Method and apparatus for manufacturing a filter element

Abstract

A method of manufacturing a filter element (200) is disclosed that includes the steps of longitudinally advancing two or more sheets (102) of filter material; separating the two or more sheets of longitudinally advancing filter material (102); collecting the separated sheets of longitudinally advancing filter material to form a partially collected rod of filter material having a longitudinally extending recess; inserting an additive release container (204) into the longitudinally extending recess; and collecting filter material around the additive release container to close the recess, thereby forming a rod comprising a longitudinally extending core of filter material and one or more additive release containers (204).

Description

[Technical Field]

[0001] The present invention relates to a filter element and a filter, a method for manufacturing a filter element, and an apparatus for manufacturing a filter element.

[0002] Tobacco filter elements or filters containing fragile capsules are known in the art. The fragile capsules typically contain liquid additives that can alter the properties of tobacco smoke passing through the filter or filter element. For example, the capsules may contain flavoring agents such as menthol that alter the flavor and other sensory properties of the tobacco smoke. Typically, the capsules are broken by the user before smoking so that the contents of the capsule are released into the surrounding filter material.

[0003] Tobacco filter elements or filters typically include a core containing cellulose acetate filter material. Cellulose acetate filter material can decompose slowly under normal environmental conditions. Filter materials made from paper or other nonwoven materials may have improved biodegradability and other properties.

[0004] Methods for manufacturing filter elements containing capsules formed from cellulose acetate tow are known in the art. Inserting capsules into filter elements formed from sheet filter materials such as paper or nonwoven fabrics is more difficult, and problems with capsule placement and homogeneity of the filter material are common.

[0005] There is a need for new methods and apparatus for manufacturing filter elements that include capsules and are formed from sheet filter materials such as paper or nonwoven fabrics. There is also a need for new filters or filter elements that include capsules and are formed from sheet filter materials such as paper or nonwoven fabrics.

[0006] A first aspect of the present invention provides a method for manufacturing a filter element, comprising the steps of: advancing two or more sheets of filter material longitudinally; separating the two or more sheets of filter material that have advanced longitudinally; collecting the separated sheets of filter material that have advanced longitudinally to form a partially collected rod of filter material having a longitudinally extending recess; inserting an additive release container into the longitudinally extending recess; and collecting filter material around the additive release container to close the recess, thereby forming a rod comprising a longitudinally extending core of filter material and one or more additive release containers.

[0007] The applicant has found that by using two or more sheets of filter material and separating them before collection, a partially collected rod of filter material having longitudinally extending recesses is obtained, into which one or more capsules can be inserted. The formation of the recesses leads to improved positioning of capsules in filter elements manufactured from sheet filter materials such as paper or nonwoven fabric. The applicant has also found that the process of the present invention results in a filter element formed from a sheet filter material having improved homogeneity.

[0008] Two or more sheets of filter material advancing in the longitudinal direction may advance continuously in the longitudinal direction.

[0009] Two or more sheets of filter material advancing in the longitudinal direction may be separated such that a gap exists between the two or more sheets of filter material advancing in the longitudinal direction, and the size of the gap may decrease as the two or more sheets are partially collected. Before capsule insertion, the two or more sheets of filter material are not completely collected, and the size of the gap between the two sheets is reduced to form a recess in the rod of partially collected filter material. When the two or more sheets are collected, the two or more sheets may remain substantially aligned vertically. In this specification, vertical alignment means that the sheets of filter material are aligned in a plane that is perpendicular to the plane from which they advance in the longitudinal direction and perpendicular to the plane that crosses the plane from which they advance in the longitudinal direction.

[0010] Preferably, two or more sheets of filter material advancing in the longitudinal direction are separated by a separator. Preferably, the step of collecting the two or more separated sheets of filter material advancing in the longitudinal direction includes the step of drawing the two or more separated sheets of filter material advancing in the longitudinal direction into a collection chamber.

[0011] The applicant has found that the separator leaves the folds of the sheet material separated so that the capsule can be positioned at the center of the partially collected filter material, thereby improving the positioning of the capsule.

[0012] Preferably, the collection chamber is a hollow element configured to collect or condense the filter material.

[0013] Preferably, the separator is coupled to the collection chamber such that two or more sheets of longitudinally advancing filter material are separated before they enter the collection chamber, and the separator prevents the complete collection of two or more sheets of longitudinally advancing filter material, thereby forming longitudinally extending recesses in the partially collected filter material.

[0014] The collection chamber may include an inlet for receiving separated sheets of filter material and an outlet for the collected or partially collected filter material to exit.

[0015] Preferably, the collection chamber tapers longitudinally from the inlet such that the inlet has a larger inner diameter than the outlet. The collection chamber acts to collect (e.g., condense) two or more sheets of filter material to form a partially collected rod of filter material having a longitudinally extending recess. The collection chamber may have an opening for receiving an inserter for inserting one or more additive release containers into the longitudinally extending recess. The opening may be positioned between the inlet and the outlet.

[0016] Following the insertion of the additive release containers as described above, the collection chamber may further collect the partially collected filter material around the additive release containers and close the recesses, thereby forming a rod comprising a core extending longitudinally along the filter material and one or more additive release containers. The collection chamber may taper after or from the opening to further collect the partially collected filter material. Alternatively, further collection may be performed by a further collection chamber joined to the first collection chamber.

