Apparatus and Methods for Making Components of a Smoking Article

In the European Patent Publications 0174645(A2) and 0212234(A2), the disclosures of which are hereby incorporated by reference, there are disclosed a number of alternative forms of smoking articles which typically embody (1) an aerosol generating cartridge comprising a fuel element for generating heat for transfer to an aerosol forming material which may contain a tobacco flavoring material, (2) a sleeve or jacket circumscribing the cartridge, the sleeve preferably including an insulating material around the fuel element and a tobacco containing material around the aerosol forming material or, alternatively, an insulating material around the entire aerosol generating cartridge and, optionally, (3) a mouthend piece, which may contain a filter element. Generally, the aerosol generating cartridge comprises a capsule containing an aerosol generating material with a fuel element at one end.

It is a purpose of this invention to provide an apparatus and methods for forming a component for the sleeve or jacket described above that can be used for production of aerosol generating modules for use in smoking articles such as, for example, a cigarette-type smoking article.

In accord with the present invention, apparatus and methods provided for forming sleeve or jacket components for use in making smoking articles. A jacket component, as used herein, comprises a removable support member, a compressible and resilient layer of material circumferentially disposed about the support member, and an outer wrapper circumferentially disposed about the layer of material to define the outer diameter of the component. This component may be used to circumscribe the fuel element or the aerosol generating cartridge of smoking articles such as those described in the aforesaid European patent applications.

In one embodiment, an apparatus in accord with the invention comprises a forming means or device that receives a length of support member and length of compressible and resilient material, preferably fibrous material in the form of a web, having a width sufficient to wrap around the support member as they pass through the forming device. As used herein, the term "web" means a substantially flat flexible elongate material having a width that is at least five times its thickness such as, for example, a non woven fibrous felt.

The forming device has an arcuate or curved surface structured to fold the web around the support member so that one edge of the web is contiguous to the other edge without any significant overlap. The device has a further tapered arcuate or curved surface encountered by the web after its folded about the support member, which surface compresses the fibrous material, at least slightly, around the support member to form a composite member having a predetermined size. The apparatus further comprises means for wrapping the composite member to maintain the desired size.

Preferably, the support member and web of material are supplied to the apparatus in a continuous manner for high speed production. Thus, preferred apparatus also comprises means for guiding the support member and web into the forming device. The apparatus also preferably comprises means for cutting the wrapped composite member into predetermined lengths that conveniently are multiples of the desired size of the component to be used in a smoking article.

A preferred forming device, in accord with the invention, comprises a funnel or trumpet-like device having an inner arcuate or curved surface that tapers inwardly from its proximal open end for receiving the inner support member and web of fibrous material to its distal end through which the composite member, having the web wrapped around the removable support member, exits. The proximal or entrance end of the device is wide enough for the web to enter without the edges curling. The inner surface of the device is arcuately shaped or curved and tapered inwardly toward the exit end to subsequently cause the edges of the web to curl up and fold around the support member. A portion of the inner surface of the device is shaped to cause one edge of the web to fold over in contact with the support member before the other edge. A second portion of the inner surface of the device is arcuately shaped or curved to cause the second edge of the web to fold over proximate to the first edge. A third portion of the inner surface of the device compresses the web, at least slightly, around the removable support member as the composite member completes its passage through the device and exits the distal end of the device having a predetermined dimension. The forming device can be made in two or more separate sections for ease of construction or, preferably, is formed in one piece. One advantage of the forming device of the invention is that the resulting composite member does not have a typical overlapping double thickness of material where the edges come together but surprisingly has a substantially uniform appearance.

The invention also comprises methods for forming sleeve or jacket components for use in making smoking articles. In one preferred embodiment, a method for forming jacket components having a removable support member comprises providing a substantially continuous web of fibrous material, such as a reel or spool of material; providing a substantially continuous length of a support member, such as tubing from a reel or spool; bringing the web and support member into contact with each other; and folding the web longitudinally around the support member to wrap the support member thereby bringing one longitudinal edge of the web contiguous to the other edge to form a composite member. Preferably, the method also comprises wrapping the composite member with an outer wrapper to provide a predetermined finished size and cutting the wrapped composite member into predetermined lengths for use in making smoking articles.

FIG. 1 is an projectional view of a preferred device for continuously forming a web around a support member in accord with the present invention;

FIG. 2 is a longitudinal section of the device of FIG. 1 taken on the line 2--2 of FIG. 1;

FIG. 3 is a bottom view of the device of FIG. 1;

FIG. 4 is a cross-sectional view taken on the line 4--4 of FIG. 2;

FIG. 5A is an projectional view illustrating a preferred embodiment composite member with the web "B" wrapped around a tubular support member "A" as produced using the device in accordance with the present invention;

FIG. 5B is a projectional view illustrating the composite member of FIG. 5A provided with a conventional outer wrapper "C";

FIG. 6 is a longitudinal section corresponding to FIG. 2 illustrating the support member "A" and web "B" being fed into the device and illustrating the outer wrapping web "C" being fed under the device;

