WO2015014999A1

WO2015014999A1 - Tobacco smoke filter and method of production

Info

Publication number: WO2015014999A1
Application number: PCT/EP2014/066637
Authority: WO
Inventors: James Reed; Gary Fulcher
Original assignee: Essentra Filter Products Development Co. Pte. Ltd; Essentra Filter Products Limited
Priority date: 2013-08-02
Filing date: 2014-08-01
Publication date: 2015-02-05
Also published as: GB201313845D0; AU2014298369B2; EP3027069A1; EP3027069B1; AU2014298369A1

Abstract

A product rod (1) comprising a plurality of individual tobacco smoke filters or filter elements (3) abutted end to end; and a wrapper (5) engaged around the plurality of filters or filter elements (3), the wrapper (5) including a, or at least one, line (7) formed in but not through the wrapper (5).

Description

TOBACCO SMOKE FILTER AND METHOD OF PRODUCTION

The present invention relates to tobacco smoke filters or filter elements and methods of their production.

Non-Wrapped Acetate (NWA) filters are well-known in the art. Typically, NWA filters comprise a self-sustaining body of continuous crimped cellulose acetate filaments bonded at their points of contact. NWA filters are characterized from conventional cigarette filters because the former do not require a separate plugwrap to wrap the filter and hold the fibrous bundle in place with a controlled circumference. NWA filters may be manufactured by a process similar to that described in UK Patent No. 1 169932 (US3,455,766). NWA filters may be sold as Pop-a-Tip™ filters for Roll-Your-Own (RYO) Smokers; they are well known and available from Filtrona Filters. Pop-a-Tip filters comprise a series of NWA filters (filter tips) wrapped in a transparent film e.g. made of BOPP or cellophane - e.g. six 14mm filters contained in a Pop-a-Tip rod of 84mm length. The NWA filters are individually pushed (or 'popped') out of the transparent wrap by smokers of RYO products, who then use the filter when rolling their cigarette. NWA filters are preferred over more conventional wrapped acetate (WA) filters, because it is much more difficult to 'pop' a WA filter from the transparent film due to increased frictional forces. However, the product can be tricky to use as a certain amount of dexterity is required to push the filter tips out from the surrounding film (e.g. some bending and flexing of the Pop-a-Tip may be necessary). In addition, the empty film-wrap needs to be separately discarded, creating a potential additional littering problem.

It is, of course, possible, for RYO smokers to buy loose individual tips and these are typically supplied in plastic bags. Such bags of tips are inconvenient for smokers to carry around; a further advantage of Pop-a-Tips is that they are of similar dimensions to a cigarette and can be packaged and sold in a packs that are much easier for the consumer to carry (e.g. similar to a cigarette pack).

Accordingly, it would be desirable to have a product that resembles a 'Pop-a-Tip' and can be packaged in a similar way; from which individual filters are more readily and easily extractable by the consumer; and which does not have the attendant expense and littering associated with the transparent overwrap. The present invention achieves these objectives.

According to the present invention in a first aspect there is provided a product rod comprising a plurality (e.g. two or more, e.g. 4-6) of individual tobacco smoke filters or filter elements abutted end to end; and a (common) wrapper engaged around the plurality of filters or filter elements, the wrapper including a (or at least one) line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a or at least one line scored into or impressed into (but not through) the wrapper). The individual tobacco smoke filters (or individual tobacco smoke filter elements) are preferably (substantially) identical (with each other). In other words, the product rod preferably comprises a plurality (e.g. two or more, e.g. 4-6) of individual identical tobacco smoke filters or individual identical filter elements abutted end to end; and a (common) wrapper engaged around the plurality of filters or filter elements, the wrapper including a (or at least one) line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a or at least one line scored into or impressed into (but not through) the wrapper).

According to the invention in a further aspect there is provided a product rod comprising a plurality (e.g. two or more, e.g. 4-6) of individual tobacco smoke filters or filter elements abutted end to end; and a (common) wrapper engaged around the plurality of filters or filter elements, the wrapper including a line (e.g. a line of weakness) substantially in register with (e.g. in register with, or within 3mm of) the or each junction between abutted filters or filter elements (that is, substantially in register with (e.g. in register with, or within 3mm of) each region where adjacent filters or filter elements abut each other), the or each line being formed in but not through the wrapper [e.g. scored into or impressed into (but not through) the wrapper)]. The individual tobacco smoke filters (or individual tobacco smoke filter elements) are preferably (substantially) identical (with each other). In other words, the product rod preferably comprises a plurality (e.g. two or more, e.g. 4-6) of individual identical tobacco smoke filters or individual identical filter elements abutted end to end; and a (common) wrapper engaged around the plurality of filters or filter elements, the wrapper including a line (e.g. a line of weakness) substantially in register with (e.g. in register with, or within 3mm of) the or each junction between abutted filters or filter elements (that is, substantially in register with (e.g. in register with, or within 3mm of) each region where adjacent filters or filter elements abut each other), the or each line being formed in but not through the wrapper [e.g. scored into or impressed into (but not through) the wrapper)].

