CA1299049C

CA1299049C - Apparatus and methods for making components of a smoking article

Info

Publication number: CA1299049C
Application number: CA000577346A
Authority: CA
Inventors: Lloyd Harmon Hancock; Jesse Arvil Stigall; Donald Ross Wilkinson
Original assignee: RJ Reynolds Tobacco Co
Current assignee: Japan Tobacco Inc
Priority date: 1987-09-15
Filing date: 1988-09-14
Publication date: 1992-04-21
Anticipated expiration: 2009-04-21
Also published as: US4893637A; KR890004646A; ATE114219T1; DE3852160D1; EP0307686A2; ES2063748T3; GR3015008T3; EP0307686A3; EP0307686B1; KR960009180B1; JPH01120272A; DE3852160T2

Abstract

APPARATUS AND METHODS FOR MAKING
COMPONENTS OF A SMOKING ARTICLE

ABSTRACT OF THE DISCLOSURE
Apparatus and method are described for forming a composite member for use in making a smoking article.
The apparatus comprises a forming device that comprises (a) an elongate structure having a curved inner surface that tapers from a larger proximal end to a smaller distal end, the proximal end of the structure being adapted to receive a support member and a layer of material which are fed simultaneously into the device, the tapering inward curved inner surface causing the edges of the fibrous layer to bend around the inner support member, and (b) a curved forming surface that causes a first edge of the material to fold over the support member while permitting the second edge to pass by the forming surface, the curved inner surface of the device further tapering to the distal end causing the second edge of the material to fold over the support member proximate to the first edge.

Description

~Z~ '3 APPARATUS AND METHODS FOR MAKING
CONPONENTS OF A SMOKING ARTICLE

S BACKGROUND OF THE INVENTION

In the European Patent Publication 0174645(A2) and 0~12234(A2), there are disclosed a number of alternative forms of smoking articles which typically embody tl) an aerosol generating cartridge comprising a fuel element for generating heat for transfer to an aerosol forming material which may contain a tobacco flavouring material, (2) a sleeve or jacket circumscribing the cartridge, the sleeve preferably including an insulating material around the fuel element and a tobacco containing materi~l around the aerosol forming material or, alternatively, an insulting material around the entire aerosol generating cartridge and, optionally, (3) a mouthend piece, which may contain ~0 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 $his in~ention 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.
.
SUMMARY_OF_THE INVENTION

