JP7657005B2 - Packing element, packing element manufacturing apparatus, and packing element manufacturing method - Google Patents

Description

The present invention relates to a filling element, a manufacturing apparatus for a filling element, and a manufacturing method for a filling element.

Patent Document 1 discloses a method for manufacturing filter elements for use in cigarettes. The filter elements are formed by stacking two or more sheets having a filtering function as filter materials, shifting them by a certain width, folding each of the stacked sheets into an S-shape or a Z-shape, and then squeezing and rolling them up into a cylindrical shape.

Special Publication No. 44-3727

The filter element can be used in flavor inhalation articles including the combustion-heating type cigarettes described in Patent Document 1, as well as in non-combustion-heating type flavor inhalation articles. The packing density of the filter material packed into the filter element significantly affects the airflow resistance when a user inhales the flavor inhalation article, and thus the smoking taste obtained by the user. If the packing density of the filter element decreases, gaps and cavities are generated in the filter element, and the smoking taste and appearance of the flavor inhalation article are significantly impaired. In other words, the packing density of the filter element is an important factor in ensuring the quality of the flavor inhalation article.

In the manufacturing method described in Patent Document 1, when changing the specifications of the flavor inhalation article and the filter element used therein, in order to adjust the packing density of the filter element, it is necessary to prepare multiple sheets and change the number of sheets, adjust the offset width of each stacked sheet, or change the specifications of the sheets themselves.

As such, conventionally, there are a wide variety of parameters for managing the filling density of filter elements formed by filling sheets, in other words, filling elements used in flavor inhalation articles, making it difficult to easily and precisely control the filling density of the filling elements in accordance with the required specifications.

The present invention has been made in consideration of such problems, and aims to provide a filling element, a filling element manufacturing apparatus, and a filling element manufacturing method that allow for easy and highly accurate control of the filling density.

In order to achieve the above object, a filling element according to one embodiment is a filling element for use in an aroma inhalation article, and comprises a folded section in which a single sheet made of nonwoven fabric is folded in a width direction intersecting with the longitudinal direction thereof to reduce its diameter to less than the diameter of the filling element, and wrapping paper which is wrapped around the folded section, and the sheet is subjected to a pressing process in which at least a portion of the sheet in the width direction is pressed, and when the total width of the sheet pressed in the width direction is defined as the total pressed width of the sheet, the ratio of the total pressed width to the sheet width in the width direction is a predetermined ratio.

The filling element manufacturing device according to one embodiment is a filling element manufacturing device for use in flavor inhalation articles, and includes a sheet processing section that processes a single sheet of nonwoven fabric while transporting it along a transport path, a folding section that folds the sheet processed in the sheet processing section in a width direction intersecting with the longitudinal direction during the sheet transport process along the transport path to form a folded rod with a diameter reduced to less than the diameter of the filling element, a wrapping section that wraps the folded rod formed in the folding section with wrapping paper to form a filling rod, and a cutting section that cuts the filling rod formed in the wrapping section into filling elements. and a cross-sectional section, each of the sheet processing sections is composed of a pair of rollers, and includes a plurality of roller sets in which each pair of rollers sandwiches and transports a sheet in a transport path, at least one of the pair of rollers constituting each roller set has a protruding ridge formed around the entire circumference of the outer circumferential surface of the roller, and the ridge is subjected to a pressing process to press at least a portion of the sheet in the width direction, and when the sum of the widths of the pressing areas where the sheet is pressed by the ridges in the width direction is defined as the total pressing width of the sheet, the ratio of the total pressing width to the sheet width in the width direction is adjusted to a predetermined ratio.

A method for manufacturing a filling element according to one embodiment is a method for manufacturing a filling element for use in an aroma inhalation article, and includes a sheet processing step in which a single sheet made of nonwoven fabric is processed while being transported, a folding step in which, during the sheet transport process, the sheet processed in the sheet processing step is folded in a width direction intersecting with the longitudinal direction to form a folded rod having a diameter reduced to a diameter equal to or smaller than the diameter of the filling element, a wrapping step in which the folded rod formed in the folding step is wrapped with wrapping paper to form a filling rod, and a cutting step in which the filling rod formed in the wrapping step is cut into filling elements, and in the sheet processing step, a pressing process is performed in which at least a portion of the sheet in the width direction is pressed during the sheet transport process, and in the pressing process, when the sum of the widths of the pressing areas where the sheet is pressed is defined as the total pressing width of the sheet, the ratio of the total pressing width to the sheet width of the sheet in the width direction is adjusted to a predetermined ratio.