In examples, the product may include more than one line (e.g. more than one line of weakness) substantially in register with (e.g. in register with, or within 3mm of) the or each junction between abutted filters or filter elements (that is, more than one line substantially in register with (e.g. in register with, or within 3mm of) each region where adjacent filters or filter elements abut each other), these lines being formed in but not through the wrapper [e.g. scored into or impressed into (but not through) the wrapper)]. In these examples the lines around a junction will be closely spaced, but may be of diiferent widdths and/or different separations.

Herein, the term identical means the same (equal, alike); in other words each individual filter has such a close similarity or resemblance to the others as to be essentially equal or interchangeable.

It will be appreciated that each (individual) filter may include more than one filter element. Thus, each (individual) filter may be a dual or triple filter, as is well known in the art.

The wrapper may be a paper (e.g. a plugwrap) or other sheet material. The paper may be a paper having basis weight of 20-140gsm, preferably 20-to 80gsm, more preferably 50 to 70gsm, for example 60gsm. The paper may be air permeable, or impermeable. The wrapper may be a cellulosic film or a cellulosic based film. The wrapper may be biodegradable. Preferably the wrapper has the 'Ready Biodegradability' level of biodegradability as measured according to OECD 301 B 'Ready Biodegradability' method (modified Sturm test), which is well known in the art. The applicants have found that scoring works better when the common product wrapper is a thicker or heavier-weight paper of basis weight above 50 gsm, e.g. 50 to 70 gsm (with the additional advantage that the heavier weight paper also provides a better 'quality' feel to the product). However, a paper of basis weight from 20 to 80 gsm offers a good compromise between ease of manufacture and cost. Forming the line (of weakness) in but not through the wrapper, e.g. by scoring the paper, may be carried out either before (to the wrapper) or after the product is assembled (after the wrapper has been engaged around the filters/filter elements) (i.e. in-line). The product may therefore be assembled at high speed using convention cigarette filter making machinery, which is a significant benefit.

The or each line (e.g. a line of weakness) formed (e.g. scored) in but not through the wrapper may be a continuous line or a discontinuous line. A continuous line is preferred. Preferably, the line is a continuous scored line (although the line may be a discontinuous scored line).

The product rod of the invention allows the smoker to easily pull or bend the product rod at each join (junction between abutted filters) to snap off individual filters/elements. The line formed (impressed, scored) in but not through the wrapper substantially in register with each junction between abutted filters/elements allows a clean break (in the wrapper) between abutting filters/elements to be achieved; a jagged break would be unsightly and unacceptable to the consumer. The (outer) wrapper of the snapped-off filter forms part of the filter tip to be used, rather than becoming redundant (as in the case of conventional Pop-a-Tips). Both WA (wrapped acetate) and NWA filters can be used in this product, increasing flexibility for the filter manufacturer.

Herein, the phrase "formed (or impressed, or scored) in but not through the wrapper" means that the line (e.g. of weakness) does not cut completely through the wrapper. Thus, for example, a perforation or line of perforations is not "formed in but not through the wrapper" (because perforation(s) are holes which extend through the wrapper).

The (or each) line formed (impressed, scored) in but not through the wrapper may be made by any means known in the art, e.g. knife (e.g. rotary knife), folding or other mechanical means. Preferably, the line formed (impressed, scored) in but not through the wrapper is visible to the naked eye (e.g sufficiently large that the consumer can see the line on the outside of the product rod, enabling him or her to clearly identify the point at which the rod should be snapped). The line formed (impressed, scored) in but not through the wrapper may be 0.01 to 0.5 mm wide, preferably 0.01 to 0.1 mm wide. The applicants have found that a line of this width may give a good visual cue, and provides optimum 'snap' characteristics. A narrower line may give an uneven or poor 'snap', whilst a wider line can result in the paper wrapper being too weak to be processed on conventional filter making and/or packaging machinery.

The product may include a further printed line (e.g. of contrasting colour to the (common) wrapper) on or in the vicinity of the line which is formed in (scored) but not through the wrapper. Such a printed line may give an additional visual cue as to where the product should be bent or snapped to release a filter.

