Filter-tipped cigarette with a removable cap, and relative manufacturing method and machine

A filter-tipped cigarette having: a tobacco portion having an outer end and an inner end; a filter butt-connected to the inner end of the tobacco portion; a first sleeve wound about the tobacco portion and the filter to connect the filter permanently and non-detachably to the tobacco portion; a cap butt-connected to the outer end of the tobacco portion, at the opposite end from the filter, and removable to smoke the filter-tipped cigarette; and a second sleeve, which is wound about the cap and the tobacco portion, is integral with the cap, and is at least partly removable axially from the tobacco portion together with and to remove the cap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the U.S. national phase of PCT/IB2013/054413, filed May 28, 2013, which claims the benefit of Italian Patent Application No. BO2012A000291, filed May 28, 2012.

TECHNICAL FIELD

The present invention relates to a filter-tipped cigarette and relative manufacturing method and machine.

BACKGROUND ART

A filter-tipped cigarette comprises a tobacco portion having an outer end and an inner end; and a filter butt-connected to the inner end of the tobacco portion and connected to the tobacco portion by a sleeve wound about the filter and partly about the tobacco portion. The outer end of the tobacco portion is free (i.e. the tobacco is left exposed), constitutes the tip of the filter-tipped cigarette, and is used by the user to light the filter-tipped cigarette.

A good-quality filter-tipped cigarette must be filled firmly, i.e. contain a sufficient amount of tobacco, at the tip. Conversely, a filter-tipped cigarette with an ‘empty’ tip, i.e. containing no tobacco, is considered poor quality. By the end of the manufacturing process, almost all filter-tipped cigarettes have perfectly filled tips, but the mechanical stress they are subjected to during subsequent transfer and packing may result in tobacco fallout from the tips. So, after forming and before wrapping each group of filter-tipped cigarettes, the tips are quality controlled optically, and the group is rejected if even only one of the filter-tipped cigarettes in it has a poorly filled tip (in other words, since a standard group of filter-tipped cigarettes comprises twenty cigarettes, nineteen good cigarettes must be sacrificed to remove one flawed one).

On filter-tipped cigarette manufacturing systems, poorly filled tips are responsible for the rejection of large numbers of cigarettes, which means substantial economic losses for which a valid solution has not yet been devised.

Patent Application GB2284339 describes a filter-tipped cigarette in which the tobacco portion is divided into two axially separable parts, but in which the tip (where the tobacco is exposed) has no protection whatsoever.

Patent Application GB810759 describes a cigarette with no filter and comprising two paper hoods covering the two opposite ends of the tobacco portion, and both of which are removable axially to smoke the cigarette. Applying the paper hoods, however, involves a particularly complex folding operation, which cannot be performed correctly at high speed. In other words, on a modern cigarette manufacturing machine (capable of producing up to 20,000 cigarettes a minute), the folding operation would result in a reduction in speed that would be unacceptable.

DESCRIPTION OF THE INVENTION

It is an object of the present invention to provide a filter-tipped cigarette and relative manufacturing method and machine designed to eliminate the above drawbacks, and which at the same time are cheap and easy to implement.

According to the present invention, there are provided a filter-tipped cigarette and relative manufacturing method and machine, as claimed in the accompanying Claims.

PREFERRED EMBODIMENTS OF THE INVENTION

Number1inFIG. 1indicates as a whole a filter-tipped cigarette.

Filter-tipped cigarette1comprises a cylindrical tobacco portion2having an outer end3and an opposite inner end4; tobacco portion2is defined by a cylinder of tobacco wound in a sheet of paper, so that the tobacco is exposed at ends3and4.

Filter-tipped cigarette1comprises a cylindrical filter5butt-connected to inner end4of tobacco portion2. In the embodiments shown in the attached drawings, one end of filter5rests directly on inner end4of tobacco portion2, but, in a different, perfectly equivalent embodiment not shown, at least one further element is interposed between the end of filter and inner end4of tobacco portion2. Filter5is connected to tobacco portion2by a sleeve6wound about filter5and partly about tobacco portion2. In actual use (i.e. when filter-tipped cigarette1is smoked by the user), outer end3of tobacco portion2is free (i.e. the tobacco is exposed); constitutes the tip of filter-tipped cigarette1, and is used by the user to light filter-tipped cigarette1.