[0017] The further step of applying an outer wrapper may help complete the collection of the partially collected rods of filter material and complete the closure of the longitudinally extending recesses.

[0018] Preferably, the separator is tapered in the longitudinal direction. The separator may have a first end having a first diameter and a second end having a second diameter, the second diameter being smaller than the first diameter. The separator may extend in and along at least a portion of the length of the collection chamber. The first end of the separator may protrude from the collection chamber, and the second end of the separator may be positioned inside the collection chamber. The separator may be tapered in the same direction as the collection chamber. The separator may be substantially conical or frustoconical. The tapered shape of the separator allows for the separation of two or more sheets of filter material while also facilitating the partial collection of a sheet of filter material.

[0019] The collection chamber may taper in the same direction as the separator, thereby partially collecting two or more sheets of filter material. The applicant has found that even at the narrowest point of the separator, two or more sheets of filter material remain separated, and after the sheets of filter material advance beyond the separator, a recess remains in the partially collected rod, which can receive the above-mentioned or each additive release container.

[0020] The applicant has found that the configuration of the separator and collection chamber maintains the alignment of two or more sheets of filter material. For example, the vertical alignment of two or more sheets of filter material is maintained. In this specification, vertical alignment means alignment in a plane that is perpendicular to the plane from which the sheets of filter material advance longitudinally and perpendicular to the plane that crosses the plane from which the sheets of filter material advance longitudinally. The applicant has found that maintaining the alignment of two or more sheets of filter material while the filter material is collected results in a core of filter material with improved homogeneity and supports capsule placement.

[0021] In one embodiment, two or more longitudinally advancing sheets of filter material can be drawn into a preliminary chamber before entering the collection chamber. The preliminary chamber may include an inlet and an outlet. The preliminary chamber may taper longitudinally away from the inlet. The inlet may have an inner diameter larger than that of the outlet. The outlet of the preliminary chamber may be joined to the inlet of the collection chamber, and the separator may extend within and along at least a portion of the length of the preliminary chamber. The first end of the separator may protrude from the preliminary chamber, and the second end of the separator may be positioned inside the preliminary chamber. The preliminary chamber and the separator may be configured such that two or more sheets of longitudinally advancing filter material are separated before entering the preliminary chamber, and the separator prevents complete collection of two or more sheets of longitudinally advancing filter material, thereby forming a longitudinally extending recess in the partially collected filter material.

[0022] The applicant has found that the presence of the preliminary chamber helps to partially collect the filter material before it enters the collection chamber. In the case of the method of the present invention using a preliminary chamber, the collection chamber includes an inlet joined to the outlet of the preliminary chamber, and the collection chamber includes an opening for receiving an inserter. The collection chamber may taper longitudinally from or after the opening, thereby collecting two or more sheets of filter material around the additive release container and closing the recess, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

[0023] The additive release container inserter may include a rotating drum or wheel that inserts the additive release container into the recess at regular intervals by rotation.

[0024] The method may include the step of cutting the rod to form a filter element comprising a longitudinally extending core of filter material and one or more additive release containers.

[0025] The method may include the step of advancing a sheet of filter material in the longitudinal direction, and the step of cutting the sheet in the longitudinal direction, thereby forming two or more sheets of filter material extending in the longitudinal direction. The two or more sheets of filter material continue to advance in the longitudinal direction following the cutting. The sheet of filter material advancing in the longitudinal direction may be cut to form two, three, four, or more sheets of filter material extending in the longitudinal direction. Alternatively, the filter material may be cut by a separate process and wound onto a reel for use in the method of the present invention.

[0026] The two or more sheets of filter material may be embossed. For example, the method may include the step of embossing two or more sheets of filter material extending in the longitudinal direction. Embossing imparts an embossed outer shape onto the two or more sheets of filter material. Embossing can be performed by an embossing machine. The embossing machine may include a rotating drum (e.g., an embossing roller) having protrusions (e.g., spikes) extending away from the surface of the drum (e.g., the surface of the embossing roller). The applicant has found that the step of embossing two or more sheets results in a filter element having a desired pressure drop and a compact or high-density end visual appearance.

[0027] The two or more sheets of filter material may include two, three, or four sheets of filter material.

[0028] Each of the two or more sheets of filter material may have a width of 50 to 200 mm, such as 75 to 175 mm, such as 80 to 150 mm, such as 90 to 125 mm, such as 100 to 120 mm, such as 110 mm.

[0029] The two or more sheets of filter material may have thicknesses of 50 μm to 100 μm, for example 60 μm to 90 μm, for example 70 μm to 90 μm, for example 80 μm to 90 μm, for example 82 μm to 88 μm, for example 83 μm to 87 μm, for example 84 μm to 86 μm, for example 85 μm.

[0030] The filter material may be cigarette filter material. The filter material may also include paper, or nonwoven materials such as air-laid nonwoven materials, melt-spun nonwoven materials, and / or melt-blown nonwoven materials.

[0031] Preferably, the filter material includes or is paper.

[0032] The paper is 25 g / m². 2 ~65g / m 2 For example, 30-60 g / m 2 For example, 30-50 g / m 2 For example, 30-40 g / m 2 For example, 32-38 g / m 2 For example, 33-37 g / m 2 For example, 36 g / m 2 It may have a basis weight.