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 ~ .
`
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removabl~ ~upport member, ~ compre6slble nnd resll~ent layzr of ~aterial circu~ferentially di~po~ad about the 8upport memb~r, and an outer wrap~r circun~erentially dlspos~d about th~ layar o~ ~atqri~l to de~lne ~he outer diameter o~ th~ component. Thi3 component may be used to circu~scribQ the tuQl ~l~ent or the aeroGol generating cartridge of ~moking articles ~uch a8 those described in the ~oresaid ~urop~an patent applications.
In one e~bodlment, an apparatus in accord with the invention comprises a forming ~eans or device that receives ~ length of ~upport ~efflber nd length of comprassibl~ and resilient ~aterial, pre~Qrably fibrous ~aterial in the Porm o~ a w0bj having a width ~u~ lent to wrap around th~ ~upport ~umb~r as they pass through th~ ~orming dovlc~. A~ u~Qd ha~ein, the term Nweb" ~ean~ a ~ubstantlally ~lat ~lax~ble elongate ~atQrial having a width that i8 at least fiv~
time3 it5 thickne~ ~u~h as, ~or axampl~ a non woven ~ibrous ~ lt.
~ he forming devi~e na~ an arcuatQ or curved eurface structured to ~old th~ wab around th~ ~upport ~ember ~o that on~ edge o~ ~be ~b is contiguou~ to the othar ~dge without any ~gni~icant overl~p. The devi~e has a ~urthar t~perad arcuate or curved ~urfa~e ~ncountered by the web ~ter lt~ ~old~d about ~he ~upport ma~ber, whi~h ~urface co~pre~s~ the ~ibrous material, at laas~ ~lightly, around th~ BUpport ~e~ber to ~orm a compo~ite member having a predetermined ~iz~. $ha ~pparatus ~urther co~pri~ means ~or ~z9~ 3 wrappinq the compo~lte ~ember to ~aintain the desired ~ize~
Preferably, the ~upport me2ber and web o~ ~aterial arQ ~upplied to the apparatu~ ln a continuous ~anner for high 6peed produotion. Thus, preferred ~pparatus ~lso comprises ~eans ~or gulding the ~upport ~embsr and web lnto thQ rOrming devio~. Th~ apparatus also preferably comprise~ ~eans for cutting the wrapped composite ~embsr into predeter~ined l~ngth~ that conveniently are ~ultiple~ Or the des~red ~iZQ of the component to be used in a smoking art~cle.
A preferred forming device, in ~c~ord with the invention, comprise~ a ~unnel or tru~pe ~ e devica ha~ing an inner arouate or ~uxved sur~acs that tapers inwardly from its proximal open end ~or re~eivlng the lnner ~upport Demb~r And we~ o~ ~lbrous ~aterial to it8 distal ~nd through ~hich the composite member, havlng thQ web wr~pp~d around the re~ovabl~ ~upport member, ex~ts. The proxi~21 or ~ntran~ ~nd o~ ~he da~ica ~c wide enough Por the web to snt~r w$thout the ~dge~ curling. Th~ innQr sur~acQ of ~h~ d~vice is arcuately shaped or ~urved and tap~red lnwardly tow rd the ~xit ~nd to eubsequ~nkly caus~ the Qd~es o~ the web to curl up and ~old around th~ 8upport ~e~ber~ A
portion of the inner sur~acs o~ the d~vice i~ ~haped to cause one edge o~ th~ web to fold ov~r in contact ~ith the 8upport me~b~r bQ~or~ th8 o~her ~dgQ, ~econd port~on oP ~he lnn~r sur~ace o~ ~ha d~ic~ ig arcuately shaped or curved to G~USQ th~ sQcond edge of th~ web to fold over proximate to the ~ir~t ~dge. A
~hlrd portion o~ the lnner ~ur~ac~ o~ the devlce compressas the web~ at least ~lightly, around the removablo support ~e~ber as the compo~ite ~ember co~pletes lts passage through the devlca and exit~ thQ
di~tal ~nd of the duvice hav~ng a prsdst2r~inéd 30~9 dimen610n. The forming devic~ can be ~ad~ in two or more ~eparat~ ~ection~ ~or ease o~ constructlon or, prQ~rably, i8 ro~m~d in onQ piecs. One advantaga o~
the ~or~ng device of the inv~ntion i~ that tha 5 re~ulting composi~e ~ember do~s not have a typical overlapping double thicknes3 o~ material where the edge~ come togsther but 3urprisingly has a substantially unifor~ appaaranc~.
The lnvention al o comprise~ method~ ~or forming sl~eve or ~acket components for u~e in making smoking articl2s. In one pre~erred 2mbodiment, a ~ethod ~or forming ~acket components having a removable support ~ember comprises prov~ding a 3ubstantially continuous web o~ ~ibrous materlal, ~u~h a~ a r~el or spool of material; providing a ~ubstantially contlnuous length of a ~upport member, such a~ tubing from a reel or spool: bringing th~ web and ~upport ~embQr into contact with each other; and ~old~ng the web longitudinally around the ~upport ~ember to wrap thQ
~upport ~ember ~hereby bringing one lcngitudinal adge o~ th~ ~eb contiguou~ to the other edge to form a co~pos~tQ ~ember~ Pr~f~ra~ly, the ~athod al30 co~pri~a~ wrapping tha compo~it~ b2r with an outer wrappsr to provide ~ predetsr~ned ~lnished size and Cutting the wrapped omposit~ ~ember into predetermined lQngths for U8~ ln ~kin~ 3moking articles.

BRI~F DESCRIPTION OF ~H~ ~AWI~S
FIG. l is an pro~ectional v18w 0~ a pra~rred devlcQ for continuously ~or~ing ~ web Around a BUpport ~ember in accord wi~h the pre~ent lnvention:
FIG. 2 is a longitudinal ~ection o~ th~ d~vice of FIG. l taken on the line 2-2 o~ FI~. l;
FIG. 3 i~ ~ bottom vlew Or the device o~ FI¢. 1:

~2~g~

FIG. 4 is a ~ro~s-~eot~onal view taken on the llne 4-4 of FIG. 2;
FIG. SA iB an pro~ctional viaw lllu~trating a preîerred Qmbodim~nt Compo~itQ ~emb~r ~ith th~ web ~B'3 wrapp¢d around a tubular 3upport ~ber "A" as produc3d uslng the device ln accordance with the present inve~tion:
FIC. 5~ i~ a pro~e~tion,al vi~w illu~trating the compos~te member of FIG. 5A ~rovided with a conventional outer wrapp~r ~C~:
FIG. 6 ig a longitudinal sectlon corresponding to FIG. 2 illustrating the support ~ember "A" ~nd we~ nB"
being fed into the devic~ and 1llustrating the outer wrapping web "C" being fed under th~ devic~:
FIGS. 7A, 7B, 7C and 7D are partial ~ro8~ sections not to scale taken on llnas ?A-7A, 7B-7B, 7c-7c and 7D-7D, r~spectiv2ly, o~ FIG. 6:
FIG, 8 is a ~ection taken at th~ ~nd o~ the for~ing d~vice showing ln cross ~ction a curved-Bupport ~or the outer wrapp~r ~n, FIG. 9 is s pro~ectional view of an alternatived~vic~ in aocordancQ with the present inv~ntlon/ which i8 made in two ~ection~;
FIG. lO i~ ction taken on th~ line lO-lO oP
FIG, g;
FIG. ll diagrammatically illu~trates a ~ethod and apparatus for Por~ing a web around a support me~ber, and wrapping and ~utting it in~o eo~ponent l~ngths;
FIG. 12 1~ a pro~ectional vi~w G~ a pra~erred ~mbodlment o~ a for~ing ~urfac~ ln tha ~orm o~ an ins~t ~or davlc~ ln ~ccord with th~ pre ent invention, whi¢h ~s illu~trat~d a~ p~rt o~ a device havin~ ~he outer ~hap~ o~ th~ devic~ o~ FIG. l:
FIG. 13 is a ~ront view of th~ in~ert o~ ~IG. 12:
FIÇ. 14 1~ a pl n Yiew o~ the lnssrt o~ ~IG. 12;

lZ9~09~9 FIG. 15 1~ a ~ids visw rrom She l~ft ~ ~ e i~rt o~ FIG. 12;
FIG. 16 is a 0ide Vi8W ~ro~ ~ha rl~ht o~ th~
~n ert o~ FIG. 12: ~nd 5FIG. 17 is a bottom view o~ the insert o~ FlG. 12.

DESCRIPTION OF ~HI~ PR8FE~RED
EMBO~IMENTS OF T~E INV~N~Q~
In accord with the present lnvention, an apparatus i8 provided for the high ~peed productlon o~ a ~ac~et component for a ~moking article, whi~h ~a~ket component co~prises, FIGS. 5A,5~, a removable tubular ~upport member nA", a layer or layer~ nB" of compressible resilient ~aterial, pra~erably a ~ibrous materlal, having a pre~errad th~ckne~s o~ about O.5 to : 15 about 2.5 ~m, ~ora pre~erably about 1 to 2 mm, circu~erentially d~pos~d about the ~upport ~ember (F~G. 5A~ and an outer wrapper 0C" circu~er~ntially di~pos~d about the layer o~ ~at~rial to pro~id~ a - pr~determined ~inal ~iza (FIa. 5B). Tha wrapped compon~nt ~ pr~fQrably formed con~inuou~ly ~ro~ a web of ~ibrous material and a ~upport ~ember ~upplisd ~rom a larg~ reel. Aftar ~or~lng, th~ oontlnuou~ langth of the wrapped oompo~nt is cut lnto- piecs~ o~
predetQr~ined ~ize, uBually a ~ultlpl~ o~ ~h~ ~ize desir~d for the ultlmate ~acX~t component ~iQC~ that 8 to b~ us~d rOr on~ s~oki~g artlolQ-An apparatue ~or ~or~lng th~ wrapped oomponQnt 35~FIG. SB) is dlagram~atlcally illustrat~d ~n FIG. 11.
Support ~A" ia ~ed wl~h l~yQr or layer~ ~" o~
oompr~ssibls re~ nt ~teri~l intu ~ormi~g d~vics 10 : to ~or~ composit2 ~ember 30. Compo~it~ ~e~ber 30 ig : fed $~o a conventional wr~pping dQvioe 60 where : wrapper "C" is airc~sarlbed around ~h~ co~pos~te ~ m~mber 30. A~ter exitin~ t~e wrapplng davic~ 60, th~

.