Filter-tipped cigarette1also comprises a cap7butt-connected to outer end3of tobacco portion2, at the opposite end from filter5. In the embodiments shown in the attached drawings, one end of cap7rests directly on outer end3of tobacco portion2, but, in a different, perfectly equivalent embodiment not shown, at least one further element is interposed between the end of cap7and outer end3of tobacco portion2. Cap7is fixed to tobacco portion2by a sleeve8, which is separate from and independent of sleeve6, and is wound about cap7and tobacco portion2. In theFIGS. 1 and 2embodiments, sleeve8is also wound about filter5(and therefore over sleeve6); whereas, in theFIGS. 3 and 4embodiments, sleeve8is not wound about filter5(i.e. terminates short of, and is located alongside and a given distance from, sleeve6).

It is important to note that sleeves6and8always have longitudinal adhesive strips (known and not shown in the drawings) to glue sleeves6and8firmly in the rolled position about tobacco portion2and/or filter5. In addition, sleeve6always has adhesive strips (known and not shown in the drawings) to glue sleeve6to filter5and tobacco portion2, so filter5is connected permanently and non-detachably to tobacco portion2.

In theFIG. 1embodiment, sleeve8has an annular tear line9, which allows cap7to be pulled off tobacco portion2. In other words, to smoke filter-tipped cigarette1, the user pulls sleeve8axially off tobacco portion2together with, and to remove, cap7. In actual use, the user grips filter5with one hand, and cap7with the other; pulls axially on cap7to tear sleeve8along tear line9; and then removes cap7and the corresponding portion of sleeve8axially from the rest of filter-tipped cigarette1. Once cap7is removed, filter-tipped cigarette1becomes an ordinary filter-tipped cigarette, which is smoked the usual way. In other words, tearing sleeve8along tear line9divides sleeve8into a movable portion integral with cap7and which is removed axially and disposed of; and into a fixed portion integral with and which remains fixed to filter5.

Tear line9is normally defined by a weak line, which is torn by exerting axial pull on (and possibly also twisting) sleeve8, and which comprises succession of cuts spaced apart in a circle around the whole of sleeve8. The cuts composing the weak line may be straight and perfectly circumferential, may be straight and slope with respect to the circumference, or may be L-shaped with a circumferential portion and an axial portion. In an alternative embodiment not shown, tear line9is defined by two parallel weak lines defining a lateral tear-off strip, which is removed and disposed of.

In a different embodiment, tear line9is defined by a pull-off strip, which is much stronger mechanically than sleeve8, is glued to sleeve8, and has a free end which is gripped and pulled by the user. The pull-off strip may be used either together with one or more weak lines (over which the pull-off strip is glued) or on its own.

In theFIG. 1embodiment, sleeve8(or rather the movable portion of sleeve8) is glued to cap7using strong-stick glue10(i.e. permanent, drying glue with an adhesive force greater than the mechanical strength of sleeve8), so the movable portion of sleeve8is non-detachable (unless it is torn) from cap7. Similarly, sleeve8(or rather the fixed portion of sleeve8) is glued to sleeve6using strong-stick glue11(i.e. permanent, drying glue with an adhesive force greater than the mechanical strength of sleeve8), so the fixed portion of sleeve8is non-detachable (unless it is torn) from sleeve6. In this embodiment, annular tear line9of sleeve8is located alongside glue11, between cap7and glue11(typically close to the dividing line between filter5and tobacco portion2, so that sleeve8is unaffected by combustion when smoking filter-tipped cigarette1).

In theFIG. 2embodiment, sleeve8is glued to sleeve6using weak-stick glue11(i.e. re-stick, non-dry glue or very weak permanent glue with an adhesive force well below the mechanical strength of sleeve8). In this embodiment, sleeve8has no tear line9, in that the whole of sleeve8is removed axially from tobacco portion2(and disposed of) by overcoming the force of glue11.

An alternative embodiment has no glue10and/or no glue11(i.e. has neither glue10nor glue11, or has glue10and no glue11, or has glue11and no glue10). In this connection, it is important to note that glues10and11are useful for improving the mechanical stability of sleeve8and cap7, but are not strictly indispensable (especially glue11), in that sleeve8enclosing cap7and tobacco portion2has a certain amount of mechanical stability even without glue10and/or glue11.

