, cellulose acetate or other textile or non-textile material capable of absorbing a liquid smoke modifying agent (e.g. a liquid flavourant). The continuous element may be a thread or yarn of, for example, cotton, rayon, cellulose acetate or other textile or non-textile material capable of absorbing a liquid smoke modifying agent (e.g. a liquid flavourant). The continuous element extending longitudinally of the (product) rod may be a continuous extruded element. The continuous extruded element extending longitudinally of the rod may comprise a thermoplastic polymer, for example, cellulose acetate, polyethylene, polypropylene, polylactic acid, polyester or mixture thereof. Preferably, the continuous extruded element extending longitudinally of the rod comprises cellulose acetate. Methods of preparing extrusion grade cellulose acetate powder are known (e.g. see US 4228246). Extrusion-grade cellulose ester pellets are commercially available from Rotuba Extruders of Linden, New Jersey under the trade mark "Naturacell". The extrusion-grade cellulose ester pellets are converted into an extruded element for use according to the invention. The continuous extruded element extending longitudinally of the rod (for example comprising an extruded thermoplastic polymer e.g. extruded cellulose acetate) may further comprise a plasticiser (e.g. triacetin). The amount of plasticiser in the continuous extruded element may be from 7 to 42% by weight of the continuous extruded element, for example from 15.1 to 35% by weight of the continuous extruded element.

The continuous element extending longitudinally of the rod may be coloured or tinted using appropriate pigments, preferably those with regulatory approval for use in food contact applications. In an example, the continuous element extending longitudinally of the rod comprises a cotton thread or a thermoplastic polymer (e.g. cellulose acetate) and a pigment (e.g. coloured or tinted pigment). The pigment is preferably one with regulatory approval for use in food contact applications. The pigment may preferably be any colour which contrasts with the (e.g. white) tobacco smoke filtering material, for example green, blue, red, orange etc. A coloured element (or coloured elements if more than one is present, see below) may provide a distinctive end appearance that is useful for anti- counterfeit purposes.

The filter rod may include one or more continuous elements extending

longitudinally of the rod. One or more of the elements may include a smoke modifying agent (e.g. flavourant). The continuous elements may be the same, or different. If more than one continuous element is present they are preferably aligned in a symmetrical pattern. The use of more than one continuous element may provide a more distinctive end appearance and/or may provide increased capacity for loading of smoke modifying agent (e.g. flavourant). Further the provision of more than one continuous extruded element may advantageously facilitate a reduction in weight or cost of the other filter components.

Preferably the, or each, continuous element extending longitudinally of the rod is aligned substantially parallel to the longitudinal axis of the rod. The continuous element could be of constant cross-section along its length, or of variable cross-section along its length.

The smoke modifying agent (e.g. flavourant) applicator may apply any smoke modifying agent (e.g. flavourant) known or suitable for use in a smoking article such as a cigarette, for example menthol, spearmint etc. Preferably the smoke modifying agent is a flavourant. The flavourant may be any flavouring agent known for use in tobacco smoke filters or filter elements. For example, the flavouring agent may be menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla etc. A preferred smoke modifying agent (flavourant) is menthol.

The tobacco smoke filtering material may be over wrapped with a wrapper, for example a wrapper of paper, for example a wrapper of an air-permeable paper. The apparatus may further comprise a wrapping device for wrapping the tobacco smoke filter rods (e.g. the rods formed by gathering the longitudinally advancing filtering material and condensing the gathering filtering material into rod form around the advancing continuous element). Wrapping devices are well known in the art.

The apparatus may further comprise a cutting device for cutting the tobacco smoke filter rods (e.g. the rods formed by gathering the longitudinally advancing filtering material and condensing the gathering filtering material into rod form around the advancing continuous element). The filter rods are made as a continuous rod. The continuous rod as it issues continuously from the production machine outlet is cut into finite lengths for subsequent use. This cutting may be into individual filters or filter elements, each of which is then attached to an individual wrapped tobacco rod to form a filter cigarette. More usually, however the continuously issuing rod is first cut into double or higher multiple (usually quadruple or sextuple) lengths for subsequent use. When the initial cut is into quadruple or higher lengths, then the latter are subsequently cut into double lengths for the filter cigarette assembly - in which the double length filter rod is assembled and joined (by ring tipping or full tipping overwrap) between a pair of wrapped tobacco rods with the combination then being severed centrally to give two individual filter cigarettes. It is this final severing which, in examples of cigarettes including filters or filter elements made using the apparatus of the invention, may reveal the end of the distinctively coloured and/or shaped element. The apparatus may make (e.g. double and higher) multiple length filter rods (and/ or filter element rods), including a plurality of filter rods (filter element rods), e.g. joined end to end.