[0033] Preferably, the additive release container may be a capsule, such as a fragile capsule. The additive release container, such as a capsule, such as a fragile capsule, may contain the additive. The additive may include a smoke modifier such as a flavoring agent and / or a liquid, solid, or other material to help filter the smoke, for example. The flavoring agent may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc.

[0034] The method may include a step of winding a continuous rod, which includes a core extending longitudinally along the filter material and one or more additive release containers, before the continuous rod is cut. The winding step may include applying an outer wrapper, such as a plug wrap, to surround the continuous rod.

[0035] The method may include a step of applying an additive material to two or more sheets of filter material. The additive may be applied after the embossing step. The additive may be a taste alterant and / or flavoring agent. Flavoring agents may include, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc.

[0036] In a further aspect of the present invention, a filter element is provided that can be obtained according to the method of the present invention, for example, according to any of the methods described above.

[0037] In a further aspect of the present invention, a filter element is provided comprising a core extending in the longitudinal direction of a filter material and an additive release container within the core extending in the longitudinal direction of the filter material, wherein the core extending in the longitudinal direction of the filter material is formed from two or more sheets of the filter material.

[0038] The additive release container may be a capsule, such as a fragile capsule. The additive release container, such as a capsule, may contain the additive. The additive may include a smoke modifier such as a flavoring agent and / or a liquid, solid, or other material to help filter the smoke, for example. The flavoring agent may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc. The amount of the additive, such as the flavoring agent, may be less than 35 mg per filter element.

[0039] Additive release containers such as capsules or fragile capsules may be spherical. The additive release container (such as a capsule or a fragile capsule) may have a width of 2.0 to 4 mm, for example 2.8 to 3.5 mm, at its widest point.

[0040] The filter element may be formed from two, three, four, or more sheets of filter material.

[0041] Two or more sheets of filter material may each have a width of 50 to 200 mm, for example 75 to 175 mm, for example 80 to 150 mm, for example 90 to 125 mm, for example 100 to 120 mm, for example 110 mm.

[0042] Two or more sheets of filter material may have a thickness of 50 μm to 100 μm, for example 60 μm to 90 μm, for example 70 μm to 90 μm, for example 80 μm to 90 μm, for example 82 μm to 88 μm, for example 83 μm to 87 μm, for example 84 μm to 86 μm, for example 85 μm.

[0043] The filter material may include paper or a non-woven fabric material. The non-woven fabric material can be an airlaid non-woven fabric material such as a McAirlaid material, a meltspun non-woven fabric material, and / or a meltblown non-woven fabric material.

[0044] Paper may have a basis weight of 25 g / m 2 ~65 g / m[[ID=​​​​​​​​​​​​​​​​​​​​The outer circumference of the filter element may be between 14mm and 26mm, for example, between 16mm and 26mm.

[0047] The length of the filter element may be 4.0 mm to 50 mm, for example, 5 mm to 32 mm. The filter element may be used as part of a tobacco smoke filter or as part of a filter for non-tobacco smokeable materials, such as marijuana. The filter element of the present invention may be incorporated into a multi-segment filter as a single segment. This allows for an increase in the number of feature parts that can be incorporated into the filter. For example, a filter element according to any of the above descriptions may be joined with further filter elements.

[0048] The filter element of the present invention may be incorporated into smoking articles such as cigarettes, cigarillos, and cigars. The filter element of the present invention may also be incorporated into tobacco heating products or e-cigarettes. The filter element may also be used independently or as part of a filter assembled by a user to form a smoking article, such as a hand-rolled cigarette article.

[0049] In a further aspect of the present invention, a filter comprising any of the above-described filter elements is provided, for example, a tobacco smoke filter. The filter, for example, a tobacco smoke filter, may further comprise one or more additional filter elements. Such a filter comprising two or more filter elements may be called a multi-segment filter.

[0050] The filter may include a filter element or an outer wrapper, such as a plug wrap, surrounding one or more filter elements. The wrapper may be paper, such as air-permeable paper. The wrapper may have a basis weight of 20 to 100 grams per square meter, for example, 20 to 50 grams per square meter. The wrapper may be coated. Further filter elements may be wrapped by an outer wrapper, such as a plug wrap, surrounding the further filter elements. The filter elements and further filter elements as defined in any of the above descriptions may be wrapped together by an outer wrapper such as a plug wrap. The outer wrapper may function to join the filter elements and secure them in place.

[0051] In a further aspect of the present invention, a smoking article is provided comprising the filter or filter element described above. The smoking article may include the filter described above joined to a rod wrapped with smoking material, such as tobacco smoking material. The smoking article may further comprise a chipping wrapper, for example, chipping paper. The chipping wrapper joins the rod wrapped with smoking material to the filter by engaging around adjacent ends of the filter and the rod wrapped with smoking material. The chipping wrapper may be configured to leave a portion of the outer surface of the filter or filter wrapper exposed. Alternatively, the filter may be joined to the rod wrapped with smoking material by a full chipping wrapper that engages around the entire length of the filter or mouthpiece and adjacent ends of the rod of smoking material.