According to the present invention in a still further aspect there is provided a product rod comprising a plurality of (e.g. two or more, e.g. 4 to 6) individual tobacco smoke filters or filter elements abutted end to end; and a (common) wrapper engaged around the plurality of filters or filter elements, the wrapper including a line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a line scored into or impressed into (but not through) the wrapper), the line extending from one end of the product rod to the other end and defining a helix about the periphery (outer surface) of the product rod. In this aspect the consumer peels back a strip along the helical line to allow filters/filter elements to be sequentially released for use, the remaining wrapper holding the remaining filters in place. The individual tobacco smoke filters (or individual tobacco smoke filter elements) are preferably (substantially) identical (with each other). In other words, the product rod preferably comprises a plurality (e.g. two or more, e.g. 4-6) of individual identical tobacco smoke filters or individual identical filter elements abutted end to end; and a (common) wrapper engaged around the plurality of filters or filter elements, the wrapper including a line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a line scored into or impressed into (but not through) the wrapper), the line extending from one end of the product rod to the other end and defining a helix about the periphery (outer surface) of the product rod. In a preferred example, the pitch of the helix defined by the line (e.g. line of weakness) formed in but not through the wrapper (that is the distance along the helical axis that results in one full turn of the helix) is the length of a single individual filter or filter element. In this example, peeling back the strip along the line for a single turn of the helix releases a single filter/filter element. The line formed (impressed, scored) in but not through the wrapper may be made by any means known in the art, e.g. knife (e.g. rotary knife), folding or other mechanical means. Preferably, the line formed (impressed, scored) in but not through the wrapper is visible to the naked eye (e.g sufficiently large that the consumer can see the line on the outside of the product rod, enabling him or her to clearly identify the point at which the rod should be snapped). The line formed (impressed, scored) in but not through the wrapper may be 0.01 to 0.5 mm wide, preferably 0.01 to 0.1 mm wide.

The line (e.g. a line of weakness) formed (e.g. scored) in but not through the wrapper may be a continuous line or a discontinuous line. A continuous line is preferred. Preferably, the line is a continuous scored line (although the line may be a discontinuous scored line).

The wrapper may be a paper (e.g. a plugwrap) or other sheet material. The paper may be a paper having basis weight of 20-140gsm, preferably 20-to 80gsm, more preferably 50 to 70gsm, for example 60gsm. The paper may be air permeable, or impermeable. The wrapper may be a cellulosic film or a cellulosic based film. The wrapper may be biodegradable. Preferably the wrapper has the 'Ready Biodegradability' level of biodegradability as measured according to OECD 301 B 'Ready Biodegradability' method (modified Sturm test), which is well known in the art.

The individual (e.g. identical or substantially identical) filters or filter elements may include a substantially cylindrical core of tobacco smoke filtering material. The tobacco smoke filtering material 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 filtering material may be paper (e.g. bleached or unbleached paper). The individual filter or filter element may further comprise a further wrapper. The further wrapper may be a paper (e.g. plugwrap). The (individual) (e.g. identical or substantially identical) filters or filter elements may comprise a self-sustaining (longitudinally extending) cylindrical core. Herein, the term "self- sustaining" (as in "self-sustaining substantially cylindrical core", "self-sustaining longitudinally extending substantially cylindrical core" etc.) means stable, rigid and self- supporting without requirement for a further wrapper (of e.g. plugwrap) to maintain its shape (e.g without requirement for a wrapper to hold the longitudinally extending continuous filaments in alignment to control the radius or circumference of the core).

The (individual) (e.g. identical or substantially identical) filters or filter elements may comprise a self-sustaining (longitudinally extending) cylindrical core comprising (e.g. formed from) a plurality of longitudinally extending substantially continuous filaments of tobacco smoke filtering material (e.g. cellulose acetate tow) which are bonded at their points of contact. In another example, the filters or filter elements may comprise a self- sustaining (longitudinally extending) cylindrical core comprising (e.g. formed from) a plurality of randomly oriented (e.g. individual or staple) fibres of tobacco smoke filtering material (e.g. cellulose acetate) which are bonded at their points of contact. Preferably the continuous filaments of tobacco smoke filtering material (or randomly oriented fibres of tobacco smoke filtering material) are continuous filaments (or randomly oriented fibres) of cellulose acetate tow. Preferably the tobacco smoke filtering material (e.g. cellulose acetate, cellulose acetate fibres or filaments) is crimped. Preferably the filaments (or fibres) are bonded at their points of contact with a bonding constituent, e.g. a plasticiser (e.g. a plasticiser which has been activated or cured to bond the filaments at their points of contact). The self-sustaining longitudinally extending cylindrical core may be, for example, a cylindrical rod of circular cross section. The self-sustaining longitudinally extending cylindrical core may be of other shape, for example the self-sustaining longitudinally extending cylindrical core may be of annular cross section such that the self- sustaining longitudinally extending cylindrical core is a longitudinally extending hollow tube comprising (e.g. formed from) fibres or filaments of tobacco smoke filtering material bonded at their points of contact. The individual (e.g. identical or substantially identical) filters and/or filter elements may further comprise one or more continuous components extending substantially longitudinally (e.g. longitudinally) of the cylindrical core. The (or a, or each) continuous component may be a thread or yarn or tape or continuous extruded element, for example a cotton thread, a cellulose acetate yarn, or a continuous extruded element of e.g. cellulose acetate such as that disclosed in WO201 1/058319. Cigarette filters which include a thread or tape element, typically longitudinally aligned therein, are well known in the prior art. They are often referred to as "Thread Filters". Thread Filters were originally proposed in US 4281671 , in which a cotton sewing thread was the preferred element. US 4281671 also disclosed how the thread could be coloured, e.g. with different colours denoting different flavours. US 4281671 discloses Thread Filters which require a wrapper around the tobacco smoke filtering material (and thread); it does not disclose filters or filter elements which include a thread but which are self sustaining (i.e. stable, rigid and self-supporting without requirement for a further wrapper).

