Patent Publication Number: US-2017347700-A1

Title: Smoking article assembly machine and method of making a smoking article

Description:
FIELD OF THE INVENTION 
     This present invention relates to a smoking article assembly machine. The present invention also relates to a method of making a smoking article. 
     BACKGROUND 
     Smoking articles, such as filter cigarettes, are generally formed of a tobacco rod and a filter wrapped in a material, such as paper. A band of paper, such as tipping paper, may be used to join together a wrapped tobacco rod and a wrapped filter. Cigarettes with different construction and configuration are possible but do generally comprise rod shaped components, such as tobacco rods and filters that are wrapped in materials in various arrangements. 
     Machinery for preparing and wrapping a web of material around a tobacco rod, a filter or an assembly of a tobacco rod and a filter may include a web handling system that handles thin strips of material, such as tipping paper, arranges and aligns the strips of material with the relevant components and feeds the strips into a wrapping process to wrap the strips of material around the components of the smoking article. 
     It is known to assemble smoking articles with a web of a sheet material, such as tipping paper, with predefined slits or apertures formed in it. 
     SUMMARY 
     According to aspects of the invention, there is provided a smoking article assembly machine having a web of tipping paper conveying path, the smoking article assembly machine comprising a mechanical cutter configured to perform a cutting action to form a pattern including a line having a dimension of at least 5 mm on a web of tipping paper passing along the web of tipping paper conveying path, and a web severing device configured to sever the web of tipping paper into segments for wrapping smoking articles. 
     The line may be a line of separation. 
     The cutting action of the mechanical cutter may be configured to define at least two sections of the web of tipping paper. 
     The mechanical cutter may be configured to perform a cutting action to form the pattern including a line in a direction along the direction of the web of tipping paper conveying path. 
     The smoking article assembly machine may further comprise a curling station configured to act on the web of tipping paper. The mechanical cutter may be configured to perform the cutting action downstream of the curling station along the web of tipping paper conveying path. 
     The mechanical cutter may be configured to perform the cutting action upstream of the web severing device along the web of tipping paper conveying path. 
     The mechanical cutter may be a crush cutting device. Alternatively, it may be another type of mechanical cutter such as a shear action cutter, e.g. a rotary scissor type cutter, or a contact cutter. 
     The crush cutting device may comprise a profiled roller and an anvil roller between which the web of tipping paper conveying path is defined. 
     The spacing between the profile roller and anvil roller may be in a range of between 3 to 5 μm. 
     The smoking article assembly machine may further comprise a pre-cutter. The pre-cutter may be configured to perform a first cutting action on said web of tipping paper and the cutting action performed by the mechanical cutter may be a second cutting action on said web of tipping paper. 
     The pre-cutter may perform a mechanical cutting action. 
     The pre-cutter may be disposed downstream of the curling station and upstream of the mechanical cutter along the web of tipping paper conveying path. More specifically, the pre-cutter is preferably disposed after the curling station but before the mechanical cutter in the direction of movement of the web of tipping paper along the conveying path. 
     The pre-cutter may be disposed upstream of the curling station along the web of tipping paper conveying path. 
     The pre-cutter may be a punch for forming perforations. Alternatively, the pre-cutter could be a shear action cutter, such as a rotary scissor type cutter, a contact cutter or a laser cutter. 
     The line may have a minimum length to width ration of 60:1. 
     According to other aspects of the invention, there is provided a method of making a smoking article, comprising conveying a web of tipping paper along a conveying path, mechanically cutting the web of tipping paper to form a pattern including a line having a dimension of at least 5 mm on the web of tipping paper, severing the web of tipping paper into segments, and assembling smoking article with the segments of tipping paper. 
     The method may further comprise curling the web of tipping paper using a curling station, wherein the web of tipping paper may be mechanically cut to form a pattern including a line having a dimension of at least 5 mm after the web of cutting paper is curled by the curling station. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will now be described, by way of example only with reference to the accompanying drawings in which: 
         FIG. 1  is a partial exploded view of a cigarette; 
         FIG. 2  is a plan view of a segment of tipping paper for forming a cigarette; 
         FIG. 3  is a schematic side elevational view of a cigarette making machine; 
         FIG. 4  is a schematic side view of a crush cutting device of the cigarette making machine; 
         FIG. 5  is a schematic illustration of process steps performed by the cigarette making machine shown in  FIG. 3 ; and 
         FIG. 6  is a schematic side elevational view of another cigarette making machine. 
     
    
    
     DETAILED DESCRIPTION 
     As used herein, the term “smoking article” includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products and other nicotine delivery product such as aerosol generation devices including e-cigarettes. The smoking article may be provided with a filter for the gaseous flow drawn by the smoker. Examples of smoking articles as described herein may comprise a cigarette with a filter in a fixed location on a rod of smokeable material such as tobacco whereas others may be telescopic in configuration. 