The present invention will now be illustrated with reference to the attached drawings in which:

FIGURE 1 is a perspective, part cut away, view of a tobacco smoke filter according to an aspect of the invention;

FIGURE 2 is a schematic side elevation view of an example of an apparatus for forming the filter of Fig 1 ;

FIGURE 3 is a cut-away view of elements of the apparatus of Fig 2; and

FIGURE 4 is a cross-section of the apparatus shown in Figs 2 and 3.

Figure 1 is a perspective, part cut away, view of a filter 1. Filter 1 includes a substantially cylindrical rod 2 of tobacco smoke filtering material in the form of a cylindrical cellulose acetate plug of length 27mm and circumference of around 25mm. The substantially cylindrical rod 2 is made from cellulose acetate tow which has been gathered and condensed into rod form by methods which are well known in the art (see e.g. below). Filter 1 includes a continuous element 7 extending longitudinally through rod 2, formed from a cotton thread. The continuous element 7 extends through the body of the rod 2 from one end of the filter to the other, thus presenting an end at each end of rod 2. The continuous element 7 has, applied thereon, a smoke modifying agent in the form of the flavourant menthol. The menthol is applied as discussed below. Filter 1 includes a paper wrapper 8 surrounding longitudinally extending core 2 which may be perforated (not shown) or air-permeable to provide a ventilated filter.

It will be appreciated that the filter of Figure 1 may be joined at its upstream end 9 to a wrapped tobacco rod (not shown) by means of, for example, a full tipping overwrap which surrounds and engages the full length of the filter 1 and the adjacent end only of the wrapped tobacco rod, to form a filter cigarette. The filter of Figure 1 may also be attached to a tobacco rod to form a filter cigarette by other means known in the art, such as ring tipping.

Figure 2 shows a schematic side elevation view of an apparatus of the invention, for forming filters according to Figure 1. A band of cellulose acetate tow 10 is drawn through funnel 15, which has an internal wall converging downstream. In passing through the funnel 15 the tow 10 is gathered and largely condensed therein. The tow 10 is further gathered and condensed into rod form as it enters and passes through a rod making and wrapping garniture 20. A continuous element 22 of cotton thread is drawn continuously from a reel (not shown) into a delivery device 24 which comprises a delivery channel in the form of a yarn tube 26 through which the element 22 advances from inlet end 30 to outlet 32 (see Fig 3) for delivery to the gathering device.

Figure 3 shows a cut-away view of elements of the delivery device 24 including the delivery channel, yarn tube 26, through which the element 22 advances from inlet end 30 to outlet 32 for delivery into the gathering device. As seen in Figures 2 and 3, element 22 advances through yarn tube 26 from the inlet end 30 to the outlet 32, passing under smoke modifying agent (e.g. flavourant) applicator 41. Applicator 41 includes a smoke modifying agent (e.g. flavourant) tube 42 through which a smoke modifying agent (e.g. flavourant) solution, here menthol flavour solution, is pumped substantially vertically downwards (that is, substantially perpendicularly to the direction in which the filtering material is

longitudinally advancing) to the yarn tube 26, The smoke modifying agent (e.g. flavourant) is applied to the element (thread) 22 in yarn tube 26, as the element 22 advances through the delivery channel (yarn tube 26) under tube 42 prior to delivery to the gathering device via outlet 32.

The element 22 (which now bears a menthol flavour) exits yarn tube 26 through outlet 32, and is drawn directly into engagement with the longitudinally advancing gathering (and largely condensed) tow in funnel 15. The element 22 travels with the tow to and through the rod making and wrapping garniture 20, where the tow 10 is further gathered and condensed into rod form around element 22 such that the element 22 is incorporated in a product continuous rod including a continuous element 22 extending longitudinally of the rod. On start up of the apparatus, the tow is threaded through the machine and funnel 15 into the garniture 20, and the free end of element 22 is threaded through tube 26 and stuck to the tow upstream of funnel 15. Thus, once the apparatus is started, the advancing tow continuously entrains the element 22 and draws it continuously from the reel through tube 26.

Wrapping paper 28 is drawn continuously from reel 30 and fed continuously into the garniture 20, the paper 28 and the tow incorporating the thread 22 being carried continuously through the garniture by endless conveyor belt 32. In the garniture 20, the tow is shaped to rod form, and the paper 28 is wrapped around and secured with a lapped and stuck seam; member 34 applies a line of adhesive to one edge of paper 28, before the overlapping edges are bought into engagement. The continuously produced wrapped rod 36 passes to a cutter 38 which severs the rod 36 into individual lengths 40 each of which include a continuous element 22. The lengths 40 may be single filter or filter elements, but, more usually, will be multiple double or higher multiple (usually quadruple or sextuple) lengths for subsequent use, as is well known.