The packing density of the packing elements can be easily and precisely controlled.

FIG. 2 is a cross-sectional view of a non-combustion heating type flavor inhalation article. FIG. 11 is a cross-sectional view of a non-combustion heating type flavor inhalation article according to a modified example. FIG. 2 is a cross-sectional view of a combustion heating type flavor inhalation article. FIG. 11 is a cross-sectional view of a combustion heating type flavor inhalation article according to a modified example. FIG. 11 is a cross-sectional view of a combustion heating type flavor inhalation article according to another modified example. FIG. 2 shows an end face of the packing element. FIG. 2 is a perspective view of a sheet before processing. FIG. 2 is a perspective view of a sheet that has been subjected to a stretching process. FIG. 11 is a perspective view of a sheet that has been subjected to a pressing process. FIG. 10 is a partially enlarged view of an end surface of the sheet of FIG. 9 . FIG. FIG. 12 is a perspective view of the packing element formed by being reduced in diameter from the state of FIG. 11 . FIG. 2 is a perspective view of a fold-in portion in which an additive is placed. FIG. 14 is a perspective view of the packing element formed by being reduced in diameter from the state of FIG. 13 . FIG. 2 is a perspective view of a fold-out portion in which a capsule is placed. FIG. 16 is a perspective view of the packing element formed by being reduced in diameter from the state of FIG. 15 . FIG. 2 is a schematic diagram of a manufacturing apparatus for a packing element. 1 is a flow chart illustrating a method for manufacturing a packing element. FIG. 4 is a perspective view of a first roller set holding a sheet; FIG. 20 is an enlarged partial cross-sectional view of the roller of FIG. 19 . FIG. 4 is a cross-sectional view of the first roller set. FIG. 4 is a cross-sectional view of the second roller set. FIG. 11 is a cross-sectional view of the third roller set. 24 is a diagram showing the end surface of a sheet having passed through each roller set of FIGS. 21 to 23. FIG. FIG. FIG. 2 is a cross-sectional view of a transport jet. FIG. 2 shows an end face of a transport jet. FIG. 2 is a cross-sectional view of the trumpet guide. FIG. 4 is a view showing an end face of the trumpet guide. FIG.

<Flavor inhalation products>
Fig. 1 shows a cross-sectional view of a non-combustion heating type flavor inhalation article 1 (hereinafter also referred to as the article). The article 1 is composed of a flavor element 2, a tubular element 4, and a filling element 6, in that order from the left side (the tip side of the article 1) as viewed in Fig. 1. The flavor element 2 is formed by filling a flavor raw material 8.

The device (flavor inhaler) used to heat the flavor element 2 is equipped with, for example, a needle-shaped heater 10. Only the heater 10 of the device is shown in FIG. 1. The item 1 is set in the device, and the heater 10 is inserted into the flavor element 2 to heat it. This causes the flavor components of the flavor raw material 8 to volatilize.

Conductive materials such as metal plates or metal particles may be mixed into the flavor raw material 8 filled in the flavor element 2. This conductive material is heated by an induced current when the device generates a magnetic field, and the heated conductive material heats the flavor element 2, causing the flavor components of the flavor raw material 8 to volatilize.

The flavor raw material 8 is, for example, shredded tobacco, a tobacco sheet, or a tobacco sheet folded in a gathered shape. The flavor raw material 8 may be a sheet made of pulp not containing tobacco to which flavoring has been added, a shredded sheet made of a non-tobacco plant, or one of these sheets folded in a gathered shape. The outer surface of the flavor raw material 8 is wrapped in cigarette paper 12.

The tubular element 4 forms an airflow path in the article 1 and is formed, for example, from a cylindrical paper tube 14. The paper tube 14 is formed from a single or double paper web. The filling element 6 is a filter body filled with a filling material 16. The filling material 16 is formed by folding a single sheet 34 made of nonwoven fabric. The circumferential surface of the filling element 6 is wrapped with wrapping paper 18.

The elements 2, 4, and 6 are arranged coaxially in the axial direction X and butted together to form a continuum. The elements 2, 4, and 6 are connected to each other by wrapping tipping paper 20 around the circumferential surface of the continuum. Air vents 22 are formed in the tubular element 4 and the tipping paper 20 to allow air to be taken into the article 1 when the article 1 is inhaled. The air taken into the article 1 from the outside through the air vents 22 cools the flavor components of the flavor element 2 and the volatile components of the additives described below, promoting the aerosolization of these components.