     Referring to  FIG. 1 , a smoking article in the form of a cigarette  1  comprises a tobacco rod  2 , which in a conventional manner comprises smokable material, such as tobacco or tobacco containing material, wrapped in a paper wrapper. It will be understood that the term cigarette may be replaced by the term smoking article throughout. A generally cylindrical filter segment  3  that comprises filter material, for example cellulose acetate wrapped in a paper plug wrap is disposed adjacent to the tobacco rod  2 . The filter segment  3  is attached to the tobacco rod  2  by means of a covering layer of sheet material  4 , preferably tipping paper. Alternatively, the tobacco rod  2  may comprise a smokable material and a second filter section (not shown) which are longitudinally aligned. 
     The tipping paper  4  in  FIG. 2  is shown as a segment to of a web of tipping paper  11  which is of a width suitable for wrapping two cigarettes  1  back-to-back in a cigarette making machine as will be explained hereinafter. Each length L of the web  11  is utilised to form an individual back-to-back cigarette pair and in use, the web  11  is cut along severing lines  12 ,  13  forming leading and trailing edges of each segment  10 . Upon wrapping of the tipping paper  4  to form the smoking articles  1 , the segment to of the web of tipping paper  11  is divided along separation line  14 . 
     As shown in  FIG. 2 , the tipping paper  4  is formed with a pattern  5 . The pattern  5  is formed by an array of lines  6 . The lines  6  are formed by cutting into the sheet material that forms the tipping paper  4 . The segment to of the web  11  of tipping paper  4  shown in  FIG. 2  forms a blank. In the present embodiment, the lines  6  are formed by a mechanical cutting action. The depth of at least some of the lines  6  extends through the thickness of the sheet material. That is, the line  6  forms a line of separation. However, some of the lines  6  may extend only partially through the thickness of the sheet material. The or each line  4  forming a line of separation defines at least two sections of the tipping paper  4 . For example, line  4   a  defines two sections  8   a ,  8   b  of the tipping paper  4  in  FIG. 2 . 
     Although an array of lines  6  are shown forming the pattern  5 , it should be understood that the pattern  5  could be made by one line  6 . Each line  6  is elongate. At least one line  6  has a length equal to or greater than 5 mm. Preferably, at least one line  6  has a length equal to or greater than 10 mm. When assembled at least one line  6  extends at least 50% around the circumference of the cigarette  1 . Preferably, when assembled at least one line  6  extends at least 80% around the circumference of the cigarette  1 . 
     The tipping paper  4  is also formed with an array of perforations  7 . The perforations  7  may be formed by laser cutting, embossing such as pin embossing or any other suitable method. The perforations  7  provide for ventilation through the tipping paper  4 . It will be understood that each perforation  7  typically has a diameter of up to 0.5 mm. It has been found that perforation holes having a greater diameter than 0.5 mm may cause the production of CO 2 . 
     A cigarette making machine suitable for producing cigarettes  1  will now be described with reference to  FIGS. 3 and 4 . The machine can be considered as a modification of a machine by Hauni Maschinenbau AG, which has been adapted to utilise a roll  22   a  of the web  11  of tipping paper  4  in the manufacture of cigarettes. Reference is also made to  FIG. 5 , which illustrates schematically the process steps performed by various parts of the machine illustrated in  FIG. 3 . 
     Tobacco rods  20  of a length suitable for forming two cigarettes back-to-back are supplied to a tobacco rod in-feed  33  shown in  FIG. 3 . Also, filter rods  21  are supplied from a hopper  35  into the machine. The filter rods  21  are of a length suitable for forming two cigarettes back-to-back. 
     The tobacco rods  20  are supplied onto a take over drum  36  and passed to a tobacco rod cutting drum  37  with an associated knife wheel  38  that cuts the tobacco rods  20  into two parts  20   a ,  20   b  which are then axially separated by means of a separating drum  39  and passed to a filter feed drum  40  where an individual filter rod  21  is placed between them as shown in  FIG. 5 . 
     The filter rods  21  are fed from hopper  35  by means of supply rollers  32   a ,  32   b ,  32   c ,  32   d  to the filter feed drum  40  and as shown in  FIG. 3 , the filter feed drum  40  acts to abut the tobacco rods  20   a ,  20   b  against opposite ends of the filter rods  21  on a common longitudinally axis. 