[0052] The filter element, filter, or smoking article according to the present invention may not be permeable, or may be permeable by methods well known in the art, for example, by the use of a pre-perforated or air-permeable filter wrapper (plug wrap) or chipping wrapper (chipping paper), and / or laser perforation of the filter wrapper and / or chipping wrapper. The mouthpiece, filter, filter element, or smoking article according to the present invention may be permeable by laser perforation of a core (and, if present, a wrapper (one or more) (plug wrap) and chipping wrapper (chipping paper)) extending longitudinally in the filter material. A permeable full chipping wrapper (chipping paper) may also be essentially air-permeable or have vents, and in permeable products where both a filter wrapper (plug wrap) and a chipping wrapper (chipping paper) are present, the permeability through the chipping wrapper (chipping paper) usually coincides with the permeability through the filter wrapper (plug wrap). Vents that pass through a filter wrapper (plug wrap), a chipping wrapper (chipping paper), or both simultaneously may be created by laser perforation during the manufacture of the mouthpiece, filter, or filter element.

[0053] In a further aspect of the present invention, a multi-rod is provided comprising a plurality of filter elements according to the present invention, arranged with their ends touching in a mirror image relationship.

[0054] In a further aspect of the present invention, an apparatus for manufacturing a filter element comprises a separator for separating two or more longitudinally advancing sheets of filter material, and a collection chamber configured to collect the separated longitudinally advancing sheets of filter material and form a rod of partially collected filter material, wherein the separator is coupled to the collection chamber such that the separator and the collection chamber form a longitudinally extending recess in the rod of partially collected filter material, and an inserter configured to insert one or more additive release containers into the longitudinally extending recess.

[0055] Preferably, the collection chamber is a hollow section configured to collect or condense the filter material to form a rod extending in the longitudinal direction of the filter material.

[0056] Preferably, the separator and the collection chamber are coupled such that two or more sheets of longitudinally advancing filter material are separated before they enter the collection chamber, and the separator prevents the complete collection of two or more sheets of longitudinally advancing filter material, thereby forming longitudinally extending recesses in the partially collected filter material.

[0057] The collection chamber may include an inlet for receiving separated sheets of filter material and an outlet for the collected or partially collected filter material to exit. Preferably, the collection chamber tapers longitudinally away from the inlet such that the inlet has a larger inner diameter than the outlet. The collection chamber acts to collect (e.g., condense) two or more sheets of filter material to form a partially collected rod of filter material having longitudinally extending recesses.

[0058] Preferably, the separator may be tapered in the longitudinal direction. The separator may have a first end having a first diameter and a second end having a second diameter, the second diameter being smaller than the first diameter. The separator may extend in and along at least a portion of the length of the collection chamber. The first end of the separator may protrude from the collection chamber, and the second end of the separator may be positioned inside the collection chamber. The separator may be tapered in the same direction as the collection chamber.

[0059] The separator may be substantially conical or frustoconical in shape. The tapered shape of the separator is configured to separate two or more sheets of filter material, while also facilitating partial collection of the sheets of filter material. The collection chamber may also taper in the same direction as the separator, thereby partially collecting two or more sheets of filter material. The applicant has found that even at the narrowest point of the separator, two or more sheets of filter material remain separated, and after the sheets of filter material advance beyond the separator, a recess remains in the partially collected rod, which can receive the above or each additive release container.

[0060] The applicant has found that the configuration of the separator and collection chamber maintains the alignment of two or more sheets of filter material. For example, the vertical alignment of two or more sheets of filter material is maintained. Herein, vertical alignment means alignment in a plane that is perpendicular to the plane from which the sheets of filter material advance longitudinally and perpendicular to the plane that crosses the plane from which the sheets of filter material advance longitudinally. The applicant has found that maintaining the alignment of two or more sheets of filter material while the filter material is being collected results in a core of filter material with improved homogeneity and also assists in capsule placement. The applicant has found that the separator leaves the folds of the sheet material separated so that a capsule can be placed in the center of the partially collected filter material, thereby improving capsule positioning.

[0061] The collection chamber may have an opening for receiving an inserter, for example, a longitudinally extending opening. This configuration allows the inserter to insert one or more additive release containers into a recess formed in the partially collected rod of filter material. The collection chamber may taper from or after the opening to close the recess, facilitating further collection of the partially collected rod of filter material around the additive release containers, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

[0062] The separator may extend within and along at least a portion of the length of the collection chamber, but not to the longitudinally extending opening. This configuration allows for the insertion of one or more additive release containers into the recess.

[0063] In one embodiment, the apparatus may include a pre-chamber including an inlet and an outlet, the pre-chamber tapering longitudinally away from the inlet. The inlet may have a larger inner diameter than the outlet.

[0064] The separator may be tapered longitudinally and extend within and along at least a portion of the length of the spare chamber. The first end of the separator may protrude from the spare chamber, and the second end of the separator may be positioned inside the spare chamber. The separator may be tapered in the same direction as the spare chamber. The tapering of the separator in the same direction as the spare chamber means that the separator may be partially positioned inside the spare chamber.

[0065] The applicant has found that the pre-chamber helps to partially collect the filter material before it enters the collection chamber.

[0066] In this embodiment, the collection chamber has an inlet joined to the outlet of a pre-chamber, and the collection chamber has an opening for receiving an inserter. The collection chamber may taper longitudinally from the end of the opening, thereby collecting two or more sheets of filter material around an additive release container and closing the recess, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

[0067] The apparatus may include a cutter configured to cut a single sheet of filter material into two or more longitudinally extending sheets of filter material. The cutter may be configured to cut a single sheet of filter material into two, three, four, or more longitudinally extending sheets of filter material.