2 shows a cross-sectional view of a non-combustion heating type article 1 according to a modified example. This article 1 has a filling element 6 in the same position as in FIG. 1, and also has a filling element 6 in an adjacent position opposite to the tubular element 4 of the flavor element 2, i.e., at the tip of the article 1. The filling element 6 at the tip is connected to the flavor element 2 by a wrapping paper 24. The heater 10 is inserted into the flavor element 2 through the filling element 6 at the tip.

At this time, the filling element 6 at the tip prevents the flavor raw material 8 from spilling from the flavor element 2 onto the base of the heater 10. In other words, the filling element 6 at the tip functions as a support segment that supports the flavor raw material 8 filled in the flavor element 2 in the article 1 so as not to spill onto the heater 10 side. This prevents the flavor raw material 8 that has spilled out from contaminating the area around the base of the heater 10 of the device.

Figure 3 shows a cross-sectional view of a combustion heating type article 1. This article 1 is composed of, in order from the tip side, a flavor element 2 and a filling element 6, and the flavor components of the flavor raw material 8 are volatilized by igniting and heating the flavor element 2. Figure 4 shows a cross-sectional view of a combustion heating type article 1 according to a modified example. This article 1 is composed of, in order from the tip side, a flavor element 2, a filter element 26, and a filling element 6. The filter element 26 is formed by wrapping a wrapping paper 30 around a filter material 28, such as acetate tow, which is different from the filling material 16 of the filling element 6. The filter element 26 is connected to the filling element 6 by wrapping paper 32.

Figure 5 shows a cross-sectional view of another modified combustion heating type product 1. This product 1 is composed of, in order from the tip side, a flavor element 2, a filling element 6, and a filter element 26, and is a pattern in which the arrangement of the filter element 26 and the filling element 6 of the product 1 in Figure 4 is changed, and the other configuration is the same as that of the product 1 in Figure 4.

<Filling element>
6 shows an end face of the packing element 6. The packing material 16 of the packing element 6 is a sheet 34, the main raw material of which is a dry nonwoven fabric in which plant pulp is bonded together with a water-soluble binder. The plant pulp may be wood pulp from a non-tobacco plant. The sheet 34 may also be formed by impregnating the nonwoven fabric with ground tobacco or an extract of tobacco.

In this case, flavor components derived from tobacco plants can be volatilized not only from the flavor element 2 but also from the filling element 6. In other words, the filling element 6 using the sheet 34 made of nonwoven fabric containing ground tobacco or tobacco extract not only functions as a filter element that serves as a filter body, but also functions as the flavor element 2.

The sheet 34 is folded in the width direction Z a predetermined number of times, for example, three or four times, to reduce its diameter, forming a folding rod 90, which is described below, and is then cut to form the folding portion 36. The width direction Z is a direction that intersects with the longitudinal direction X of the sheet 34 (the same direction as the axial direction X).

The filling element 6 is formed by wrapping the periphery of the folded-in portion 36 with the wrapping paper 18 and gluing and wrapping both ends of the wrapping paper 18. By folding one sheet 34 to form the folded-in portion 36 and thus the filling element 6, it is not necessary to prepare multiple sheets 34 and change the number of sheets 34, adjust the offset width of each stacked sheet 34, or change the specifications of the sheet 34 itself, as in the conventional method, in order to adjust the packing density of the filling element 6.

Therefore, compared to conventional cases, the packing density of the filling elements 6 can be easily and precisely controlled. Furthermore, by subjecting the sheet 34 to the treatment described below, the folded portion 36 can further optimize the packing density of the sheet 34 as the packing material 16, and can more effectively prevent the occurrence of gaps and cavities in the packing elements 6.

Figure 7 shows a perspective view of sheet 34 before treatment. Sheet 34 is formed from nonwoven fabric that is intertwined without being woven, and therefore has almost irreversible extensibility in the longitudinal direction X and has raised portions 38 on the front and back surfaces. Sheet 34 has a thickness t including raised portions 38.