In theFIGS. 1 and 2embodiments, sleeve8is also wound about filter5(and therefore over sleeve6), whereas, in theFIGS. 3 and 4embodiments, sleeve8is not wound about filter5(i.e. terminates short of, and is located alongside and a given distance from, sleeve6).

In theFIG. 3embodiment, sleeve8is glued to tobacco portion2using strong-stick glue12(i.e. permanent, drying glue with an adhesive force greater than the mechanical strength of sleeve8); and annular tear line9of sleeve8is located alongside glue12, between cap7and glue12. Tearing sleeve8along tear line9divides sleeve8into the movable portion integral with cap7and which is removed axially and disposed of; and into the fixed portion integral with and which remains fixed to tobacco portion2.

In theFIG. 4embodiment, sleeve8is glued to tobacco portion2using weak-stick glue12(i.e. re-stick, non-dry glue or very weak permanent glue with an adhesive force well below the mechanical strength of sleeve8). In this embodiment, sleeve8has no tear line9, in that the whole of sleeve8is removed axially from tobacco portion2(and disposed of) by overcoming the force of glue12.

In theFIG. 5embodiment, sleeve6and sleeve8are initially joined at annular tear line9, which allows sleeve8to be torn off sleeve6when sleeve8is removed axially from tobacco portion2together with, and to remove, cap7. In this embodiment, sleeve8is preferably (but not necessarily) glued to cap7using strong-stick glue10(i.e. permanent, drying glue with an adhesive force greater than the mechanical strength of sleeve8).

In theFIG. 6embodiment, filter-tipped cigarette1comprises a further cap13, which is located at the opposite end from cap7, rests against the outer end of filter5, and is removable (at the same time as cap7) to smoke filter-tipped cigarette1. Like cap7, cap13is preferably glued to sleeve8using strong-stick glue (i.e. permanent, drying glue with an adhesive force greater than the mechanical strength of sleeve8). In theFIG. 6embodiment, sleeve8is wound about cap7and cap13, and so has annular tear line9. In theFIG. 6embodiment, sleeve8is preferably not glued to either tobacco portion2or sleeve6, in that, even without glue11or12, sleeve8cannot be removed axially from tobacco portion2or filter5without tearing sleeve8along tear line9.

In theFIG. 7embodiment, filter-tipped cigarette comprises both caps7and13; and two sleeves8located at opposite ends of sleeve6and initially joined to sleeve6at respective annular tear lines9. In actual use, the user tears off the two sleeves8(integral with respective caps7and13) along the two annular tear lines9, to remove sleeves8together with respective caps7and13from filter-tipped cigarette1. In this embodiment, sleeves8are preferably (but not necessarily) glued to respective caps7and13using strong-stick glues10and14(i.e. permanent, drying glues with an adhesive force greater than the mechanical strength of sleeves8).

In a preferred, but not compulsory, embodiment, caps7and13are made of filter manufacturing material (e.g. acetate), i.e. caps7and13may be made from the same material as filter5. Making caps7and13from normally used filter manufacturing material has the advantage that this material is in itself cheap and, above all, is available in large quantities at cigarette factories, thus eliminating the economic and logistic drawbacks involved in procuring additional material. In an alternative embodiment, caps7and13are made from any type of low-density plastic material (e.g. polystyrene foam) or rolled paper/cardboard. It is important to note that, whichever the case, caps7and13do not have the necessary filtering properties or size to act as filters, even when made from filter manufacturing material (and even more so when made from plastic or paper). Cap7serves solely to mechanically protect the tip (i.e. outer end3of tobacco portion2) of filter-tipped cigarette1, and must be removed prior to smoking the cigarette (i.e. cap7can never be used instead of filter5, which is the only part of filter-tipped cigarette1with suitable filtering properties). Similarly, cap13serves solely to protect the free end of filter5from contamination, and must be removed prior to smoking filter-tipped cigarette1(i.e. cap13can never be used together with filter5, which is the only part of filter-tipped cigarette1with suitable filtering properties).