, ~Z9~30~1~

wrapped ~acket component 35 is cut ~y a ~onventional cutting dev$c~ 65 lnto d~sir~d lengths ~or ~urth~r u~e in ~aklng smoking articles.
Wlth reference to the drawings, FIGS. 1 to 3 s illustra a a pre~errad ~or~ng ~eYlc~ lO for continuously forming ~he non-wrapped co~ponent or composlt6 nQ~ber 30 (FIG. 5A~. ~or~lng d3vlca lO has a ~irst open, ~unnel or trumpet-llke inl~t Qnd 11 that is wids enough to r~ceive the ~ull wldth o~ the web o~
~ibrous material ~B" Isee 'FIG. 7A) be~ ng used. The curved or arcuate lnner 6ur~ace o~ device lO tapers inwardly fro~ the entranca end ll to th~ exit end 15 through which the composlte membex 30 ~w~thout an outer wrapper) leaves the d~vlce. Pr~erably, the ~orming device de~ines a passageway having a generally decr~asing cross-~ectional ~rea ~ro~ th~ ~ntranca end to the exit end.
A~ illustrAted, d~vice lO co~pr~ ~a3 thr~e ~ectlons 17, 18, 1~ for~ ln on~ ~nt~gr&I plQ¢e. How~var, each o~ the ~ection~ could be ~ormed ~eparately and ~echanlcally held together during u a.
The ~irst saation 17 i8 the ~ntrance Eection.
Thi8 section has an lnn~r curvad ~ur~ace 27 that tapers inwardly away fro~ opening 12 in the entrance 2s end 11. Th~ inner Gurved sur~ace 27 of ~he antrance 8~ct~ on 17 provides an opening 12 Or ~ufficient width to per~it ~he web "B" to ~ntQr wi~hout dl3tortion (FIG. 7A). A~ sur~ace 27 taper~ in~ard, ~he ~d~s o~
wQb ~B" are curled up ~nd ~oldod partially around the 30 BUpport ~ber "A" by the curved tap~red ~urface (FIG. 7B).
The 6~cond saction 18 ~e~ FIGS. 2, 7C~ is th~ ~id ~sction of the devics. ~h~o sectlon 18 h~ a~l lnner curv~d curfacq 28 ~hat continues to taper inwardly away ~ro~ t:he ~irst ~ection 170 Th~ ectl on 18 ~2~9~

also has a arcuate or cur~ed separat~ gorming sur~ace 24 ~FI~S. 2, 3, 4, 7C) attached at one ~id~ to ~urface 28 and extending part~ally acros~ ~h~ open area enclo~ed by 6ur~ace 28 SFI~.S. 4, 7~. 5he ~ormi~g aur~ace 24 ~old~ one longitudinal ~dg~ 37 o~ ~eb ~B"
over nnd ln contact wi~h ~upport "A" whil~ per~itting tha other lonqitudinal ~dge 38 o~ web "~ to pa~s by ~urface 24 con~trainsd only by the curvatur~ and taper of surface ~8 (FIG. 7C).
1~ Alternativsly, the forming ~ur~ace ~ay be provided by an insert 70 (FIGS. 12 - 17) havlng forming 6ur~ace 24. Insert 70 i9 6et into th~ mid section Or the tapexed ~unnel like de~ice 10 A5 lllu~trated in FIG.
12. In tha ~nsert illustrated, curved ~ur~ace 75 has a radius o~ about 0.156 ln. to ~old layer "B" in contact with 8upport ~An.
Th~ thlrd ~ection 19 S 8aQ FIG~o 2, ~D) ha~ a curved urf ac~ 29 ~hat contlnues tha i~ward tapQr *rom thR ~id section 18 to thQ ~xit ~nd 15 whQrQ the co~poaita ~ember 30 (FIG. 5A) i8 ~or~ed to prQdeter~in~d 81z~, pr~ferably vith web ~B~ compr~ssed about tube ~A". In ~hi~ third s~ctlon ~hn other long$tudinal adge 38 of th~ wcb ~ olded over and in contact wi~h re~ovable ~upport ~ember aA" ~o ~h~t longitudinal sdges 37, 38 ar~ brought together to ~ake a re~ulting layer havin~ sub~tantlal uni~ormity. It i~ beli~v~d that thQ two ~dges 37, 38 ar~ brought together in an interengaged or i~tarl~cQd ~anner (FIG.
5A) rather than ~guarely ~butting, ~dgo to ~dg~. In ~ny ~ve~t, web ~BN 1 ~ub~tantially uni~or~ly ~rapped around tube ~A", i.a. wlthout an ovarlapplng odge ~hat result3 in two thic~n~s~es o~ w~b at th~ overlap. The continu~d tap~r o~ sur~ace 29 in con~unction wl~h a channel ~haped guid8 41 (FIG. 8) ~h~n ~o~prs~3es ~he web "B" around ~upport NA~ to a pr~deten~in~d ~z~ ~t exit end 15. The thicknes~, dsn~ity, w~dth o~ web and th8 8upport dimension~ are ~hosen to ~aka the layer uniform wh~n wrapped. Thu~, rolling th~ ~rapped composlte member 35 between tho thumb and rorQ~nger provides a uniform smooth ~nsation.
The formlng d~v~ce 10 oan be u ad on,.~or ~xample, a Haunl ~DF-2 ~ilter making machin~. Ths co~po~ite me~ber 30, FIG. 5A, i3 wrappQd wlth conventional cigar2tte paper wrapping "C", FIG. 53, in a conventional wrapping device on the KDF-2 l~mediately upon exiting the forming d~v~ce 10. ~he ~orming device 10 ls pla~ed over a channel-shapQd ~ember 41 (FIGS. 6, ~), embodying a semi-c$rcular ~urface 45 (FIG. 8) as in the Hauni gDF-2. Tbe sur~ace 45 cooperates wi~h the forming dQvics 10 to ma~nt~in the shape of the composit~ member 30. Th~ outar wrapper ~C"/ FIG. 8, usually conventional cl~ar~tte paper, is ~ed between the ~or~ing devlcQ 10 and the channel-haped quide 41 tse~ FI~S. 6,- 8). A~ the compo~ite ~smber 30 and wrappar ~C~ l~av~ ~he ~i~tal end 15, they enter a conv~ntional ~rapping device (~ee 60, FIG. 11) that 1~ part o~ the ~ppar~tu~, wh~ch de~ic~ wraps and ~eals ~he wrapper ~C~ about th~
composit~ member 30.
Aftar the wrapper "C~ iB ~rapped and ~ealed around lay~r ~B~ to ~or~ compo3it~ ~e~b~r 30, FIG. SB, thQ
dlamet~r of th~ co~pon~nt ~ ~lx~d. A cutt~r ~e~ 65, FIG. 11) is arranged ~ran versely of th~ wrapping device ~or cutting the wrapped co~po~t~ ~e~bQr 30 into predetar~lned lengths ~or ~urth~r handling ln making 3mo~ing articlas. Typl~ally, ~he length~ ~r~ a multiple o~ the 6iza desired to b~ u~d ~or ~ach smoking article. ~or ex~Mple, ~ a 10 ~ ~o~ponent length is used ~or eaGh s~oking article, ~ho length o~
the wrapped composite ~embar ~ay be, ~or ~xampl~, 80 m~.