FIGS. 7A, 7B, 7C and 7D are partial cross sections not to scale taken on lines 7A--7A, 7B--7B, 7C--7C and 7D--7D, respectively, of FIG. 6;

FIG. 8 is a section taken at the end of the forming device showing in cross section a curved support for the outer wrapper "C";

FIG. 9 is a projectional view of an alternative device in accordance with the present invention, which is made in two sections;

FIG. 10 is a section taken on the line 10--10 of FIG. 9;

FIG. 11 diagrammatically illustrates a method and apparatus for forming a web around a support member, and wrapping and cutting it into component lengths;

FIG. 12 is a projectional view of a preferred embodiment of a forming surface in the form of an inset for devices in accord with the present invention, which is illustrated as part of a device having the outer shape of the device of FIG. 1;

FIG. 13 is a front view of the insert of FIG. 12;

FIG. 14 is a plan view of the insert of FIG. 12;

FIG. 15 is a side view from the left of the insert of FIG. 12;

FIG. 16 is a side view from the right of the insert of FIG. 12; and

FIG. 17 is a bottom view of the insert of FIG. 12.

In accord with the present invention, an apparatus is provided for the high speed production of a jacket component for a smoking article, which jacket component comprises, FIGS. 5A,5B, a removable tubular support member "A", a layer or layers "B" of compressible resilient material, preferably a fibrous material, having a preferred thickness of about 0.5 to about 2.5 mm, more preferably about 1 to 2 mm, circumferentially disposed about the support member (FIG. 5A) and an outer wrapper "C" circumferentially disposed about the layer of material to provide a predetermined final size (FIG. 5B). The wrapped component is preferably formed continuously from a web of fibrous material and a support member supplied from a large reel. After forming, the continuous length of the wrapped component is cut into pieces of predetermined size, usually a multiple of the size desired for the ultimate jacket component piece that is to be used for one smoking article.

An apparatus for forming the wrapped component 35 (FIG. 5B) is diagrammatically illustrated in FIG. 11. Support "A" is fed with layer or layers "B" of compressible resilient material into forming device 10 to form composite member 30. Composite member 30 is fed into a conventional wrapping device 60 where wrapper "C" is circumscribed around the composite member 30. After exiting the wrapping device 60, the wrapped jacket component 35 is cut by a conventional cutting device 65 into desired lengths for further use in making smoking articles.

With reference to the drawings, FIGS. 1 to 3 illustrate a preferred forming device 10 for continuously forming the non-wrapped component or composite member 30 (FIG. 5A). Forming device 10 has a first open, funnel or trumpet-like inlet end 11 that is wide enough to receive the full width of the web of fibrous material "B" (see FIG. 7A) being used. The curved or arcuate inner surface of device 10 tapers inwardly from the entrance end 11 to the exit end 15 through which the composite member 30 (without an outer wrapper) leaves the device. Preferably, the forming device defines a passageway having a generally decreasing cross-sectional area from the entrance end to the exit end.

As illustrated, device 10 comprises three sections 17, 18, 19 formed in one integral piece. However, each of the sections could be formed separately and mechanically held together during use.

The first section 17 is the entrance section. This section has an inner curved surface 27 that tapers inwardly away from opening 12 in the entrance end 11. The inner curved surface 27 of the entrance section 17 provides an opening 12 of sufficient width to permit the web "B" to enter without distortion (FIG. 7A). As surface 27 tapers inward, the edges of web "B" are curled up and folded partially around the support member "A" by the curved tapered surface (FIG. 7B).

The second section 18 (see FIGS. 2, 7C) is the mid section of the device. This section 18 has an inner curved surface 28 that continues to taper inwardly away from the first section 17. The mid section 18 also has a arcuate or curved separate forming surface 24 (FIGS. 2, 3, 4, 7C) attached at one side to surface 28 and extending partially across the open area enclosed by surface 28 (FIGS. 4, 7C). The forming surface 24 folds one longitudinal edge 37 of web "B" over and in contact with support "A" while permitting the other longitudinal edge 38 of web "B" to pass by surface 24 constrained only by the curvature and taper of surface 28 (FIG. 7C).

Alternatively, the forming surface may be provided by an insert 70 (FIGS. 12-17) having forming surface 24. Insert 70 is set into the mid section of the tapered funnel like device 10 as illustrated in FIG. 12. In the insert illustrated, curved surface 75 has a radius of about 0.156 in. to fold layer "B" in contact with support "A".

The third section 19 (see FIGS. 2, 7D) has a curved surface 29 that continues the inward taper from the mid section 18 to the exit end 15 where the composite member 30 (FIG. 5A) is formed to a predetermined size, preferably with web "B" compressed about tube "A". In this third section the other longitudinal edge 38 of the web "B" is folded over and in contact with removable support member "A" so that longitudinal edges 37, 38 are brought together to make a resulting layer having substantial uniformity. It is believed that the two edges 37, 38 are brought together in an interengaged or interlaced manner (FIG. 5A) rather than squarely abutting, edge to edge. In any event, web "B" is substantially uniformly wrapped around tube "A", i.e. without an overlapping edge that results in two thicknesses of web at the overlap. The continued taper of surface 29 in conjunction with a channel shaped guide 41 (FIG. 8) then compresses the web "B" around support "A" to a predetermined size at exit end 15. The thickness, density, width of web and the support dimensions are chosen to make the layer uniform when wrapped. Thus, rolling the wrapped composite member 35 between the thumb and forefinger provides a uniform smooth sensation.