<Sheet Stretching Treatment>
8 shows a perspective view of the sheet 34 that has been stretched. The sheet 34 is stretched to be longer in the longitudinal direction X, and the thickness t of the sheet 34 is reduced to a smaller value t1. In addition, the sheet 34 is lengthened in the longitudinal direction X, and the surface area of the sheet 34 is increased, so that the density (fleece density) of the napped portion 38 on the front and back surfaces of the sheet 34 is reduced. By adjusting the degree of stretching of the sheet 34, the thickness and nap density of the entire sheet 34 can be controlled. Therefore, it is possible to form the folded portion 36 having a plurality of different packing densities, and thus the packing element 6, using one type of sheet 34.

<Sheet pressing process>
Fig. 9 shows a perspective view of the sheet 34 that has been subjected to a pressing process. Fig. 10 shows a partial enlarged view of an end face of the sheet 34 in Fig. 9. The sheet 34 is subjected to a pressing process in which at least a part of the sheet 34 in the width direction Z is pressed. The sheet 34 shown in Fig. 6, which is an example of a pressing form, has a number of pressed regions A1 each having a width D1 in the width direction Z and a number of non-pressed regions A2 each having a width D2 in the width direction Z formed along the longitudinal direction X, as shown in Fig. 7.

The non-pressed area A2 is an area of the sheet 34 other than the pressed area A1, and includes an incompletely pressed inclined surface and a flat surface that is not pressed at all. When the sum of the widths D1 of the pressed areas S1 where the sheet 34 is pressed in the width direction Z is defined as the total pressed width Dt1 of the sheet 34, the ratio of the total pressed width Dt1 to the width of the sheet 34 in the width direction Z, i.e., the sheet width Ds, is a predetermined ratio. This predetermined ratio is set to 50% or less.

In the pressed area A1 of the sheet 34, the thickness t1 is reduced to a smaller thickness t2 by pressing. In addition, the raised portion 38 is crushed, so that the nap density on the front and back surfaces of the sheet 34 in the pressed area A1 is drastically reduced. On the other hand, the non-pressed area A2 of the sheet maintains the thickness t1 and the nap density after the stretching process.

By adjusting the range of the pressing area A1 of the sheet 34 and setting the ratio of the total pressing width Dt1 to the sheet width Ds to a predetermined ratio, that is, by adjusting the degree of pressing the sheet 34, it is possible to control the thickness and nap density of the entire sheet 34. Therefore, it is possible to easily form the folded-in portion 36 having a plurality of filling densities, and thus the filling element 6, using one type and one sheet 34.

Figure 11 shows an oblique view of the folded-in portion 36. Figure 12 shows an oblique view of the filling element 6 formed by shrinking the diameter from the state of Figure 11. As a result of folding the sheet 34, an opening 40 is formed in part of the circumferential direction of the folded-in portion 36, over the axial direction X. The opening 40 is blocked by shrinking the folded-in portion 36 with the opening 40 formed and then wrapping it with wrapping paper 18, and the filling element 6 shown in Figure 12 is formed.

In this way, by folding one sheet 34 to form the fold-in portion 36, it is no longer necessary to prepare multiple sheets 34 and change the number of sheets 34, adjust the offset width of each stacked sheet 34, or change the specifications of the sheet 34 itself, as was done in the conventional method, in order to adjust the packing density of the filling elements 6.

Therefore, the packing density of the filling elements 6 can be easily and precisely controlled. In addition, by adjusting the number of times a sheet 34 is folded, the folding form, or the degree of diameter reduction of the folded portion 36, it is possible to optimize the packing density of the filling elements 6. This prevents gaps and cavities from occurring in the filling elements 6, ensuring the quality of the product 1.

Furthermore, when stretching and pressing the sheet 34, the parameters for managing the filling density of the filling elements 6 are only the settings of the degree of stretching and pressing for one sheet 34. This makes it possible to control the filling density of the filling elements 6 even more easily and with higher precision. Furthermore, by further optimizing the filling density of the filling elements 6 through the stretching and pressing of the sheet 34, the occurrence of gaps and cavities in the filling elements 6 can be more effectively prevented, improving the reliability of ensuring the quality of the article 1.

In particular, when pressing the sheet 34, the predetermined ratio of the total pressing width Dt1 to the sheet width Ds is set to 50% or less. This allows the nap portion 38 to remain on the sheet 34 in an area that is more than 50% of the sheet width Ds, thereby preventing an extreme decrease in the nap density of the sheet 34 and more reliably preventing the occurrence of gaps and cavities in the filling elements 6.