Inside the packet of cigarettes, filter-tipped cigarettes1may be inserted with caps7or13visible (i.e. at the top extraction opening of the packet). In which case, at least some of caps7or13may be printed with patterns or wording visible when the packet is opened, and/or at least some of caps7or13may have gripping means to facilitate grip (and therefore axial withdrawal) of the corresponding filter-tipped cigarettes1. For example, one cap7or13may have gripping means defined by an outer insert (thread or tape) fixed to cap7or13, or defined by appropriately shaping cap7or13(for example, cap7or13may be laser sculpted, or may be pressed or cut mechanically). It is important to note that each packet of cigarettes need only contain one filter-tipped cigarette1with a cap7or13with gripping means, in that only the first filter-tipped cigarette1is difficult to withdraw and, once this is removed, the rest can be withdrawn fairly easily.

In one embodiment, cap7and/or cap13may be impregnated with aromatic substances to impart a given aroma to the tobacco in tobacco portion2(the aroma seeps slowly by proximity from cap7or13to the tobacco in tobacco portion2or to filter5).

In another embodiment, sleeve8may be impregnated with aromatic substances.

Menthol is the preferred aromatic substance used to aromatize cap7and/or cap13and/or sleeve8.

Firstly, cap7of filter-tipped cigarette1described prevents tobacco fallout from the tip (i.e. from outer end3of tobacco portion2) during the packing process to form the packet of cigarettes, as well as during subsequent transport and handling of the packet.

Secondly, sleeve8covering at least part of filter-tipped cigarette1provides a large area for printed advertising or embellishments, and, being ‘disposable’ material which is eliminated prior to smoking the cigarette, poses no restrictions as to the choice of ink (e.g. fluorescent paints may safely be used). Likewise, the exposed face of cap7or13also provides an area for printed advertising or embellishments, and, being ‘disposable’ material which is eliminated prior to smoking the cigarette, poses no restrictions as to the choice of ink.

Finally, filter-tipped cigarette1described is also better suited for single (i.e. loose) retail, by being mechanically stronger and better sealed than conventional filter-tipped cigarettes. Filter-tipped cigarette1inFIGS. 6 and 7is particularly suitable for loose retail, by tobacco portion2and filter5being sealed completely by caps7and13and sleeve8, which are all fully removed and disposed of prior to smoking filter-tipped cigarette1.

FIG. 8show a manufacturing sequence by which to produce the filter-tipped cigarette inFIG. 1. Because this sequence involves connecting cap7and filter5at the same time to tobacco portion2, a conventional filter assembly machine must be modified accordingly.

As shown inFIG. 8a, to begin with, a double cap (i.e. twice as long as cap7of each filter-tipped cigarette1) is cut in half by a blade into two side by side caps7(FIG. 8b). As shown inFIG. 8c, the two side by side caps7are parted axially to form a gap, into which a double tobacco portion2(i.e. twice as long as tobacco portion2of each filter-tipped cigarette1) is fed, as shown inFIG. 8d. As shown inFIG. 8e, the double tobacco portion2is cut in half by a blade into two tobacco portions2. As shown inFIG. 8f, the two side by side tobacco portions2are parted axially to contact respective caps7and at the same time form a gap, into which a double filter5(i.e. twice as long as filter5of each filter-tipped cigarette1) is fed, as shown inFIG. 8g.

As shown inFIG. 8h, a double sleeve6(i.e. twice as long as sleeve6of each filter-tipped cigarette1) is wound about double filter5and partly about tobacco portions2; and a double sleeve8(i.e. twice as long as sleeve8of each filter-tipped cigarette1) is wound about double filter5, tobacco portions2and caps7, and over double sleeve6. In one embodiment, double sleeve6is wound on first, and double sleeve8is wound on afterwards, completely independently of double sleeve6. Alternatively, double sleeve6is first superimposed on double sleeve8, and both double sleeves6and8(formed into one) are wound on together simultaneously. Once both double sleeves6and8are wound on, double filter5and double sleeves6and8are cut centrally by a blade to divide the two filter-tipped cigarettes1joined at filters5.

TheFIG. 8manufacturing sequence produces two parallel filter-tipped cigarettes1at a time. Alternatively, one filter-tipped cigarette1may be produced at a time.

