Method of forming smoking articles with mouth end cavities

• US 10,123,561 B2
• Filed: 07/19/2013
• Issued: 11/13/2018
• Est. Priority Date: 08/06/2012
• Status: Active Grant

• Current Assignee: Philip Morris Products SA (Philip Morris Limited)
• Original Assignee: Philip Morris Products SA (Philip Morris Limited)
• Inventors: Kadiric, Alen
• Primary Examiner(s): Yaary, Eric
• Application Number:
  US14/417,450
• Publication Number:
  US 20150208720A1
• Time in Patent Office: 1,943 Days
• CPC Class Codes: A24C 5/005 Treatment of cigarette paper
• CPC Class Codes: A24C 5/47 Attaching filters or mouthpieces to cigars or cigarettes, e.g. inserting filters into cigarettes or their mouthpieces A24C5/52 takes precedence
• CPC Class Codes: A24C 5/476 adapted for cigars or cigarettes with a hollow mouthpiece, e.g. recess filter cigarettes
• CPC Class Codes: A24D 1/02 with special covers
• CPC Class Codes: A24D 1/045 with smoke filter means A24D1/047 takes precedence
• CPC Class Codes: A24D 3/0291 for hollow tipped filters, e.g. recess filters
• CPC Class Codes: A24D 3/048 containing additives
• CPC Class Codes: A24D 3/061 containing additives entrapped within capsules, sponge-like material or the like, for further release upon smoking constructional aspects of the filter A24D3/048
• CPC Class Codes: A24D 3/17 Filters specially adapted for simulated smoking devices

Abstract

A method of producing smoking articles, the method comprising a first step of providing a continuous array of first filter members (42), second filter segments (20) and tubular members (40). A tubular member (40) is provided between each pair of consecutive first filter members (42) and a second filter segment (20) is provided between each first filter member (42) and each tubular member (40). Each second filter segment (20) contains one or more breakable capsules, wherein each breakable capsule comprises an outer shell and an inner core containing an additive. The continuous array of first filter members (42), second filter segments (20) and tubular members (40) is then wrapped with a continuous sheet of plug wrap (44) to form a wrapped filter array, wherein the plug wrap (44) has a basis weight of less than 90 grams per square meter. The wrapped filter array is cut at an intermediate position along each first filter member (42) to provide multiple filter rods, each filter rod comprising two first filter segments (18), a tubular member (40) positioned between the first filter segments (18) and a second filter segment (20) provided between each first filter segment (18) and the tubular member (40). Next, a tobacco rod (12) is provided in axial alignment with and adjacent to each first filter segment (18) of one of the filter rods, and the filter rod and a portion of each tobacco rod (12) are wrapped in a tipping wrapper (50). Finally, the tipping wrapper (50) and the filter rod are cut at an intermediate position along the length of the tubular member (40) to form multiple smoking articles (10), each smoking article (10) comprising a tobacco rod (12) connected to a filter (14), wherein each filter (14) comprises a first filter segment (18) downstream of the tobacco rod (12), a second filter segment (20) downstream of the first filter segment (18), and a hollow tube segment (22) positioned between the second filter segment (20) and the mouth end of the filter (14). The hollow tube segment (22) defines a cavity (24) at the mouth end of the filter (14).

Claims

1. A method of producing smoking articles, the method comprising the steps of:

providing a continuous array of first filter members, second filter segments and tubular members, wherein a tubular member is provided between each pair of consecutive first filter members, the tubular member being formed of a plurality of overlapping paper layers, wherein adjacent paper layers are adhered together by an intermediate layer of adhesive, and wherein a second filter segment is provided between each first filter member and each tubular member, wherein each tubular member has a length from 4 mm to 30 mm and a compressive strength at 50% compression from about 20 Newtons to about 50 Newtons, each second filter segment containing one or more breakable capsules, each breakable capsule comprising an outer shell and an inner core containing an additive;

wrapping the continuous array of first filter members, second filter segments and tubular members with a continuous sheet of plug wrap to form a wrapped filter array, wherein the plug wrap has a basis weight of less than 90 grams per square meter;

cutting the wrapped filter array at an intermediate position along each first filter member to provide multiple filter rods, each filter rod comprising two first filter segments, a tubular member positioned between the first filter segments and a second filter segment provided between each first filter segment and the tubular member;

providing a tobacco rod in axial alignment with and adjacent to each first filter segment of a filter rod;

wrapping the filter rod and a portion of each tobacco rod in a tipping wrapper; and

cutting the tipping wrapper and the filter rod at an intermediate position along the length of the tubular member to form multiple smoking articles, each smoking article comprising a tobacco rod connected to a filter, wherein each filter comprises a first filter segment downstream of the tobacco rod, a second filter segment downstream of the first filter segment, and a hollow tube segment positioned between the second filter segment and the mouth end of the filter, the hollow tube segment defining a cavity at the mouth end of the filter.

2. A method according to claim 1, further comprising providing a segment plug wrap circumscribing each second filter segment, wherein each segment plug wrap is substantially impermeable to the additive in the inner core of the one or more breakable capsules.

3. A method according to claim 1, wherein the wall of each tubular member has a thickness of between 150 micrometers and 500 micrometers.

4. A method according to claim 1, wherein each tubular member comprises a coating layer on an inner surface thereof.

5. A method according to claim 2, wherein the wall of each tubular member has a thickness of between 150 micrometers and 500 micrometers.

6. A method according to claim 2, wherein each tubular member comprises a coating layer on an inner surface thereof.

7. A method according to claim 3, wherein each tubular member comprises a coating layer on an inner surface thereof.

8. A method according to claim 1, wherein the tipping wrapper has a basis weight of less than about 70 gsm.