<Placement of additives in the folded part>
13 shows a perspective view of the folded-in portion 36 in which the additive 42 is disposed. The folded-in portion 36 has an opening 40 that opens in the axial direction X of the folded-in portion 36 in a part of its circumferential direction, and the additive 42 is disposed inside the folded-in portion 36 through the opening 40. This allows the additive 42 to be disposed at an appropriate position of the packing element 6 while optimizing the packing density of the packing element 6.

Furthermore, the folded-in portion 36 is formed with a U-shaped cross-sectional recess 44 that is connected to the opening 40 and is recessed up to the center of the folded-in portion 36 in the radial direction Y. The additive 42 is arranged in the axial direction X of the recess 44 through the opening 40. This ensures that the additive 42 is arranged in the center of the folded-in portion 36 in the radial direction Y.

Figure 14 shows a perspective view of the filling element 6 formed by shrinking the diameter from the state shown in Figure 13. When the folded-in portion 36 is shrinked and wrapped with the wrapping paper 18, the opening 40 is blocked. Therefore, the additive 42 does not protrude from the folded-in portion 36, and the filling element 6 in which the additive 42 is disposed inside the folded-in portion 36 can be easily and reliably formed. In addition, when the folded-in portion 36 is shrinked, the recessed stripe 44 in which the additive 42 is disposed is filled with the sheet 34.

This ensures that the additive 42 is positioned at the center of the radial direction Y of the folded-in portion 36. In addition, the components of the additive 42 can be uniformly evaporated in the radial direction Y from the center of the radial direction Y of the filling element 6. This improves the reliability of ensuring the quality of the filling element 6 and, ultimately, the article 1. The additive 42 may be an additive made of a liquid that is sorbed in the grooves 44, or it may be a thread that is placed in the grooves 44. When a thread is placed, the thread is impregnated with an additive made of a liquid.

The additive 42 may also be a conductive member in the form of a thread or a long, thin plate. The filling element 6, which uses a sheet 34 made of a nonwoven fabric containing ground tobacco or tobacco extract, has the function of a flavor element 2. The conductive member is heated by an induced current when the device generates a magnetic field, and the heated conductive member heats the filling element 6, causing the flavor components derived from the tobacco plant contained in the filling element 6 to volatilize.

<Capsule placement in fold-in section>
15 shows a perspective view of the folded-in portion 36 in which a capsule 46 is disposed. The capsule 46 has an outer shell formed from an easily breakable material, and the outer shell encapsulates an additive. By forming an opening 40 in the folded-in portion 36, the capsule 46 can be disposed at a predetermined position inside the folded-in portion 36 through the opening 40. The capsule 46 is disposed, for example, at a central position in the axial direction X of the folded-in portion 36.

Figure 16 shows a perspective view of the filling element 6 formed by shrinking the diameter from the state shown in Figure 15. When the folded-in portion 36 is shrinked and wrapped with the wrapping paper 18, the opening 40 is blocked. Therefore, the capsule 46 does not protrude from the folded-in portion 36, and the filling element 6 with the capsule 46 disposed inside the folded-in portion 36 can be easily and reliably formed. In addition, when the folded-in portion 36 is shrinked, the grooves 44 are filled with the sheet 34, and the sheet 34 is tightly attached around the capsule 46.

This allows the capsule 46 to be reliably fixed at a predetermined position in the axial direction X at the center of the radial direction Y of the folded-in portion 36. In addition, the additive components released from the capsule 46 can be uniformly dispersed in the radial direction Y from the center of the radial direction Y of the filling element 6. This ensures the quality of the filling element 6 and, ultimately, the article 1.

In addition, since the capsule 46 is fixed in close contact with the sheet 34 at the center of the fold-in portion 36 in the radial direction Y, it becomes easier for the user to crush the capsule 46 with his/her fingers to release the additive, improving user convenience. The additive constituting the additive 42 sorbed in the grooves 44, the additive impregnated in the threads, and the additive encapsulated in the capsule 46 are, for example, flavoring agents such as menthol, and may further include activated carbon, an aerosol bulking agent, etc.

In addition, a substantially spherical conductive member may be used instead of the capsule 46. One or more of these conductive members are arranged in the filling element 6. The filling element 6, which uses a sheet 34 made of tobacco powder or nonwoven fabric impregnated with tobacco extract, has the function of the flavor element 2. The conductive member is heated by an induced current when the device generates a magnetic field, and the heated conductive member heats the filling element 6, causing the flavor components derived from the tobacco plant contained in the filling element 6 to volatilize.