[0068] The inserter may include a rotating drum or wheel configured to insert the above-mentioned or each additive release container into a longitudinally extending recess.

[0069] The apparatus may include a rod cutter configured to cut a rod comprising a core extending longitudinally in the filter material and one or more additive release containers to form a filter element.

[0070] The apparatus may include an embossing machine. The embossing machine may include a rotating drum (e.g., an embossing roller) having protrusions (e.g., spikes) that extend away from the surface of the drum (e.g., the surface of the embossing roller). The embossing machine can emboss two or more sheets of filter material. The applicant has found that embossing two or more sheets results in a filter element having a desired pressure drop and a visual appearance of compact or high-density edges.

[0071] The device may include a packaging element for wrapping the forward rod before it is cut.

[0072] The apparatus may include an additive applicator for applying additives to two or more sheets of filter material. The additives may be taste denaturants and / or flavoring agents. Flavoring agents may include, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc.

[0073] In a further aspect of the present invention, there is a device for separating and collecting two or more sheets of filter material, comprising a collection chamber having an inlet and an outlet, wherein the inlet has a larger diameter than the outlet such that the collection chamber tapers longitudinally, and a separator extending in at least a portion of the path into the collection chamber and protruding from the inlet of the collection chamber, wherein the separator and the collection chamber are configured to separate and partially collect two or more sheets of filter material, thereby forming a partially collected longitudinal rod of filter material having longitudinally extending recesses.

[0074] The collection chamber may include an inlet for receiving separated sheets of filter material and an outlet for the partially collected filter material to exit. The collection chamber acts to collect (e.g., condense) two or more sheets of filter material to form a partially collected rod of filter material having longitudinally extending recesses.

[0075] The separator may be tapered in the same direction as the collection chamber.

[0076] The separator may be substantially conical or frustoconical in shape. The tapered shape of the separator separates two or more sheets of filter material while also facilitating partial collection of the sheets of filter material. The collection chamber may also taper in the same direction as the separator, thereby partially collecting two or more sheets of filter material. The applicant has found that even at the narrowest point of the separator, two or more sheets of filter material remain separated, and after the sheets of filter material advance beyond the separator, a recess remains in the partially collected rod, which can receive the above-mentioned or each additive release container.

[0077] The applicant has found that the configuration of the separator and collection chamber maintains the alignment of two or more sheets of filter material. For example, the vertical alignment of two or more sheets of filter material is maintained. Herein, vertical alignment means alignment in a plane that is perpendicular to the plane from which the sheets of filter material advance longitudinally and perpendicular to the plane that crosses the plane from which the sheets of filter material advance longitudinally. The applicant has found that maintaining the alignment of two or more sheets of filter material while the filter material is being collected results in a core of filter material with improved homogeneity and also assists in capsule placement. The applicant has found that the separator leaves the folds of the sheet material separated so that a capsule can be placed in the center of the partially collected filter material, thereby improving capsule positioning.

[0078] The collection chamber may have an opening for receiving an inserter for inserting one or more additive release containers, for example, a longitudinally extending opening. This configuration allows the inserter to insert one or more additive release containers into recesses formed in a partially collected rod of filter material. The collection chamber may taper from or after the opening to close the recesses, facilitating further collection of the partially collected rod of filter material around the additive release containers, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

[0079] The separator may extend within and along at least a portion of the length of the collection chamber, but not to the longitudinally extending opening. This configuration allows for the insertion of one or more additive release containers into the recess.

[0080] In one embodiment, the apparatus may include a pre-chamber including an inlet and an outlet, the pre-chamber tapering longitudinally away from the inlet. The inlet may have a larger inner diameter than the outlet.

[0081] The separator may be tapered longitudinally and extend within and along at least a portion of the length of the spare chamber. The first end of the separator may protrude from the spare chamber, and the second end of the separator may be positioned inside the spare chamber. The separator may be tapered in the same direction as the spare chamber. The tapering of the separator in the same direction as the spare chamber means that the separator may be partially positioned inside the spare chamber.

[0082] The applicant has found that the pre-chamber helps to partially collect the filter material before it enters the collection chamber.

[0083] In this embodiment, the collection chamber has an inlet joined to the outlet of a pre-chamber, and the collection chamber has an opening for receiving an inserter. The collection chamber may be longitudinally tapered from or behind the end of the opening, thereby collecting two or more sheets of filter material around an additive release container and closing a recess, thereby forming a continuous rod comprising a longitudinally extending core of filter material and one or more additive release containers.

[0084] An apparatus for separating and collecting two or more sheets of filter material may be included as part of an apparatus for manufacturing a filter element.

[0085] The collection chamber is sometimes called the collection shoe. The spare chamber is sometimes called the support shoe.

[0086] Preferred embodiments of the present invention will be described below with reference to the attached drawings. [Brief explanation of the drawing]

[0087] [Figure 1] This is a schematic diagram of the method of the present invention. [Figure 2] This is a partial perspective view of the apparatus according to the present invention. [Figure 3] A side view of a part of the apparatus according to the present invention in use. [Figure 4] This is a rear view of a part of the apparatus according to the present invention in use. [Figure 5] This is a side view of the separator according to the present invention. [Figure 6] This is a perspective view of the filter element according to the present invention. [Figure 7] This is a cross-sectional view of the filter element according to the present invention. [Figure 8] This is a perspective view of a device for separating and collecting two or more sheets of filter material.