~2~49 In a typi~al operat$on, it ~ay ~e dQsir~d to ~orm a component that h2~ a cirCu~rencQ o~ ~bout 24.1 mm to maXe a smoking artiola such ~s daac~ibed ~n the aforesaid European patant publ~cations. A tube made o~ low density polyethyl~ne having an outer diameter of O.178 inches with a 0.020 inch wall thickn~s ~ay be USQ~ as th~ r~movable ~u~pport ~Qmber. A glass ~ib~r web about 0.032 inch ~hick having a density Or about 160 to 180 g/m2 ~ay be used to wrap the tube.
To obtain a ~aterial thickness o~ ~b~ut 1.5 to 1.6 ~m around the tube, two layers o~ the glass ~iber material are used and wrapped si~ult neously around the tubular support ~embe~ ~B" by the ~orming device 10. A web width o~ the ~aterial o~ ~bout 19 m~ is ~u~icient to wrap around ~he tubular upport n~ber to obtain thQ ~inal composit~ ~ ~ er 30 having a circu~er~ncs of a~out 24.1 m~. On~ laysr o~ ~ibrous ~b can b~ us~d i~ provid~d i~ ~uit~bl~ thicXness and width.
An alt~rnativa ~or~ing dQvi~ 50 ~ada in accordanc~ ~ith th~ prQ~en~ lnv~ntion 1~ ~own ~n FIGS. 9 ~nd 10. The ~oxming dsYic~ 50 comprises a ~rusto conical 3haped funnel 51 ~3de, ~or æxampl~, ~rom about 18 gauge ata~nl~ 8t~ hs~t. In o~e o~bodiment thQ largQ opQn inl~t ~i~st end 51a through which tha web and support ~ember ~tQr is about one inc~ in~ld~ dia~eter (I.D.). ThQ ~unnel 51 ~ro~
tapers down to ~bout 11/32 inch ~.D. at ~he ~xit and 51b and ona ~dgQ 53 of th~ 3talnl~s ~he~t i~ ~paced - 30 away ~ro~ th~ othQr ~dg~ 54 l~aving a gap oS about 3/32 inch at thQ ex$t and. A brac~et 52 ls used to position th~ funn~l 57 on a ~odirled ~ r ~aking apparatus.