<Production apparatus and method for packing element>
Fig. 17 shows a schematic diagram of a manufacturing apparatus 50 for the packing element 6, and Fig. 18 shows a flow chart illustrating a manufacturing method for the packing element 6. The manufacturing apparatus 50 includes a sheet supply section 52, a sheet processing section 54, a folding section 56, a wrapping section 58, and a cutting section 60.

When the production of the filling element 6 is started, the sheet supply section 52 supplies one continuous sheet 34 made of nonwoven fabric to the conveying path 62 (S1: sheet supply step). Next, the sheet processing section 54 processes the sheet 34 while transporting it on the conveying path 62 (S2: sheet processing step).

The sheet processing section 54 includes a first roller set 64, a second roller set 66, and a third roller set 68, and a control unit 70. Each roller set 64, 66, and 68 is composed of a pair of rollers Ra and Rb, and each pair of rollers Ra and Rb sandwiches and transports the sheet 34 on the transport path 62.

At least one of the rotation shafts of the pair of rollers Ra, Rb constituting each roller set 64, 66, 68 is connected to the drive shaft of a motor (not shown) and is rotated and driven individually by each motor. Each motor is electrically connected to a control unit 70. The rotation speed of each roller set 64, 66, 68 is controlled via each motor by a signal from the control unit 70.

The control unit 70 adjusts the difference in the rotational speed between the roller sets 64, 66, and 68, thereby adjusting the difference in the conveying speed of the sheet 34 between the roller sets 64, 66, and 68. As a result, in the sheet processing step, the stretching process shown in FIG. 8 is performed on the sheet 34 (P1: stretching process).

Specifically, the rotation speed of the downstream roller set (second roller set 66 or third roller set 68) is made faster than the rotation speed of the upstream roller set (e.g., first roller set 64) in the conveying path 62. This makes the conveying speed of the sheet 34 in the downstream roller set faster than the conveying speed of the sheet 34 in the upstream roller set, and the sheet 34 is stretched in the longitudinal direction X between the upstream roller set and the downstream roller set.

Figure 19 shows an oblique view of the first roller set 64 sandwiching the sheet 34. The roller Ra has a number of protruding ridges 72 formed around the entire circumference of the outer circumferential surface of the roller Ra. Each ridge 72 forms a pressed area A1 on the sheet 34. A number of grooves 74 are formed on the outer circumferential surface of the roller Ra in conjunction with the formation of each ridge 72. Each groove 74 forms a non-pressed area A2 on the sheet 34.

During the conveyance process of the sheet 34, each ridge 72 digs into the surface of the sheet 34 and presses the sheet 34, in other words, grips the sheet 34, and the sheet 34 is unwound from the first roller set 64 toward the second roller set 66. As a result, in the sheet processing step, the pressing process shown in FIG. 9 is performed on the sheet 34 (P2: pressing process).

Figure 20 shows an enlarged cross section of the roller Ra of Figure 19. A pressing surface 76 is formed at the tip of the convex rib 72. The pressing surface 76 has a width D3 in the width direction Z of the roller Ra (the same as the axial direction of the roller Ra). A bottom surface 78 is formed in the groove rib 74. The groove rib 74 has a width D4 in the width direction Z. The width D3 of the pressing surface 76 is equal to the width D1 of the pressing area A1 of the sheet 34 shown in Figure 10. Furthermore, the width D4 of the groove rib 74 of the roller Ra is equal to the width D2 of the pressing area A2 of the sheet 34 shown in Figure 10.

21 to 23 show examples of combinations of rollers Ra and Rb that make up each roller set 64, 66, 68. FIG. 21 shows a cross-sectional view of the first roller set 64. In this first roller set 64, as shown in FIG. 19, a large number of ridges 72 are formed over the entire width direction Z of the roller Ra and around the entire circumference of the outer periphery of the roller Ra. FIG. 22 shows a cross-sectional view of the second roller set 66. In this second roller set 66, ridges 72 of a larger width than those in FIG. 21 are formed at both ends of the roller Ra in the width direction Z and around the entire circumference of the outer periphery of the roller Ra.

Figure 23 shows a cross-sectional view of the third roller set 68. In this third roller set 68, three ridges 72 of the same width as in Figure 21 are formed at three locations in the center and both ends of the roller Ra in the width direction Z, and all around the outer periphery of the roller Ra. In this third roller set 68, three ridges 72 of the same width as in Figure 22 are formed at three locations in the center and both ends of the roller Rb in the width direction Z, and all around the outer periphery of the roller Rb.