The (or a, or each) continuous component extending longitudinally of the cylindrical core may be coloured or tinted, e.g. using appropriate dyes or pigments, preferably those with regulatory approval for use in food contact applications. The (or a, or each) continuous component may be of a contrasting colour to the tobacco smoke filtering material. In an example, the (or a, or each) continuous component further comprises a dye or pigment (e.g a dye or pigment which has regulatory approval for use in food contact applications). The dye or pigment may preferably be any colour which contrasts with the (e.g. white) tobacco smoke filtering material, for example green, blue, red, orange etc. If two or more continuous components extending substantially longitudinally (e.g. longitudinally) of the cylindrical core are present, the first continuous component may be of the same colour, or a different colour, to the second continuous component. The use of coloured component(s) (e.g. coloured cotton thread or threads) provides a product filter, element or rod with a distinctive end appearance that is useful for anti-counterfeit purposes.

The common wrapper may be coloured or tinted, e.g. using appropriate dyes or pigments, preferably those with regulatory approval for use in food contact applications. The common wrapper may be of a contrasting colour to the tobacco smoke filtering material of the filters/filter elements.

The filtering material of the filters/filter elements may be coloured or tinted, e.g. using appropriate dyes or pigments, preferably those with regulatory approval for use in food contact applications. The filtering material of the filters/filter elements may be of a contrasting colour to the common wrapper.

The continuous component may bear a smoke modifying agent such as a flavouring agent. The flavouring agent 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. The agent may contain nicotine or a salt or derivative thereof. Preferably the flavouring agent is menthol. The individual (e.g. identical or substantially identical) filters or filter elements may include an additive (e.g. an adsorbent). The additive may be a particulate additive. The particulate additive may any particulate additive suitable for use in a tobacco smoke filter - e.g. activated carbon, zeolite, ion exchange resin (e.g. a weakly basic anion exchange resin), sepiolite, silica gel, alumina, molecular sieves, carbonaceous polymer resins and diatomaceous earths. The particulate additive may be a mixture of two, or more, materials. The additive may include a flavourant - e.g. menthol - e.g. the additive may be sepiolite granules to which menthol has been applied. The individual (e.g. identical or substantially identical) filters or filters element may comprise a longitudinally extending core of tobacco smoke filtering material and an additive (e.g. carbon) with at least one end free of additive (to present a clean end to the smoker). The individual filters or filters element may be 'monocarbon' filters or filter elements - i.e. a filters/elements including a single longitudinally extending core of filtering material and additive (e.g. carbon) that has at least one end free of additive and e.g. which can be manufactured in a one-pass process (e.g. the 'Active Patch' filter, as disclosed in, for example, GB 2261 152, and the 'Smooth Core' filter, as disclosed in, for example, WO 2006/059134). The individual (e.g. identical or substantially identical) filters may comprise: a downstream (e.g. longitudinally extending, e.g. substantially cylindrical) core of tobacco smoke filtering material; an upstream (e.g. longitudinally extending, e.g. substantially cylindrical) core of tobacco smoke filtering material spaced longitudinally (upstream) of the downstream core; a wrapper (e.g. an outer wrapper) engaged around and joining the spaced upstream and downstream cores to define a cavity between the spaced upstream and downstream cores. The filter may include an additive in the cavity such that the individual filters are triple granular filters. The tobacco smoke filter or filter element 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 24 to 25 mm. A tobacco smoke filter of the invention may be of length 10 to 40 mm, e.g. 1 1 to 25 mm, e.g. 12 to 16 mm, e.g. 14mm. A tobacco smoke filter element of the invention may be of length 5 to 30mm, e.g. 6 to 20mm, e.g. 8 to 15 mm, e.g. 10 to 12 mm.

Filters and filter elements from product rods according to all aspects of the invention may be used generally as (or in) a filter tip for use with a individually rolled cigarette (e.g. a hand rolled cigarette) or a Roll Your Own or Make-Your-Own product.

According to the present invention in a further aspect there is provided a method of producing a product rod comprising a plurality (e.g 2 or more, e.g. 4 to 6) of individual (e.g. identical or substantially identical) tobacco smoke filters or filter elements abutted end to end, and a wrapper engaged around the plurality of filters or filter elements, wherein the wrapper includes a or at least one line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a line scored into or impressed into (but not through) the wrapper); the method comprising:

applying a wrapper to a longitudinally advancing flow comprising pluralities

(groups) of individual (e.g. identical or substantially identical) filters or filter elements arranged between (e.g. pre-formed) dual filter rods, each dual filter rod comprising two (e.g. identical or substantially identical) filters/elements joined end to end, wherein the filters/filter elements and filter rods are abutted end to end [to thereby form a continuous wrapped rod comprising pluralities (groups) of abutted filters or filter elements arranged between (and abutted to) dual filter rods];

cutting the continuous wrapped rod in register with the dual filter rods such that the dual filter rod is cut into two individual filters/filter elements, to thereby provide a plurality of product rods each comprising (e.g. identical or substantially identical) filters or filter elements; forming the or each line (e.g. line of weakness) in but not through the wrapper [e.g. by scoring or impressing the line into but not through the wrapper (e.g. with a rotary knife)].