[0088] Figure 1 shows a schematic diagram of the process of the present invention.

[0089] The filter material 104 is unwound from the reel 102 and advanced in the longitudinal direction L. The filter material is a pre-cut sheet of paper filter material, which includes two individual sheets of paper filter material wound on the same reel 102. Each sheet has a width of 110 mm, a thickness of 85 μm, and a density of 36 g / m². 2 It has a basis weight of . Two sheets 104 advance together in parallel in the longitudinal direction. The longitudinal edge of one sheet abuts the longitudinal edge of the other sheet. It will be understood that three or more sheets of filter material, for example, three or four or more sheets of filter material advancing in the longitudinal direction may be used. It will be understood that two or more sheets of filter material may be formed as part of the method of the present invention. For example, a single sheet of filter material may be advanced in the longitudinal direction and cut in the longitudinal direction to make multiple sheets. It will be understood that nonwoven sheet material may also be used.

[0090] The advancing sheet 104 of the filter material is embossed by an embossing machine 106. The embossing machine 106 is equipped with a rotating roller having spikes protruding from the outer surface of the roller. The advancing sheet of filter material is drawn between the roller and a flat surface, or between the roller and a second smoothing roller (shown in Figure 1), and the embossing roller embosses the sheet of filter material. The applicant has found that embossing the sheet of filter material results in a desired pressure drop and a high-density or compact visual edge appearance.

[0091] An embossed sheet of filter material is then advanced and flattened by a wire 108. The flattened sheet of filter material is then separated by a separator in the form of a separator cone 110. The separated sheets of filter material pass through a pre-chamber 116, where the two sheets are collected together, and the sheets remain separated when a recess is formed in a partially collected rod of filter material. The partially collected rod of filter material then passes through a collection chamber 122, where one or more capsules are inserted into the recess in the partially collected rod of filter material by a capsule inserter 130 equipped with a rotating wheel. The rod is then further collected and condensed by the collection chamber 122, thereby closing the recess and forming a rod comprising a core extending longitudinally in the filter material and one or more additive release containers within the core of the filter material.

[0092] The rod is advanced longitudinally and wrapped with an outer wrapper such as a plug wrap to form a wrapped rod. The rod is wrapped with an outer wrapper using techniques known in the art. Finally, the wrapped rod is cut by a rod cutter 140 to form a filter element which includes a longitudinally extending core of the filter material containing one or more additive release containers placed within the core of the filter material. The rod cutter is a standard rod cutter known in the art.

[0093] Next, the collection step, capsule insertion step, and apparatus will be described in more detail with reference to Figures 2 to 4 and Figure 8.

[0094] As the flattened tow 104 advances and enters the reserve chamber 116, the two sheets are separated by a cone 110. The cone 110 comprises a first end 112 and a second end 114. The first end has a wider diameter than the second end, such that the cone tapers longitudinally from the first end to the second end. The cone is formed from metal.

[0095] As shown in Figures 3 and 4, the cone 110 separates the two sheets of filter material as they enter the pre-chamber 116.

[0096] The spare chamber 116 comprises an inlet 118 and an outlet 120. The inlet 118 has a larger diameter than the outlet 120 so that the spare chamber 116 tapers longitudinally from the inlet 118 to the outlet 120. The cone 110 is partially positioned within the spare chamber 116 such that a portion of the cone 110 protrudes away from the inlet 118 of the spare chamber 116. The spare chamber 116 is formed of metal.

[0097] The cone 110 is fixed within the pre-chamber 116 by a mechanical support. Before the sheet of filter material is drawn into the pre-chamber 116, the sheet is separated by the cone 110. Once the sheet of filter material is drawn into the pre-chamber 116, the sheet remains separated by the cone 110, but as the filter material advances longitudinally, the gap between the sheets decreases as the diameter of the cone 110 decreases. Simultaneously, the filter material is partially collected by the inner surface of the pre-chamber 116. As the diameter of the pre-chamber 116 decreases, the filter material is collected and condensed, forming a partially collected rod of filter material. The cone 110 prevents complete collection of the filter material and forms a recess in the partially collected rod from the filter material. The applicant has found that the cone 110 leaves the folds of the sheet material separated so that a capsule can be positioned at the center of the partially collected filter material, thereby improving the positioning of the capsule.

[0098] A partially collected rod of filter material is drawn into a collection chamber in the form of a collection shoe 122. The collection shoe 122 includes an inlet 124 and an outlet (not shown). The inlet of the collection shoe has a larger diameter than the outlet of the collection shoe. The cross-sectional diameter of the collection shoe remains constant initially in the first section 126. In the second section 127 of the collection shoe, the cross-sectional diameter decreases so that the second section 127 tapers longitudinally. The third section 128 has a constant cross-sectional diameter. It will be understood that the collection shoe does not have to include the third section 128. A longitudinally extending opening is positioned on the upper surface of the collection shoe, extending partially along the first section 126 and the second section 127 of the collection shoe. The opening is configured to receive a capsule inserter wheel 130.

[0099] The capsule inserter wheel 130 is supplied by a hopper (not shown).