In this way, at least one of the pair of rollers Ra, Rb constituting each roller set 64, 66, 68 is formed with a protruding ridge 72 that protrudes around the entire outer periphery of the roller to grip and transport the sheet 34. Each ridge 72 is subjected to a pressing process that presses at least a portion of the sheet 34 in the width direction Z, thereby performing the pressing process described above.

Figure 24 shows the end surface of the sheet 34 that has passed through each of the roller sets 64, 66, 68 in Figures 21 to 23. When the sum of the widths D1 of the pressing areas A1 where the sheet 34 is pressed by the ridges 72 in the width direction Z is defined as the total pressing width Dt1 of the sheet 34, the ratio of the total pressing width Dt1 to the sheet width Ds is adjusted to a predetermined ratio. As mentioned above, this predetermined ratio is 50% or less. Here, as shown in Figure 24, the center of the back surface of the sheet 34 in the width direction Z is pressed by the ridges 72 of the roller Rb of the third roller set 68 to form a pressing area A1.

On the other hand, at the center of the surface of the sheet 34 in the width direction Z, a pressing area A1 is formed by the convex ribs 72 of the rollers Ra of the first roller set 64 and the rollers Ra of the third roller set 68. The width D1 of the pressing area A1 formed by the convex ribs 72 of the rollers Rb of the third roller set 68 is greater than the width D1 of the pressing area A1 formed by the convex ribs 72 of the rollers Ra of the first roller set 64 and the rollers Ra of the third roller set 68.

24, the width D1 of the pressing area A1 formed by the ridges 72 of the roller Rb of the third roller set 68 is added to the total pressing width Dt1, and the width D1 of the pressing area A1 formed by the ridges 72 of the roller Ra of the first roller set 64 and the roller Ra of the third roller set 68 is not added to the total pressing width Dt1. In other words, when the pressing areas A1 formed by the roller sets 64, 66, and 68 overlap in the width direction Z, the width D1 of the larger pressing area A1 is added to the total pressing width Dt1 as a representative.

By adjusting in advance the area of the pressing surface 76 of the ridges 72 formed on each roller set 64, 66, 68, the number of ridges 72, the range of formation of the ridges 72, etc., the ratio of the total pressing width Dt1 to the sheet width Ds can be set to a desired predetermined ratio. In detail, in each roller set 64, 66, 68, taking into consideration the range of formation of the ridges 72 that overlap in the width direction Z of the sheet 34, the area of the pressing surface 76 of the ridges 72, the number of ridges 72, the range of formation of the ridges 72, etc. that contribute to the total pressing width Dt1 of the sheet 34 are adjusted.

This allows the ratio of the total pressing width Dt1 to the sheet width Ds to be adjusted. The gripping force of the ridges 72 on the sheet 34 can be adjusted by changing the gap between the pair of rollers Ra and Rb, the protruding height of the ridges 72, the area of the pressing surface 76 of the ridges 72, the number of ridges 72, etc. Optimizing the gripping force of the ridges 72 on the sheet 34 improves the accuracy of the stretching process.

Next, the folding section 56 folds the sheet 34 processed in the sheet processing section 54 in the width direction Z during the conveying process of the sheet 34 in the conveying path 62 to form a folding rod 90 with a diameter reduced to less than the diameter of the filling element 6 (S3: folding step). The folding rod 90 becomes the folding portion 36 when the filling rod 98 formed in a later step is cut to become the filling element 6.

During the folding process of the sheet 34, the folding section 56 forms an opening 40 that opens in the axial direction X of the folding rod 90 at a portion of the circumferential direction of the folding rod 90. Furthermore, the folding section 56 forms a recessed rib 44 that is connected to the opening 40 and has a U-shaped cross section that is recessed to the center of the folding rod 90 in the radial direction Y. Specifically, the folding section 56 includes, in order from the upstream side of the conveying path 62, a preliminary folding guide 80, a transport jet 82, a trumpet guide 84, and a tongue 86.

Figure 25 shows a front view of the preliminary folding guide 80. The preliminary folding guide 80 includes a guide roller 80a and a rotating shaft 80b that rotatably supports the guide roller 80a. During the process of conveying the sheet 34 in the conveying path 62, the guide roller 80a contacts the center of the sheet 34 in the width direction Z from below. This causes the sheet 34 to bend upward in a convex shape in the thickness direction.