~;Z9~3 For~ing devic~ SO comprises curvQd ~ur~aces that per~or~ tha Sunction or the f~rst two sactions ~17, 18) o~ d~vice 10 which ~as discussQd abov~. A ~cond t~per3d conical section 55, (FI~. 9) ~hich ~5 u~d in conjunction with ~orming dQvice 50, per~orms the ~unction o~ the third 6sction ~19) o~ devica 10. As illustrated ln FIG. 10, as tubul~r support A ~xits rrom ~he funnel 51, one longi~udinal ~dge 37 ot web ~ i5 ~olded ovex tube ~A" under ædge 54 o~ the device 50 while ~he second longitudinal edge 38 of web extends along the inner sur~ace o~ the ~unnel 51 toward edge 53.
Aft~r exiting ~rom the ~orming de~ice 5~, ~he support tub~ A and web ~" enter lmm~diately into a 15 tapered section 55 wh~re ~he saeond longitudinal ~dge 38 oS wQb ~B" $g ~old~d proximate th~ ~irst and web WB~ i~ compr~ssed, at l~ast ~lightly, ~round tube "A"
to a pr~det~r~in~d ~iz~ as th~ co~po~it~ ~e~ber 30 ~xits the taperad pa~ 55. Th~ composit~ bQr ~an 20 t~en b~ wrappad ~i~h an outer ~rapp~r wi~h a conv~ntional wrapping d~Yic~ ~F~ , as discussed above.
It can b~ r~adily appr~ciatad ~hat o~her cros~-sQctional ohap~d ~upport ~eD~e~ can be wrapped 2~ with a ~lbrous ~eb, in accord with th~ ~nv~n~ion, ~y suitabl~ ~odi~$cation of ~h~ c~oss-s~ction o~ the ~orming ~Q~ice u~2d.
In accord ~i~h th~ $n~2ntion, ~othod~ ~re provided ~or ~zking ~ack~t co~pon~ntQ ~o~ u~o in making omo~ing 30 article . A pref~rr~d ~e~hod ~or making ~acket ~omponents 1~ accord wi~h th~ present inv~ntion compris~ providing a ~ubstant~ally continuous la~g~h o~ fibrou~ material, for ~nst~nca, ln ~h~ ~orm oS a ~Qb or ribbon o~ pr~d~termined ~idth and ~hickn~ss 35 wound on ro~l or ~pool and pro~idin~ a substantially 0~

continuous ~upport ~har ~uch as tubing wound on a r~Ql or spool. The w~b ~nd ~upport m~b~r ~re b~ought together longitudinally and the w~b i5 lonyitudinally fold~d ~round th~ ~upport ~Q~bQr to haVQ ono ~dge contiguous to tha other ~dge. ThQ ~ibrous layer ls then comprQssed to provide a predetQrminQd ~inal size wherein th~ support me~bar $g substankially uni~ormly wr~pped with the ~ibrous ~aterial.
Pre~erably, th~ ~i2ed member is ~hen wrapped with 10 an outer wrapper to maintain the ~inal ~ize. For convenient handling ~or use in making smoking articles, the wrapped composits member is proferably cut ~nto lengths that are 2 ~ultipl~ o~ the length of a jacket co~ponent used for making a smoking ~sticl~.
$his invention has been descr~bed in detail including the preSerrsd e~bodiments ~h~rao~. ~w~ver, it w~ll be appreciated that tho~ ~killed in ~a art, upon consideration o~ thi~ 3p~ci~icatlon, ~ay n~ake ~odi~ication ~nd improv~nents within th~ spirit and 20 3COp~ O:~ thQ irlv~ntion, which i~ de~ined by the appended claims.

Claims

1. A device for forming a composite member for use in making a smoking article, the composite member comprising a removable support member circumscribed by a layer of compressible and resilient material, the device comprising (a) an elongate structure having a curved inner surface that tapers from a larger proximal and to a smaller distal end, the proximal end of the structure being adapted to receive the support member and the layer of material which are fed simultaneously into the device, the tapering inward curved inner surface causing the longitudinal edges of the layer of material to bend around the inner support member, and (b) a curved forming surface that causes a first longitudinal edge of the material to fold over the support member while permitting the second longitudinal edge to pass by the forming surface, the curved inner surface of the device further tapering to the distal end causing the longitudinal second edge of the material to fold over the support member proximate to the first longitudinal edge.

2. The device of claim 1, wherein the curved inner surface is not a closed surface, the device thereby having a longitudinal opening in the surface extending from end to end.

3. The device of claim 2, further comprising a curved cooperating surface positioned adjacent the longitudinal opening which cooperates with the curved inner surface and curved forming surface to form the composite member.

4. The device of claim 2, wherein the support member is fed into the device between the layer of material and the curved inner surface.

5. The device of claim 1, wherein the curved inner surface tapering to the distal end is structured to cause the layer of material to compress around the removable support member.

6. The device of claims 1 or 4, wherein the curved forming surface is located intermediate the proximal and distal ends of the elongate structure and is disposed between the curved inner surface of the elongate structure and the layer of material.

7. Apparatus for continuously forming an elongate jacket member for use in making smoking articles, the jacket member comprising a removable support member, a layer of fibrous material circumferentially disposed about the support member and a wrapper circumferentially disposed about the layer of material, the apparatus comprising:
means for guiding a support member into the apparatus, means for guiding a layer of material into the apparatus, forming means for receiving the support member and the layer of material and forming the layer of material around the support member;
compressing mean for compressing the layer of fibrous material around the support member to a predetermined dimension; and wrapping means for disposing a wrapper around the material to maintain the predetermined dimension.