[0100] Capsule inserter wheels are known in the art. Capsule inserter wheels utilize vacuum and air jet systems to collect capsules and insert them into longitudinally extending recesses. In such a system, a first wheel (not shown) has a number of equally spaced grooves around its cylindrical surface. A hopper containing capsules releases the capsules, which are collected by the grooves of the first wheel. A vacuum pump applies suction to the grooves so that each groove collects a single capsule.

[0101] A second, smaller wheel 130 is positioned below the first wheel. The second wheel 130 has a plurality of grooves spaced evenly apart around its cylindrical surface. Capsules collected by the first wheel are transferred to the second wheel 130. At the bottom of the travel path of a given groove on the first wheel, the suction applied to that groove is stopped, and the capsule is transferred by gravity to the corresponding groove on the second wheel. The capsule is held in the groove of the second wheel 130 by suction applied by a vacuum pump. The bottom of the second wheel 130 is positioned within the opening of the collection shoe 122. At the bottom of the travel path of a given groove, the suction applied to that particular groove is stopped and replaced by a jet of air directed towards the capsule, thereby releasing the capsule into a longitudinally extending recess.

[0102] An alternative capsule inserter wheel may be used, and an alternative capsule inserter wheel configuration is described here. The capsule inserter wheel has radially extending cylindrical recesses spaced at equal intervals around its cylindrical surface. The base of each recess is formed by the free end of a plunger or piston. Each piston is elastically biased radially toward the center of the wheel by a spring, but is movable radially outward against this spring bias, sweeping through the recesses and thus ensuring the ejection of their contents. The continuous motion of the piston or plunger as the wheel rotates clockwise is facilitated by a stationary cam surface that engages with the radially inner end of the piston or plunger over a portion of its travel path.

[0103] As the inserter wheel rotates, each recess is filled with individual fragile capsules from the hopper as the recesses move around the top of their travel paths. A piston or plunger, actuated by a cam surface, emptys the capsules from the inserter wheel recesses and places them into the recesses extending longitudinally along the forward rod of the partially collected filter material at the bottom of the recess's travel path.

[0104] The opening in the collection shoe 122 allows the capsule inserter wheel to extend into the collection shoe 122, thereby inserting one or more capsules into recesses in the rod of partially collected filter material. Since the rotational speed of the capsule inserter 130 and the longitudinal speed of the advancing rod of partially collected filter material are constant, the capsules are inserted into the rod of partially collected filter material at regular intervals and positioned at regular intervals within the core of the filter material. The presence of recesses in the rod of partially collected filter material assists in the placement of one or more capsules and improves the positioning of the capsules within the completed filter element.

[0105] Following capsule insertion, the partially collected rod continues to advance longitudinally and is further collected by the walls of the collection shoe. As the inner diameter of the collection shoe decreases, the partially collected rod is further collected and condensed so that the recess closes and a longitudinally advancing rod comprising a core of filter material extending longitudinally and one or more capsules is provided.

[0106] As described above with reference to Figure 1, further process steps are performed on the rod.

[0107] Figure 8 shows an apparatus for separating and collecting two or more sheets of filter material. The apparatus includes the same structure and components as those described above with reference to Figures 2 to 4, but the apparatus does not include a capsule inserter.

[0108] Figure 5 shows a side view of the cone 110. As shown in Figure 5, the cone has a first end 112 having a larger diameter than the second end 114. The first section of the cone, extending from the first end 112, has a constant diameter. The second section of the cone extends from the first section and has a diameter that decreases from the first end of the second section to the second end of the second section, so that the second section tapers. The last third section extends from the second end of the second section and has a narrower, constant diameter.

[0109] Figure 6 is a perspective view of the filter element according to the present invention.

[0110] The filter element 200 shown in Figure 6 has a density of 36 g / m². 2 The filter material comprises a core 202 extending longitudinally, formed from two sheets of paper filter material having a basis weight of 0 and a thickness of 85 μm, each sheet having a width of 110 mm. The core 202 contains a capsule 204 positioned at the center of the core. The capsule is a fragile capsule containing 2.5 g of menthol in an oil carrier. The diameter of the capsule is 3.35 mm. The filter element 200 also includes a paper plug wrap 206 surrounding the core and secured by overlapping and glued seams, as known in the art. The filter element has a circumference of 24 mm and a length of 27 mm.

[0111] Figure 6 shows a perspective cross-sectional view of the filter element 200 shown in Figure 5. Figure 6 shows the structure of a capsule 204 containing a gelatin-containing capsule shell 208 and a liquid menthol flavoring solution 210 inside the capsule shell. It will be understood that other flavorings may be included in the capsule 204.

[0112] The filter elements shown in Figures 5 and 6 can be manufactured according to the method described above with reference to Figures 1 to 4.

[0113] The filter element 200 shown in Figures 5 and 6 can be joined to a wrapped tobacco rod (not shown) to form a filtered smoking article such as a filtered cigarette. The filter element 200 may also be joined to a tobacco rod wrapped with ring chipping paper, the chipping paper engaging only around adjacent ends of the filter element and the wrapped tobacco rod, thereby leaving a portion of the plug wrap 206 exposed. Alternatively, the filter may be joined by a full chipping overlap that engages around the entire length of the filter element and adjacent ends of the wrapped tobacco rod.