The forming device 10 can be used on, for example, a Hauni KDF-2 filter making machine. The composite member 30, FIG. 5A, is wrapped with conventional cigarette paper wrapping "C", FIG. 5B, in a conventional wrapping device on the KDF-2 immediately upon exiting the forming device 10. The forming device 10 is placed over a channel-shaped member 41 (FIGS. 6, 8), embodying a semi-circular surface 45 (FIG. 8) as in the Hauni KDF-2. The surface 45 cooperates with the forming device 10 to maintain the shape of the composite member 30. The outer wrapper "C", FIG. 8, usually conventional cigarette paper, is fed between the forming device 10 and the channel-shaped guide 41 (see FIGS. 6, 8). As the composite member 30 and wrapper "C" leave the distal end 15, they enter a conventional wrapping device (see 60, FIG. 11) that is part of the apparatus, which device wraps and seals the wrapper "C" about the composite member 30.

After the wrapper "C" is wrapped and sealed around layer "B" to form composite member 30, FIG. 5B, the diameter of the component is fixed. A cutter (see 65, FIG. 11) is arranged transversely of the wrapping device for cutting the wrapped composite member 30 into predetermined lengths for further handling in making smoking articles. Typically, the lengths are a multiple of the size desired to be used for each smoking article. For example, if a 10 mm component length is used for each smoking article, the length of the wrapped composite member may be, for example, 80 mm.

In a typical operation, it may be desired to form a component that has a circumference of about 24.1 mm to make a smoking article such as described in the aforesaid European patent publications. A tube made of low density polyethylene having an outer diameter of 0.178 inches with a 0.020 inch wall thickness may be used as the removable support member. A glass fiber web about 0.032 inch thick having a density of about 160 to 180 g/m.sup.2 may be used to wrap the tube. To obtain a material thickness of about 1.5 to 1.6 mm around the tube, two layers of the glass fiber material are used and wrapped simultaneously around the tubular support member "B" by the forming device 10. A web width of the material of about 19 mm is sufficient to wrap around the tubular support member to obtain the final composite member 30 having a circumference of about 24.1 mm. One layer of fibrous web can be used if provided in a suitable thickness and width.

An alternative forming device 50 made in accordance with the present invention is shown in FIGS. 9 and 10. The forming device 50 comprises a frusto conical shaped funnel 51 made, for example, from about 18 gauge stainless steel sheet. In one embodiment the large open inlet first end 51a through which the web and support member enter is about one inch inside diameter (I.D.). The funnel 51 from tapers down to about 11/32 inch I.D. at the exit end 51b and one edge 53 of the stainless sheet is spaced away from the other edge 54 leaving a gap of about 3/32 inch at the exit end. A bracket 52 is used to position the funnel 57 on a modified filter making apparatus.

Forming device 50 comprises curved surfaces that perform the function of the first two sections (17, 18) of device 10 which was discussed above. A second tapered conical section 55, (FIG. 9) which is used in conjunction with forming device 50, performs the function of the third section (19) of device 10. As illustrated in FIG. 10, as tubular support A exits from the funnel 51, one longitudinal edge 37 of web "B" is folded over tube "A" under edge 54 of the device 50 while the second longitudinal edge 38 of web 35 extends along the inner surface of the funnel 51 toward edge 53.

After exiting from the forming device 50, the support tube A and web "B" enter immediately into a tapered section 55 where the second longitudinal edge 38 of web "B" is folded proximate the first and web "B" is compressed, at least slightly, around tube "A" to a predetermined size as the composite member 30 exits the tapered part 55. The composite member can then be wrapped with an outer wrapper with a conventional wrapping device (FIG. 11), as discussed above.

It can be readily appreciated that the other cross-sectional shaped support members can be wrapped with a fibrous web, in accord with the invention, by suitable modification of the cross-section of the forming device used.

In accord with the invention, methods are provided for making jacket components for use in making smoking articles. A preferred method for making jacket components in accord with the present invention comprises providing a substantially continuous length of fibrous material, for instance, in the form of a web or ribbon of predetermined width and thickness wound on a reel or spool and providing a substantially continuous support member such as tubing wound on a reel or spool. The web and support member are brought together longitudinally and the web is longitudinally folded around the support member to have one edge contiguous to the other edge. The fibrous layer is then compressed to provide a predetermined final size wherein the support member is substantially uniformly wrapped with the fibrous material.

Preferably, the sized member is then wrapped with an outer wrapper to maintain the final size. For convenient handling for use in making smoking articles, the wrapped composite member is preferably cut into lengths that are a multiple of the length of a jacket component used for making a smoking article.

This invention has been described in detail including the preferred embodiments thereof. However, it will be appreciated that those skilled in the art, upon consideration of this specification, may make modifications and improvements within the spirit and scope of the invention, which is defined by the appended claims.