The wrapper may be a paper (e.g. a plugwrap) or other sheet material. The paper may be a paper having basis weight of 20-140gsm, preferably 20-to 80gsm, more preferably 50 to 70gsm, for example 60gsm. The paper may be air permeable, or impermeable. The wrapper may be a cellulosic film or a cellulosic based film. The wrapper may be biodegradable. Preferably the wrapper has the 'Ready Biodegradability' level of biodegradability as measured according to OECD 301 B 'Ready Biodegradability' method (modified Sturm test), which is well known in the art. The or each line (e.g. the line of weakness) may be substantially in register with (e.g. in register with, or within 3mm of) the or each junction between abutted filters or filter elements. The line (e.g. the line of weakness) may extend from one end of the product rod to the other end and define a helix about the periphery (outer surface) of the product rod. The or each line (e.g. the line of weakness) formed (impressed, scored) in but not through the wrapper may be made by any means known in the art, e.g. knife, folding or other mechanical means. Preferably, the line formed (impressed, scored) in but not through the wrapper is visible to the naked eye (e.g sufficiently large that the consumer can see the line on the outside of the product rod, enabling him or her to clearly identify the point at which the rod should be snapped). The line formed (impressed, scored) in but not through the wrapper may be 0.01 to 0.5 mm wide, preferably 0.01 to 0.1 mm wide.

The product may include a further printed line (e.g. of contrasting colour to the (common) wrapper) on or in the vicinity of the line which is formed in (scored) but not through the wrapper. Such a printed line may give an additional visual cue as to where the product should be bent or snapped to release a filter. The or each line (e.g. a line of weakness) formed (e.g. scored) in but not through the wrapper may be a continuous line or a discontinuous line. A continuous line is preferred. Preferably, the line is a continuous scored line (although the line may be a discontinuous scored line).

According to the present invention in a still further aspect there is provided a method of producing a product rod comprising a plurality (e.g 2 or more, e.g. 4 to 6) of individual (e.g. identical or substantially identical) tobacco smoke filters or filter elements abutted end to end, and a wrapper engaged around the plurality of filters or filter elements, wherein the wrapper includes a or at least one line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a line scored into or impressed into (but not through) the wrapper); the method comprising:

applying a wrapper which includes a or at least one line (e.g. a line of weakness) formed in but not through the wrapper (e.g. a line scored into or impressed into (but not through) the wrapper) to a longitudinally advancing flow comprising pluralities (groups) of individual (e.g. identical or substantially identical) filters or filter elements arranged between (e.g. pre-formed) dual filter rods, each dual filter rod comprising two (e.g. identical or substantially identical) filters/elements joined end to end, wherein the filters/filter elements and filter rods are abutted end to end [to thereby form a continuous wrapped rod comprising pluralities (groups) of abutted filters or filter elements arranged between (and abutted to) dual filter rods];

cutting the continuous wrapped rod in register with the dual filter rods such that the dual filter rod is cut into individual (e.g. identical or substantially identical) filters/filter elements, to thereby provide a plurality of product rods each comprising filters or filter elements.

The lines (e.g. the lines of weakness) formed in but not through the wrapper may be preformed (e.g. by scoring or impressing/embossing the wrapper) in the wrapper such that there is a line substantially in register with (e.g. in register with, or within 3mm of) the or each junction between abutted filters/filter elements/dual filter rods [e.g. to form a line substantially in register with (e.g. in register with, or within 3mm of) the or each junction between abutted filters or filter elements in the final product rod]. The lines (e.g. the lines of weakness) formed in but not through the wrapper may be preformed (e.g. by scoring or impressing/embossing the wrapper) in the wrapper as lines aligned across the width of the wrapper, each line being separated from the adjacent line by a distance corresponding to the length of a single filter/filter element. In the case, the method may include a step of substantially aligning/registering the lateral lines (e.g. the lines of weakness) formed in but not through the wrapper with the junctions between abutted filters/filter elements (e.g. prior to or during wrapping). In another example the method includes a step of generating - e.g. with a knife - (lateral) lines (e.g. the lines of weakness) formed in but not through the wrapper across the width of the wrapper prior to, preferably immediately prior to, application of the wrapper. The lines (e.g. the lines of weakness) formed (impressed, scored) in but not through the wrapper may be made by any means known in the art, e.g. knife, folding or other mechanical means. Preferably, the lines formed (impressed, scored) in but not through the wrapper are visible to the naked eye (e.g sufficiently large that the consumer can see the line on the outside of the product rod, enabling him or her to clearly identify the point at which the rod should be snapped). The line formed (impressed, scored) in but not through the wrapper may be 0.01 to 0.5 mm wide, preferably 0.01 to 0.1 mm wide.