     The abutting arrangement of rods  20   a ,  21 ,  20   b  is then transferred to a swash-plate drum  41  where they are joined together by means of a tipping paper segment  10  that comprises a cut portion of the web  11  of tipping paper  4  shown in  FIG. 2 , e.g. between severing lines  12  and  13 . As will be explained later, the tipping paper segment to is cut from the web  11  and is coated with glue so that when the arrangement is transferred to rolling drum  43 , the tipping paper segment to is wrapped around the filter rod  21  and is dimensioned to overlap the ends of the tobacco rods  20   a ,  20   b  so that they become joined together as illustrated by the arrangement in  FIG. 5 . 
     The joined rods  20   a ,  21 ,  20   b  then pass on to a transfer drum  45  so as to be fed to a cutting drum  46  with an associated rotary knife  47  which cuts the joined rods  20   a ,  21 ,  20   b  into two separate cigarettes  1 ,  1 ′ which are then fed via a transfer drum  48  to a turning drum  49  where the cigarettes  1 ,  1 ′ of each pair are arranged to face in the same direction ready for packaging. 
     The web  11  of tipping paper  4  is fed sequentially from a feed arrangement comprising two rolls  22   a ,  22   b  so that a continuous supply of the web  11  of tipping paper  4  can be provided to a cigarette making machine. Thus, when one of the supply rolls  22   a  becomes exhausted, supply can continue from the other roll  22   b  and the empty roll can be replaced. 
     Prior to placement of the supply rolls  22   a ,  22   b  on the cigarette making machine, plain web rolls are acted on by a perforation station (not shown) to form the perforations  7  in the web  11  of tipping paper  4 . The perforation station (not shown) is typically remote from the cigarette making machine, or may be included in the cigarette making machine. Also the web  11  may be perforated at a perforation station adjacent the cigarette making machine and supplied from the adjacent station into the cigarette making machine. 
     Referring again to  FIG. 3 , the web  11  of tipping paper  4  is fed from one of the rolls  22   a ,  22   b  to a curling station  50 . The curling station  50  operates on the web  11  of tipping paper  4  in order to weaken its structural integrity on one side to enable it to curl into a cylinder readily when wrapped around the rods  20   a ,  20   b ,  21  on the drums  41 ,  43  as shown in  FIGS. 3 and 5 . In the curling station  50 , the tipping paper  4  is passed over a fixed curling edge, also known as a curling bar, to weaken the structural integrity of the tipping paper slightly on one face. In conventional cigarette making machines the web  11  with perforations is able to withstand the curling treatment. However, it has been found that the presence of a pattern  5  including a line  6  having a dimension of at least 5 mm on the web  11  of tipping paper  4  passing through the curling station  50  may cause the web to be at least partially damaged. 
     As shown in  FIG. 3 , the web  11  of tipping paper  4  is acted on by a mechanical cutter  70 , downstream of the curling station  50 . The mechanical cutter  70  acts on the web  11  of tipping paper  4  to form at least one line  6  of the pattern  5 . The mechanical cutter  70  performs a cutting action on the web  11  of tipping paper  4  as it passes through the mechanical cutter  70 , along the web  11  of tipping paper  4  conveying path. The mechanical cutter  70  makes cuts in the web  11  of tipping paper  4  that are predominantly in the machine direction, i.e. in the direction in which the tipping paper  4  is being conveyed, rather than in the cross-wise direction perpendicular to the direction of travel of the tipping paper  4 . 
     A web tensioner  65  is provided upstream of the curling station  50  in the embodiment shown in  FIG. 3 . The web tensioner  65  or web reservoir provides for accurate control of the tension of the web  11  of tipping paper  4  at the mechanical cutter  70 . In an alternative embodiment, the web tensioner  65  is disposed between the curling station  50  and the mechanical cutter  70 . A paper guide (not shown) aligns the web  11  of tipping paper  4  in a direction transverse to the direction of the web  11  of tipping paper conveying path  4 . The paper guide ensures that the web  11  of tipping paper  4  is accurately aligned prior to being received by the mechanical cutter  70 . 
     Referring to  FIG. 4 , the mechanical cutter  70  in the present embodiment is a crush cutting device. The crush cutting device acts on the web  11  of tipping paper  4  to perform a crush cut, also known as a burst cut, on the web  11  to form the or each line  6  of the pattern  5 . The crush cutting device acting as the mechanical cutter  70  comprises a profiled roller  71  and an anvil roller  72 . The profiled roller  71  and anvil roller  72  are spaced apart from each other to define a gap  73 . The gap  73  defines part of the web  11  of tipping paper  4  conveying path. That is, the web  11  passes between the profiled roller  71  and the anvil roller  72 . 
     The profiled roller  71  has a cylindrical outer surface  74 . Raised protrusions (not shown) extend from the profiled roller  71 . The raised protrusions define the or each line  6  of the pattern  5 . The raised protrusions define a rotary die. The anvil roller  72  has a cylindrical outer surface  75 . The cylindrical outer surface  75  of the anvil roller  72  is smooth. That is, the cylindrical outer surface  75  of the anvil roller  72  does not have any raised protrusions. 