FIG. 9show a manufacturing sequence by which to produce the filter-tipped cigarette inFIG. 1. Because this sequence involves connecting cap7after filter5to tobacco portion2, no substantial changes are needed to a conventional filter assembly machine. That is, the conventional filter assembly machine connects filter5to tobacco portion2; and, downstream from the conventional filter assembly machine, tobacco portion2, already fitted with filter5(and therefore with sleeve6connecting filter5integrally to tobacco portion2), is processed on a cap assembly machine (in series with the conventional filter assembly machine) to connect cap7to tobacco portion2.

As shown inFIG. 9a, to begin with, a double cap (i.e. twice as long as cap7of each filter-tipped cigarette1) is cut in half by a blade into two side by side caps7(FIG. 9b). As shown inFIG. 9c, the two side by side caps7are parted axially to form a gap, into which two tobacco portions2, already fitted with a double filter5(i.e. twice as long as filter5of each filter-tipped cigarette1) and with a corresponding double sleeve6(i.e. twice as long as sleeve6of each filter-tipped cigarette1), are fed as shown inFIG. 9d. The two tobacco portions2are joined axially by double filter5and double sleeve6(alternatively, the two tobacco portions2may be fed, already divided axially, i.e. at filters5, into the gap between the two caps7). As shown inFIG. 9e, a double sleeve8(i.e. twice as long as sleeve8of each filter-tipped cigarette1) is wound about double filter5, tobacco portions2and caps7, and over double sleeve6. As shown inFIG. 9f, once double sleeve8is wound on, double filter5and double sleeves6and8are cut centrally by a blade to divide the two filter-tipped cigarettes1joined at filters5.

The only alteration needed to the conventional filter assembly machine is therefore eliminating the central cut of double filter5(and of corresponding double sleeve6), which is carried out later on the cap assembly machine after winding on double sleeve8.

FIG. 10show a variation of theFIG. 9manufacturing sequencer theFIG. 9manufacturing sequence produces two parallel filter-tipped cigarettes at a time, whereas theFIG. 10manufacturing sequence produces only one filter-tipped cigarette1at a time.

TheFIG. 8-10manufacturing sequences for producing filter-tipped cigarette1and described in detail above may also be applied to produce theFIGS. 3 and 4filter-tipped cigarettes1. The only difference is that, sleeve8not being superimposed on sleeve6in theFIGS. 3 and 4filter-tipped cigarettes1, sleeves6and8are always wound on physically separately (even when wound on simultaneously). Moreover, using theFIG. 9manufacturing sequence, the double filter5and corresponding double sleeve6may already be cut into half (i.e. into two filters5and two corresponding sleeves6) when the two tobacco portions2are fed into the gap between the two caps7as shown inFIG. 9d. By way of a further example,FIG. 11show the manufacturing sequence for producing theFIGS. 3 and 4filter-tipped cigarettes1in exactly the same way as inFIG. 8.

TheFIG. 8manufacturing sequence for producing filter-tipped cigarette1and described in detail above may also be applied to produce theFIG. 5filter-tipped cigarette1. The only difference is that, sleeve8being initially joined to sleeve6in theFIG. 5filter-tipped cigarette1, sleeves6and8are always wound on together and simultaneously. By way of a further example,FIG. 12show the manufacturing sequence for producing theFIG. 5filter-tipped cigarette1in exactly the same way as inFIG. 8.

FIG. 13show a manufacturing sequence by which to produce theFIG. 6filter-tipped cigarette. Because this sequence involves connecting caps7and13and filter5at the same time to tobacco portion2, a conventional filter assembly machine must be modified accordingly.

To begin with, a double cap7(i.e. twice as long as cap7of each filter-tipped cigarette1) is cut in half by a blade into two side by side caps7. As shown inFIG. 13a, the two side by side caps7are parted axially to form a gap, into which a double tobacco portion2(i.e. twice as long as tobacco portion2of each filter-tipped cigarette1) is fed, as shown inFIG. 13b. As shown inFIG. 13c, the double tobacco portion2is cut in half by a blade into two tobacco portions2. As shown inFIG. 13d, the two side by side tobacco portions2are parted axially to contact respective caps7and at the same time form a gap, into which a more than double filter5(i.e. more than twice as long as filter5of each filter-tipped cigarette1) is fed, as shown inFIG. 13e.