The or each line (e.g. a line of weakness) formed (e.g. scored) in but not through the wrapper may be a continuous line or a discontinuous line. A continuous line is preferred. Preferably, the line is a continuous scored line (although the line may be a discontinuous scored line). The lines (e.g. the lines of weakness) formed in but not through the wrapper may be preformed (e.g. by scoring or impressing/embossing the wrapper) in the wrapper such that it (the line) extends from one end of the product rod to the other end and defines a helix about the periphery of the product rod. The wrapper may be a cellulosic film or a cellulosic based film. The wrapper may be biodegradable. Preferably the wrapper has the 'Ready Biodegradability' level of biodegradability as measured according to OECD 301 B 'Ready Biodegradability' method (modified Sturm test), which is well known in the art.

Preferably the wrapper is a paper (e.g. plugwrap). The (e.g. individual e.g. pre-formed) filters and/or (e.g. individual e.g. pre-formed) filter elements in the flow (of filters or filter elements) are preferably aligned such that the longitudinally axes of their cylindrical cores are oriented along the longitudinal direction of the flow.

The invention includes any filter cigarette made using a filter according to the invention. The present invention will now be illustrated with reference to the following Examples and the attached drawings in which FIGURE 1 schematically illustrates a product rod of filters according to an embodiment of the invention; FIGURE 2 is a different view of the product rod of filters of Figure 1 ; FIGURE 3 schematically illustrates a method and apparatus which may be used to manufacture the product of e.g. Figures 1 and 2; and FIGURE 4 illustrates a product rod of filters according to a further embodiment of the invention.

Figures 1 and 2 show a NWA product rod 1 according to one embodiment of the invention.

The product rod 1 comprises six individual tobacco smoke filters 3 each of around 17.5 mm circumference and length 14mm abutted end to end. The individual tobacco smoke filters 3 are identical with each other. Each filter 3 includes a self-sustaining substantially cylindrical core formed from a plurality of longitudinally extending substantially continuous filaments of crimped cellulose acetate tow which are bonded at their points of contact (i.e. each filter 3 is a NWA filter). The product rod 1 also includes a wrapper 5 comprising paper of basis weight 60 gsm which is engaged around the filters 3 thereby forming a wrapped cylinder of six filter elements of length 84mm. As is best seen in Figure 2, the wrapper includes five continuous lines 7, each line being formed in but not through the wrapper; in this example the lines have been scored into (but not through) the wrapper using a knife. Each line 7 is approximately 0.1 mm wide, and is visible to the naked eye. Each line 7 is in register with a junction between two abutted filters 3 (in other words, in register with each region where adjacent filters or filter elements abut each other).

In use the smoker takes product rod 1 and pulls or bends the rod at the join closest to one end of the product rod (indicated by the line 7 closest to the end) to snap off an individual filter [the rod 1 snaps along the line (of weakness) 7]; the filter is then used when rolling a RYO cigarette. The lines 7 are sufficiently wide (i.e. in the longitudinal direction of the rod), and extends around the rod, so the consumer can see the lines 7 on the outside of the finished rod 3, enabling him to clearly identify the point at which the rod should be snapped. The scored lines 7 formed in but not through the wrapper enable a clean break between adjoining tips to be achieved - a jagged break would be unsightly and unacceptable to the consumer. The section of the outer wrapper 5 around the individual filter is retained and forms part of the filter to be used, rather than becoming redundant (and discarded) in the case of conventional Pop-a-Tips.

Figure 3 shows a method and apparatus according to a further embodiment of the invention which may be used to manufacture the product of Figures 1 and 2. As can be seen in Figure 3 a flow of pre-formed filters 103 and pre-formed dual filter rods 103a is longitudinally advanced in the direction of arrow 104 into a garniture unit 106.

The pre-formed (identical) filters 103 are each of around 17.5 mm circumference and length 14 mm. Each filter 103 includes a self-sustaining substantially cylindrical core formed from a plurality of longitudinally extending substantially continuous filaments of crimped cellulose acetate tow which are bonded at their points of contact. The pre-formed dual filter rods 103a are each of around 17.5 mm circumference and length 28 mm. Each rod 103a includes a self-sustaining substantially cylindrical core formed from a plurality of longitudinally extending substantially continuous filaments of crimped cellulose acetate tow which are bonded at their points of contact. The filters 103 are NWA filters and may, as well as dual rods 103a, be manufactured by a process similar to that described in UK Patent No. 1 169932 (US3,455,766), in which filaments of cellulose acetate tow to which a plasticiser has been applied are fed into a forming station where a belt is folded around the tow until the longitudinal edges of the belt are juxtaposed and the tow is confined within the belt; the tow is thus formed into a longitudinally extending cylinder by the belt. The belt is then moved to a heat treating station where a heating fluid (e.g. steam) is passed through the belt into contact with the tow to activate the plasticizer. The belt and tow therewithin are then moved through a cooling station where cool air or other fluid is passed through the belt into contact with the tow to deactivate the plasticizer, if necessary, and dry the tow by removal of condensed steam, whereby the tow is made rigid to form a continuous self sustaining and stable longitudinally extending rod. The continuous self sustaining and stable longitudinally extending rod is cut into base rods of filters for subsequent use also by methods well known in the art.