8. The apparatus of claim 7 wherein the forming means comprises means for folding an elongate layer of material longitudinally around the support member so that one longitudinal edge of the material is contiguous to the outer longitudinal edge.

9. The apparatus of claim 7 wherein the forming means and compressing means together comprise a tapered device having an entrance end and an exit end through which the support member and layer of fibrous material pass, wherein the entrance end is larger than the exit end, the device comprising a section having a curved forming surface that folds a first longitudinal edge of the fibrous layer around the support member, and a further section having an interior curved surface that tapers inwardly toward the exit end to fold the other longitudinal edge of the layer around the support member contiguous to the first longitudinal edge and that compresses the layer around the support member to a predetermined size.

10. The apparatus of claim 7, wherein the forming means comprises:
a series of sections of curved surfaces that define a passageway that tapers from a larger entrance end to a smaller exit end;

wherein a first section beginning near the entrance end comprises a first curved surface tapering inwardly toward the exit end that causes the longitudinal edges of the fibrous layer to bend around the support member as the fibrous layer and support member pass through the first section;
wherein the second section follows the first section and comprises a second curved surface that continues to taper inwardly toward the exit end;
the second section further having a curved forming surface that extends from the second surface into the passageway to cause a first longitudinal edge of the fibrous layer to fold over the support member while permitting the second longitudinal edge to pass by the forming surface; and wherein a third section follows the second section and comprises a third curved surface that continues to taper inwardly toward the exit end, causing the second longitudinal edge of the fibrous layer to fold over the support member contiguous to the first edge.

11. The apparatus of claim 10, wherein the forming means has a longitudinal opening extending from the entrance end to the exit end.

12. The apparatus of claim 11, further comprising a curved cooperating surface positioned adjacent the longitudinal opening which cooperates with the curved surfaces and the curved forming surface to form the elongate jacket member.

13. The apparatus of claim 11, wherein the support member is fed into the forming means between the fibrous layer and the first curved surface.

14. The apparatus of claims 7, 9 or 10, wherein the means for guiding the support member into the apparatus comprises means for providing and guiding a substantially continuous length of the support member and the means for guiding a layer of material into the apparatus comprise means for providing and guiding a substantially continuous length of the layer of material.

15. Apparatus for forming components for smoking articles, the components comprising a predetermined length of an inner elongate support member having a layer of fibrous material at least 0.5 mm thick circumferentially disposed therearound and having an outer wrapper circumferentially disposed around the fibrous layer, the apparatus comprising:
forming means;
support guide means for guiding the elongate length of support member into the forming means;
web guide mean for guiding the web of fibrous material having a predetermined width into the forming means;
the forming means comprising a curved inner surface defining a passage for receiving the support member and web and for folding the web of material around the support member so that one longitudinal edge of the web is contiguous to the other longitudinal edge;

compressing means for compressing the fibrous material around the support member to a predetermined dimension;
wrapping means for holding the fibrous material around the support member at the predetermined dimension and wrapping the fibrous material with an outer wrapper to maintain the predetermined dimension to form a wrapped composite member;
and cutting means for cutting the wrapped composite member into predetermined lengths.

16. The apparatus of claim 15 wherein the cutting means cuts the wrapped composite member into lengths that are a multiple of the desired size of the component to be used in a smoking article.

17. The apparatus of claim 15 wherein the forming means and compressing means together comprise a tapered device having an entrance end and an exit end through which the support member and web pass, wherein the entrance end is larger than the exit end, the device comprising a section having a curved forming surface that folds on longitudinal edge of the web around the support member, and a further section having an interior curved surface that tapers inwardly toward the exit end to fold the other longitudinal edge of the web around the support member contiguous to the one edge and that compresses the web around the support member to a predetermined dimension.

18. The apparatus of claim 15, wherein the forming means comprises:
a series of sections of curved surfaces that define a passageway that tapers from a larger entrance end to a smaller exit end;
wherein a first section beginning near the entrance end comprises a first curved surface tapering inwardly toward the exit end that causes the longitudinal edges of the fibrous web to bend around the support member as the web and support member pass through the first section;
wherein a second section follows the first section and comprises a second curved surface that continues to taper inwardly toward the exit end;
the second section further having a curved forming surface that extends from the second surface into the passageway to cause a first longitudinal edge of the fibrous web to fold over the support member while permitting the second longitudinal edge to pass by the forming surface; and wherein a third section follows the second section and comprises a third curved surface that continues to taper inwardly toward the exit end, causing the second longitudinal edge of the fibrous web to fold over the support member contiguous to the first edge.

19. The apparatus of claim 18, wherein the forming means ha a longitudinal opening extending from the entrance end to the exit end.