Claims

1. A method for manufacturing a filter element, Steps include advancing two or more sheets of filter material in the longitudinal direction, A step of separating the two or more sheets of filter material that are advancing in the longitudinal direction, The steps include collecting the separated sheets of filter material advancing in the longitudinal direction to form a partially collected rod of filter material having longitudinally extending recesses, The steps include inserting the additive release container into the longitudinally extending recess using an additive release container inserter, The steps include: collecting the filter material around the additive release container to close the recess, thereby forming a rod comprising a core extending in the longitudinal direction of the filter material and one or more additive release containers; Includes, A method comprising a drum or wheel configured to rotate and insert the additive release containers into the longitudinally extending recesses.

2. The two or more sheets of filter material advancing in the longitudinal direction are separated by a separator and / or The method according to claim 1, wherein the step of collecting the two or more separated sheets of filter material advancing in the longitudinal direction includes the step of drawing the two or more separated sheets of filter material advancing in the longitudinal direction into a collection chamber.

3. The method according to claim 2, wherein the separator is coupled to the collection chamber such that the two or more sheets of longitudinally advancing filter material are separated before they enter the collection chamber, and the separator prevents the complete collection of the two or more sheets of longitudinally advancing filter material, thereby forming longitudinally extending recesses in the partially collected filter material.

4. The collection chamber comprises an inlet for receiving the separated sheets of filter material and an outlet for the partially collected filter material to exit, and the collection chamber tapers longitudinally away from the inlet, and / or The separator is tapered in the longitudinal direction and / or extends within and along at least a portion of the length of the collection chamber and / or The method according to claim 2 or 3, wherein the separator tapers in the same direction as the collection chamber.

5. The method according to claim 3 or 4, wherein the two or more separated longitudinally advancing sheets of filter material are drawn into a pre-chamber before entering the collection chamber, for example, the pre-chamber having an inlet and an outlet, the outlet of the pre-chamber being joined to the inlet of the collection chamber, and the separator extending in and along at least a portion of the length of the pre-chamber.

6. The method according to claim 5, wherein the auxiliary chamber is tapered in the longitudinal direction so as to move away from the entrance of the auxiliary chamber.

7. The two or more sheets of the filter material are embossed and / or, The filter material includes a nonwoven fabric material and / or The filter material includes paper and / or The method according to any one of claims 1 to 6, wherein the two or more sheets of filter material advancing in the longitudinal direction include two, three, or four sheets of filter material advancing in the longitudinal direction.

8. The method according to any one of claims 1 to 7, comprising the step of cutting the rod to form a filter element comprising a core extending in the longitudinal direction of the filter material and one or more additive release containers.

9. A filter element comprising a core extending in the longitudinal direction of the filter material and an additive release container sealed within the core extending in the longitudinal direction of the filter material, The core extending in the longitudinal direction of the filter material is formed from two or more sheets of the filter material, and A filter element in which the filter material includes paper or a nonwoven fabric material.

10. The filter element according to claim 9, wherein the additive release container is a capsule.

11. A filter comprising the filter element according to claim 9 or 10.

12. A smoking article comprising the filter element according to claim 9 or 10 or the filter according to claim 11.

13. Apparatus for manufacturing filter elements, A separator that separates two or more sheets of filter material that advance in the longitudinal direction, A collection chamber configured to collect the separated longitudinally advancing sheets of filter material and to form a rod of partially collected filter material, The separator is coupled to the collection chamber such that the separator and the collection chamber form a longitudinally extending recess within the rod of partially collected filter material, An inserter configured to insert one or more additive release containers into the longitudinally extending recess, Equipped with, The apparatus comprises a drum or wheel configured to rotate and insert one or more additive release containers into longitudinally extending recesses.

14. The collection chamber comprises an inlet for receiving the separated sheets of filter material and an outlet for the partially collected filter material to exit, and the collection chamber tapers longitudinally away from the inlet, and / or The apparatus according to claim 13, wherein the separator is tapered in the longitudinal direction and extends within and along at least a portion of the length of the collection chamber, for example, the separator is tapered in the same direction as the collection chamber.

15. The apparatus according to claim 13 or 14, comprising a pre-chamber including an inlet and an outlet, wherein the outlet of the pre-chamber is joined to the inlet of the collection chamber, and the separator extends in and along a portion of the length of the pre-chamber, for example, the pre-chamber tapering longitudinally away from the inlet.

16. The collection chamber is provided with a longitudinally extending opening for receiving the inserter, and / or The collection chamber is configured to collect the filter material around the additive release container and close the recess, thereby forming a continuous rod comprising a core extending longitudinally in the filter material and one or more additive release containers, and / or The apparatus according to any one of claims 13 to 15, wherein the apparatus comprises a rod cutter configured to cut a rod having a core extending in the longitudinal direction of a filter material and one or more additive release containers to form a filter element.

17. An apparatus for separating and collecting two or more sheets of filter material, A collection chamber comprising an inlet and an outlet, wherein the inlet has a larger diameter than the outlet such that the collection chamber tapers in the longitudinal direction, A separator extending in at least a portion of the path into the collection chamber and protruding from the inlet of the collection chamber, The separator and the collection chamber are configured to separate and partially collect two or more sheets of filter material, thereby forming a partially collected longitudinally extending rod of filter material having longitudinally extending recesses. The separator tapers in the same direction as the collection chamber. Device.

Images