Conventional Pop-a-Tip manufacture takes place on a dual rod filter making machine. These machines are well known in the art and normally used for combining two different types of base rod, which are held in two different hoppers on the machine. For Pop-a-Tip manufacture the two hoppers are filled with the same base rod type and these base rods are cut down (to provide the required tip length), aligned in an end-to-end relationship, wrapped in transparent film and cut to the final required Pop-a-Tip length. In the process of making product rods according to the present invention the two hoppers of the dual rod filter making machine (not shown) are also filled with base rods of filters 103 manufactured as set out above. One hopper is used to cut down the base rods to individual filters 103 of the required tip length (14mm) and the other hopper is used to cut down the base rods to dual filter rods 103a of the required tip length (28mm) and the dual rod machine is then set to arrange and align the filters 103 and dual filter rods 103a in an end-to-end relationship such that each dual filter rod 103 is separated form the next rod 103a by four individual filters 103 to provide the flow of pre-formed filters 103 and multiple (dual) filter rods 103a. As can be seen in Fig 3 the filters 103 are aligned and abutted end to end (i.e. there are no spaces between individual filters 103 or filters 103 and filter rods 103a) prior to longitudinal advancement in the direction of arrow 104 into the garniture unit 106.

The garniture unit 106 includes a compression shoe 108 through which the aligned and abutted filters 103 and dual filter rods 103a are passed prior to wrapping in the garniture. Compression shoes are known in the art for control of the final circumference of the finished rod.

A wrapper 105 of paper of basis weight 60 gsm (which has been prescored, see below) is applied to the continuously advancing flow of filters or filter elements in the garniture 106 in the conventional manner, to thereby form a continuous wrapped rod 1 1 1 comprising groups of four individual filters 103 separated by dual filter rods 103a. The continuous wrapped rod 1 1 1 is then cut in register with a position half way along each dual filter rod 103a (see arrow 222) by methods known in the art to provide intermediate product rods of around 17.5mm circumference and 84mm length, each containing six individual, identical, 14 mm long filters 103 in a common paper wrapper, the wrapper including lines formed in but not through the wrapper, each line being substantially in register with (e.g. in register with, or within 3mm of) a junction between abutted filters 103.

The lines formed in but not through the wrapper 105 are preformed, by scoring lines in the wrapper 105. The lines are scored across the width of the wrapper with a knife or similar, and each line is separated from the adjacent line by a distance corresponding to the length of a single filter 103. The apparatus is configured to substantially aligning or substantially registering the lateral lines formed in but not through the wrapper 105 with the junctions between abutted filters 103 (e.g. prior to and/or during wrapping), so that each line is in register with, or within 3mm of, a junction between abutted filters in the final product rod. The resulting product rod is a product as shown in Figures 1 and 2.

Figure 4 shows a NWA product rod 51 according to another embodiment of the invention. The product rod 51 comprises six individual (identical) tobacco smoke filters 53 each of around 17.5 mm circumference and length 14mm abutted end to end. Each filter 53 includes a self-sustaining substantially cylindrical core formed from a plurality of longitudinally extending substantially continuous filaments of crimped cellulose acetate tow which are bonded at their points of contact (i.e. each filter 53 is a NWA filter). The product 51 also includes a wrapper 55 comprising paper of basis weight 60 gsm which is engaged around the filters 53 thereby forming a wrapped cylinder of six filter elements of length 84mm. The wrapper includes a line 57 formed in but not through the wrapper (e.g. a line 57 scored into but not through the wrapper), the line 57 extending from one end of the product rod 51 to the other (end) and defining a helix (spiral) about the periphery of the product rod. The line is of width 0.1 mm.

The product rod 51 may be made by the methods described above. It will be appreciated that if the wrapper is pre-scored (i.e. scored before application to the filters/elements of the product rod), the line will have to be carefully located so it forms a continuous helix after the wrapper is wrapped around the filters/elements.

In use of the embodiment of Figure 4, the consumer peels back a strip of the wrapper along the line 57 (which is a line of weakness) to allow individual filter tips to be sequentially released for use; the remaining portion of the wrapper holds the remaining filters in place. It will be appreciated that in this case the wrapper is discarded, rather than remaining part of the filter.

In another example (not shown) the pitch of the helix defined by the line 57 (that is the distance along the helical axis and also along the product rod that results in one full turn of the helix) may be 14mm, the length of a single individual filter or filter element. In this example, peeling back a single turn of the helix of the wrapper (along the line) releases a single filter/filter element.

Claims

1 . A product rod comprising a plurality of individual tobacco smoke filters or filter elements abutted end to end; and a wrapper engaged around the plurality of filters or filter elements, the wrapper including a, or at least one, line formed in but not through the wrapper.