The delivery device further comprises an adjuster mechanism for adjusting the position of the yarn tube 26 and the element 22 advancing there-through up and/or down a substantially vertical axis with reference to the longitudinally advancing filtering material (i.e. for adjustment of the position of the element within the product rod in the x axis). As can be seen in the embodiment of Figures 2, 3 and 4, the yarn tube 26 and smoke modifying agent (e.g. flavourant) tube 42 are both mounted on a mounting 100. The mounting 100 includes mounting pins 103 which engage with vertical slots 104 on a stand 102, so that the mounting 100 (and tubes 26 and 42 located thereon) can be moved move vertically up and down in relation to stand 102 by vertical movement of pins 103 within slots 104. As best seen in Fig 4 smoke modifying agent tube 42 passes through a vertical hole in stand 102, and includes an adjuster 50 engaged around tube 42. The adjuster 50 includes a first element which is connected to the smoke modifying agent (e.g. flavourant) tube 42, and a second element which is mounted to the stand 02. The first and second elements are engaged with each other such that operation [e.g. rotation e.g. mechanically, e.g. via a control device and a stepper motor, not shown] of the adjuster 50 moves the first and second elements in relation to each other, so that the smoke modifying agent (e.g. flavourant) tube 42, the mounting 100 (which is connected to tube 42) and the yarn tube 26 (which is connected to the mounting 100), move substantially vertically up and down in relation to the stand 02. Thus, operation of the adjuster 50 allows movement of smoke modifying agent (e.g. flavourant) tube 42 up and down through the hole in stand 102, thereby effecting movement of the mounting 100 vertically up and down in relation to the stand 102, which in turn effects vertical movement of the tube 26 located on the mounting 100 in a substantially vertical direction along the axis of smoke modifying agent (e.g.

flavourant) tube 42.

The mechanism thus allows adjustment of the delivery device and the element advancing there-through, with reference to the longitudinally advancing filtering material, up and/or down the substantially vertical axis of the smoke modifying agent (e.g. flavourant) applicator (i.e. up and/or down the vertical axis of tube 42). Adjustment of the delivery device 24 in this way allows adjustment of the element (thread) 22 passing through the outlet into engagement with the longitudinally advancing tow as it condenses into rod form, vertically up or down, thereby allowing effective adjustment and centering of the element in the (substantially) vertical direction (in the x axis) within the product filter rod.

The adjuster mechanism may also include a rotational adjuster 06 mounted on mounting 100 for adjustment of the flavour tube 26 clockwise and/or anticlockwise about the substantially vertical axis of smoke modifying agent (e.g. flavourant) tube 42.

Operation of the rotational adjustment mechanism (e.g. mechanically, e.g. via a control device and a stepper motor, not shown) moves the yarn tube 26 clockwise and/or anticlockwise around the vertical axis of tube 42. Adjustment in this way moves the outlet 32 of tube 26 substantially laterally from side to side within the longitudinally advancing tow as it condenses into rod form, thereby allowing effective adjustment and centering of the element in the (substantially) horizontal direction, (i.e. adjustment of the position of the element within the product rod in the y axis), within the product filter rod.

Claims

1. Apparatus for making tobacco smoke filter rods which include a continuous element extending longitudinally of the rod, the apparatus comprising:

a delivery device for advancing a continuous element; and

a gathering device for gathering a longitudinally advancing filtering material and condensing the gathering filtering material into rod form around the advancing continuous element;

a smoke modifying agent applicator for applying smoke modifying agent to the element as it advances through the delivery channel prior to delivery to the gathering device, the smoke modifying agent applicator being oriented (e.g. substantially

perpendicularly to the direction in which the filtering material is longitudinally advancing) to apply the smoke modifying agent substantially vertically to the element as it advances through the channel.

2. An apparatus according to claim 1 wherein the delivery device further comprises an adjuster for adjusting the position of the delivery device and the element advancing there- through, with reference to the longitudinally advancing filtering material, up and/or down a substantially vertical axis.

3. An apparatus according to claim 2 wherein the adjuster is engaged with or around the smoke modifying agent applicator so that the position of the delivery device and the element advancing there-through is adjusted up and/or down the substantially vertical axis of the smoke modifying agent applicator.

4. An apparatus according to claim 1 , 2 or 3 including a lateral adjuster for adjusting the position of the delivery device and the element advancing there-through, with reference to the longitudinally advancing filtering material, rotationally about the substantially vertical axis of the smoke modifying agent applicator.

5. An apparatus according to any preceding claim wherein the smoke modifying agent applicator is a flavourant applicator.

6. An apparatus substantially as hereinbefore described with reference to Figures 2, 3 and 4 appended hereto.

7. A tobacco smoke filter rod made using an apparatus according to any preceding claim.