As shown inFIG. 13f, the more than double filter5is cut at two points by two side by side blades to form two filters5on either side (and butt-connected to the two tobacco portions2) and a double cap13(i.e. twice as long as cap13of each filter-tipped cigarette1) in the middle. In this embodiment, cap13is obviously made of the same material as filter5. As shown inFIG. 13g, a sleeve6is wound about each filter5and partly about the corresponding tobacco portion2; and a double sleeve8(i.e. twice as long as sleeve8of each filter-tipped cigarette1) is wound about filters5, tobacco portions2and caps7and13, and over sleeves6. In one embodiment, sleeves6are wound on first, and double sleeve8is wound on afterwards, completely independently of sleeves6. Alternatively, sleeves6are first superimposed on double sleeve8, and sleeves6and double sleeve8(formed into one) are wound on together simultaneously. Once sleeves6and double sleeve8are wound on, double cap13and double sleeve8are cut centrally by a blade, as shown inFIG. 13h, to form two separate caps13and so divide the two filter-tipped cigarettes1joined at caps13.

FIG. 14show a manufacturing sequence by which to produce theFIG. 6filter-tipped cigarette. Because this sequence involves connecting caps7and13after filter5to tobacco portion2, no substantial changes are needed to a conventional filter assembly machine. That is, the conventional filter assembly machine connects filter5to tobacco portion2; and, downstream from the conventional filter assembly machine, tobacco portion2, already fitted with filter5(and therefore with sleeve6connecting filter5integrally to tobacco portion2), is processed on a cap assembly machine (in series with the conventional filter assembly machine) to connect caps7and13to tobacco portion2.

As shown inFIG. 14a, to begin with, a double cap (i.e. twice as long as cap7of each filter-tipped cigarette1) is cut in half by a blade into two side by side caps7(FIG. 14b). As shown inFIG. 14c, the two side by side caps7are parted axially to form a gap, into which two tobacco portions2, each already fitted with filter5and sleeve6, are fed as shown inFIG. 14d. The two filters5are positioned a given axial distance apart, so as to form a gap, into which a double cap13(i.e. twice as long as cap13of each filter-tipped cigarette1) is fed as shown inFIG. 14e. As shown inFIG. 14f, a double sleeve8(i.e. twice as long as sleeve8of each filter-tipped cigarette1) is wound about filters5, tobacco portions2and caps7and13, and over sleeves6. As shown inFIG. 14g, once double sleeve8is wound on, double cap13and double sleeve8are cut centrally by a blade to form two separate caps13and so divide the two filter-tipped cigarettes1joined at caps13.

As regards theFIG. 14dstep, the two tobacco portions2fitted with filters5and with sleeves6may be supplied already separated, or may be supplied joined at filters5, and be cut centrally later on.

TheFIG. 14manufacturing sequence produces two parallel filter-tipped cigarettes1at a time. Alternatively, one filter-tipped cigarette1may be produced at a time, as shown inFIG. 15.

The above sequences for producing filter-tipped cigarettes1are performed on a manufacturing machine for producing filter-tipped cigarette1. The manufacturing machine comprises: a rolling unit for producing a tobacco portion2having an outer end3and an inner end4; a first connecting station for butt-connecting a filter5to inner end4of tobacco portion2; a first winding station for winding a sleeve6about tobacco portion2and filter5, to connect filter5second connecting station for butt-connecting a cap7to outer end3of tobacco portion2, so the cap is located at the opposite end from filter5and is removable to permanently and non-detachably to tobacco portion2; a smoke filter-tipped cigarette1; and a second winding station for winding a sleeve8about cap7and tobacco portion2, so sleeve8is integral with cap7and at least partly removable axially from tobacco portion2together with, and to remove, cap7.

The above sequences for producing filter-tipped cigarettes1have numerous advantages, by enabling filter-tipped cigarettes1to be produced quickly (i.e. at a high operating speed comparable with those of modern cigarette manufacturing systems) and cheaply (i.e. with only minor, non-invasive alterations to existing conventional filter assembly machines).