2. A product rod comprising a plurality of individual tobacco smoke filters or filter elements abutted end to end; and a wrapper engaged around the plurality of filters or filter elements, the wrapper including a line substantially in register with the or each junction between abutted filters or filter elements, the or each line being formed in but not through the wrapper.

3. A product rod according to claim 1 or claim 2 wherein the individual tobacco smoke filters, or individual tobacco smoke filter elements, are identical or substantially identical.

4. A product rod according to any preceding claim wherein the wrapper is paper (e.g. a plugwrap) or other sheet material.

5. A product rod according to claim 4 wherein the paper has basis weight of 20-140 gsm.

6. A product rod according to claim 4 or 5 wherein the paper has basis weight of 20- 80gsm.

7. A product rod according to any preceding claim wherein the or each line is scored into or impressed into but not through the wrapper.

8. A product rod according to any preceding claim wherein the (or each) line is of width 0.01 mm to 0.5mm.

9. A product rod comprising a plurality of individual tobacco smoke filters or filter elements abutted end to end; and a wrapper engaged around the plurality of filters or filter elements, the wrapper including a line formed in but not through the wrapper, the line extending from one end of the product rod to the other end and defining a helix about the periphery of the product rod.

10. A product rod according to claim 9 wherein the pitch of the helix defined by the line is the length of a single individual filter or filter element.

1 1 . A product rod according to any of claims 9 or 10 wherein the line is of width 0.01 to 0.5mm.

12. A product rod according to any of claims 9 to 1 1 wherein the individual tobacco smoke filters, or individual tobacco smoke filter elements, are identical or substantially identical.

13. A product rod according to any of claims 9 to 12 wherein the wrapper is paper (e.g. a plugwrap) or other sheet material.

14. A product rod according to claim 13 wherein the paper has basis weight of 20-140 gsm.

15. A product rod according to claim 13 or 14 wherein the paper has basis weight of 20- 80gsm.

16. A product rod according to any preceding claim wherein the individual filters or filter elements include a substantially cylindrical core of tobacco smoke filtering material.

17. A product rod according to any preceding claim wherein the individual filters or filter elements include a self-sustaining (longitudinally extending) cylindrical core of tobacco smoke filtering material.

18. A product rod according to any preceding claim wherein the individual filters or filter elements include a self-sustaining (longitudinally extending) cylindrical core comprising (e.g. formed from) a plurality of longitudinally extending substantially continuous filaments of tobacco smoke filtering material (e.g. cellulose acetate tow) which are bonded at their points of contact.

19. A product rod according to any preceding claim wherein the individual filters or filter elements include a self-sustaining (longitudinally extending) cylindrical core comprising (e.g. formed from) a plurality of randomly oriented (e.g. individual or staple) fibres of tobacco smoke filtering material (e.g. cellulose acetate) which are bonded at their points of contact.

20. A product rod according to any preceding claim wherein the individual filters or filter elements include one or more continuous components extending substantially longitudinally (e.g. longitudinally) of the cylindrical core.

21 . A product rod substantially as hereinbefore described with reference to Figures 1 and 2, or Figure 4.

22. A method of producing a product rod comprising a plurality (e.g 2 or more, e.g. 4 to 6) of individual tobacco smoke filters or filter elements abutted end to end, and a wrapper engaged around the plurality of filters or filter elements, wherein the wrapper includes a or at least one line formed in but not through the wrapper ; the method comprising:

applying a wrapper to a longitudinally advancing flow comprising pluralities

(groups) of individual filters or filter elements arranged between dual filter rods, each dual filter rod comprising two filters/elements joined end to end, wherein the filters/filter elements and filter rods are abutted end to end to thereby form a continuous wrapped rod comprising pluralities (groups) of abutted filters or filter elements arranged between (and abutted to) dual filter rods;

cutting the continuous wrapped rod in register with the dual filter rods such that the dual filter rod is cut into two individual filters/filter elements, to thereby provide a plurality of product rods each comprising filters or filter elements;

forming the or each line in but not through the wrapper .

23. A method of producing a product rod comprising a plurality (e.g 2 or more, e.g. 4 to 6) of individual tobacco smoke filters or filter elements abutted end to end, and a wrapper engaged around the plurality of filters or filter elements, wherein the wrapper includes a or at least one line formed in but not through the wrapper; the method comprising:

applying a wrapper which includes a or at least one line formed in but not through the wrapper toa longitudinally advancing flow comprising pluralities (groups) of individual filters or filter elements arranged between dual filter rods, each dual filter rod comprising two filters/elements joined end to end, wherein the filters/filter elements and filter rods are abutted end to end to thereby form a continuous wrapped rod comprising pluralities (groups) of abutted filters or filter elements arranged between (and abutted to) dual filter rods;

cutting the continuous wrapped rod in register with the dual filter rods such that the dual filter rod is cut into individual filters/filter elements, to thereby provide a plurality of product rods each comprising filters or filter elements.

24. A method of producing a product rod substantially as hereinbefore described with reference to Figure 3.