20. The apparatus of claim 19, further comprising a curved cooperating surface positioned adjacent the longitudinal opening which cooperates with the curved inner surfaces and curved forming surface to form the composite member.

21. The apparatus of claim 19, wherein the inner support member is fed into the forming means between the fibrous web and the first curved surface.

22. The apparatus of claim 15 wherein the support guide means comprises means for providing and guiding a substantially continuous length of the support member, and the web-guide means comprises means for providing and guiding a substantially continuous length of the web of fibrous material.

23. A device for forming an elongate composite member comprising an inner support member circumferentially surrounded by a layer of fibrous material, the device comprising: :
a series of sections of curved surfaces that define a passageway that tapers from a larger entrance end to a smaller exit end;
wherein a first section beginning near the entrance end comprises a first curved surface tapering inwardly toward the exit end that causes the longitudinal edges of the fibrous layer to bend around the support member as the fibrous layer and support member pass through the first section;

wherein the second section follows the first section and comprises a second curved surface that continues to taper inwardly toward the exit end;
the second section further having a curved forming surface that extends from the second surface into the passageway to cause a first longitudinal edge of the fibrous layer to fold over the support member while permitting the second longitudinal edge to pass by the forming surface; and wherein a third section follows the second section and comprises a third curved surface that continues to taper inwardly toward the exit end, causing the second longitudinal edge of the fibrous layer to fold over the support member contiguous to the first edge.

24. A device for forming an elongate composite member comprising an inner support member circumferentially surrounded by a layer of fibrous material, the device comprising a longitudinally-tapering funnel open at its opposite ends for receiving at the larger end the support member and fibrous material with the support member and fibrous material disposed substantially symmetrically with respect to the longitudinal axis, the funnel comprising a first curved cross-sectional portion for folding the opposite marginal edges of the fibrous material partway around the support, a second longitudinally-tapering curved cross-sectional portion for folding one of the partially-folded marginal edges of the fibrous material relative to the other to dispose the partially-folded marginal edge about the support member in engagement therewith, and a third longitudinally-tapering curved cross-sectional portion for folding the other partially-folded marginal edge of the fibrous material about the support member relative to the first marginal edge into engagement with both the support member and the first marginal edge of the fibrous material.

25. A device according to claim 24 wherein said first portion defines an axially-elongate first conical surface, said second portion defines an axially-elongate second conical surface eccentric with respect to the first conical surface and said third portion defines a third axially elongate conical surface concentric with respect to the first conical surface.

26. A device according to claim 24 wherein said second portion comprises an axially-elongate conical segment disposed within the funnel with one longitudinal edge abutting the wall of the funnel and with the other longitudinal edge of the conical segment spaced from the wall of the funnel.

27. A device according to claim 24 wherein the third portion tapers to a cross section such as to compress the fibrous material about the support to a predetermined size.

28. A device according to claim 24 comprising means for supporting an outer wrapper in relation with the fiber-wrapped support member for wrapping about the fiber-wrapped support member.

29. A device according to claim 28 wherein said means defines an elongate support of circular cross section aligned with the longitudinal axis of the funnel for guiding the wrapper into concentric engagement with the fiber-wrapped support member and holding the wrapper in arcuate contact with the fiber-wrapped support member for subsequent wrapping about the fiber-wrapped support member.

30. A device according to claim 29 wherein cutting means is arranged to be moved transversely of the elongate wrapped support member intermediate its ends for cutting the composite structure comprising the fiber-wrapped support member into components of predetermined length.

31. A method for making jacket components for use in making smoking articles, the jacket component comprising a removable support member circumscribed by a layer of compressible and resilient material and having a wrapper circumferentially disposed about the layer of material, the method comprising:
providing a substantially continuous length of support member;
providing a substantially continuous length of fibrous material having a predetermined width and thickness suitable for covering the circumference of the support member;
folding the material longitudinally around the support member so that one longitudinal edge of the material is contiguous to the other longitudinal edge to provide a layer of material around the support member; and wrapping the layer of material to form an elongate wrapped composite member.

32. The method of claim 31, further comprising the step of compressing the layer of material around the support member prior to the wrapping step.

33. The method of claim 32, further comprising cutting the elongate wrapped composite member into lengths of predetermined size.

34. The method of claim 31, wherein the step of folding the material around the support member comprises the steps of first folding one longitudinal edge of the fibrous material over and in contact with the support member and thereafter folding the other longitudinal edge over and in contact with the support member so that the longitudinal edges are contiguous with each other without any significant overlap.

35. The method of claims 31 or 34, wherein the step of providing the substantially continuous length of fibrous material comprises providing two layers of fibrous material and the step of folding the material around the support member comprises simultaneously folding the two layers of fibrous material around the support member.