     The spacing between the free edge of the raised protrusions (not shown) on the profiled roller  71  and cylindrical outer surface  75  of the anvil roller  72  is between 3 and 5 μm in the present embodiment. The thickness of the web  11  of tipping paper  4  is typically 0.025-0.055 mm. However, it will be understood that the dimensions may vary. Rotation of the profiled roller  71  and anvil roller  72  is synchronised. The rotational speed of the profiled roller  71  and anvil roller  72  corresponds to the throughput speed of the web  11  of tipping paper  4 . As the web  11  passes between the profiled roller  71  and anvil roller  72 , the rollers  71 ,  72  act on either side of the web  11 . The part of the web  11  received between the raised protrusions on the profiled roller  71  and the cylindrical outer surface  75  of the anvil roller  72  is compressed. That is, the material is crushed therebetween. The material on which the cutting action is performed is crushed by at least 80% of the thickness of the web  11  of tipping paper  4 . The crushing action causes the material to burst along the line of material acted on by the profiled roller  71 , and so forms a line of separation. With this action, it is possible to perform a separation action that does not require piercing of the web  11  of tipping paper  4 . In the present embodiment, the or each line  6  has a minimum length to width ration of 60:1. 
     It has been found that, by performing a cutting action on the web  11  of tipping paper  4  downstream of the curling station  50 , it is possible to form patterns  5  on the web  11  of tipping paper  4  that have not previously been possible without damage occurring to the tipping paper  4  in the cigarette making machine  4 . For example, in the present embodiment the mechanical cutter  70  is configured to perform a cutting action to form the pattern  5  including lines in a direction along the direction of the web  11  of tipping paper conveying path  4 . Furthermore, it is possible to form such a pattern  5  including lines  6  having a dimension of at least 5 mm online the cigarette making machine. It will also be understood that the mechanical cutter  70  can be retrofitted to a cigarette making machine. 
     Referring to  FIG. 3 , the web  11  of tipping paper  4  passes from the mechanical cutter  70  to a gluing station  55 . This includes a gluing roller  56  that applies to predetermined pattern of glue on to one side of the web  11 , transferred by a transfer roller  57  from a tray  58 . The web  11  with glue applied then passes over a feed roller  59  to a web severing device  60 . The web severing device  60  has a rotary patch cutter that includes a plurality of radially extending blades that cut the web  11  into tipping paper segments to to be applied to successive tobacco and filter rod arrangements as illustrated in  FIG. 5 . Referring to  FIG. 2 , the web severing device  600  cuts the web  1  along severing lines  12 ,  13  to form the individual tipping paper segments  10 . 
     In the above described embodiments, a cutting action is performed at the mechanical cutter  70  to form one or more lines  6  having a dimension of at least 5 mm on the web  11  of tipping paper  4  and, optionally, prior to rolls  22   a ,  22   b  of the web  11  of tipping paper  4  being received by the cigarette making machine to form perforations  7 . However, it will be understood that in another embodiment the cigarette making machine has a pre-cutter to perform a cutting action on the web  11  of tipping paper  4  to form perforations  7 . One such embodiment is shown in  FIG. 6 . The embodiment shown in  FIG. 6  is generally the same as the embodiments described above and so a detailed description will be omitted. However, in this embodiment the cigarette making machine has a pre-cutter  80  disposed along the web  11  of tipping paper  4  conveying path. 
     In this embodiment, the pre-cutter  80  is disposed upstream of the curling station  50  along the web  11  of tipping paper  4  conveying path. The pre-cutter  80  is configured to form perforations, or other cutting actions in which the cuts have a dimension less than 5 mm. The pre-cutter  80  may have different forms, including a laser cutting device, a pin embossing device or a shear action cutter. 
     The pre-cutter  80  is configured to perform a first cutting action on the web  11  of tipping paper  4 . The cutting action performed by the mechanical cutter  70  is a second cutting action on said web  11  of tipping paper  4 . By providing the pre-cutter  80  upstream of the curling station  50  it is possible to separate a first cutting action from a second cutting action. Such an arrangement allows a robust web  11  having an online cutting action performed on it to pass through the curling station  50 , whilst providing for a further cutting action to be performed on the web  11  prior to being combined with the rods  20   a ,  20   b ,  21 . 
     In a further embodiment, it will be understood that the pre-cutter is disposed downstream of the curling station  50  and upstream of the mechanical cutter  70  along the web  11  of tipping paper  4  conveying path. With such arrangements, it is possible to form the perforations or other cutting action that is not performed by the mechanical cutter  70  online the cigarette making machine. 
     In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior smoking article assembly machine and/or method of making a smoking article. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.