Figure 26 shows a cross-sectional view of the transport jet 82, and Figure 27 shows the upstream end face of the transport jet 82 in the transport path 62. The transport jet 82 is cylindrical and has a large diameter portion 82a on the upstream side of the transport path 62 and a small diameter portion 82b continuing to the large diameter portion 82a. The inner circumferential surface 82c of the transport jet 82 is tapered in a stepped manner from the large diameter portion 82a to the small diameter portion 82b.

Inside the transport jet 82, a baffle plate 88 is erected from the inner circumferential surface 82c toward the center in the radial direction. The transport jet 82 draws in the curved sheet 34 that has passed through the preliminary folding guide 80 with air accompanied by wind pressure, folds the sheet 34 in the width direction Z a predetermined number of times by sandwiching the baffle plate 88, and further reduces its diameter as it is transported from the large diameter portion 82a to the small diameter portion 82b. This forms a folding rod 90.

Figure 28 shows a cross-sectional view of the trumpet guide 84, and Figure 29 shows the upstream end face of the trumpet guide 84 in the conveying path 62. The trumpet guide 84 is cylindrical and has an inner circumferential surface 84a that gradually reduces in diameter from the upstream side of the conveying path 62. Inside the trumpet guide 84, a baffle plate 92 is erected from the inner circumferential surface 84a toward the radial center. Each baffle plate 88, 92 is installed inside the transport jet 82 and the trumpet guide 84, extending along their axial directions.

The trumpet guide 84 releases the folding rod 90 that has passed through the transport jet 82 together with air accompanied by wind pressure, and the air dissipates as the rod is released, unravelling and opening the fibers of the folding rod 90. The folding rod 90 formed by the transport jet 82 also passes through the trumpet guide 84 while sandwiching the baffle plate 92. This allows the folding state of the folding rod 90 formed by the transport jet 82 to be maintained in the trumpet guide 84.

In this way, the transport jet 82 and the trumpet guide 84 have baffles 88, 92 extending from their inner circumferential surfaces 82c, 84a toward the center in the radial direction. The curved sheet 34 passing through the preliminary folding guide 80 is subjected to air accompanied by wind pressure and folded between the baffles 88, 92 to form a folding rod 90. When the sheet 34 is folded between the baffles 88, 92, the opening 40 and the grooves 44 described above are formed in a portion of the circumferential direction of the folding rod 90.

30 shows a cross-sectional view of the tongue 86. The tongue 86 is cylindrical and has an inner peripheral surface 86a that is equal to or smaller than the diameter of the filling element 6. The folding rod 90 that has passed through the trumpet guide 84 is reduced in diameter in the tongue 86 to equal to or smaller than the diameter of the filling element 6, the opening 40 is blocked, and the grooves 44 are filled with the sheet 34.

17, the folding section 56 includes an additive supply unit 94. The additive supply unit 94 has a nozzle 94a for supplying the additive 42. The nozzle 94a is inserted into both the transport jet 82 and the trumpet guide 84. The additive supply unit 94 supplies the additive 42 from the nozzle 94a through the opening 40 to the inside of the folding rod 90 at least before the folding rod 90 is transported to the tongs 86 (P3: additive supply process). In detail, the additive supply unit 94 supplies the additive 42 through the opening 40 along the axial direction X of the groove 44.

The folding section 56 also includes a capsule supply unit 96. The capsule supply unit 96 includes a cylindrical rotating holder 96a, and the capsules 46 are held in the rotating holder 96a. The capsule supply unit 96 rotates the rotating holder 96a at least before the folding rod 90 is transported to the tongs 86, and intermittently drops and supplies the capsules 46 held in the rotating holder 96a into the inside of the folding rod 90 through the opening 40 (P4: capsule supply process). In detail, the capsule supply unit 96 supplies the capsules 46 to a predetermined position in the axial direction X of the groove 44 through the opening 40, for example, to the center position in the axial direction X when the folding section 36 is reached.

17, the wrapping section 58 supplies the wrapping paper 18 and wraps the folded rod 90 formed in the folding section 56 with the wrapping paper 18 to form a filling rod 98 (S4: wrapping step). Next, the cutting section 60 cuts the filling rod 98 formed in the wrapping section 58 into filling elements 6 (S5: cutting step), and the production of the filling elements 6 is completed.

As described above, the filling element 6 of the embodiment includes the folding portion 36 and the wrapping paper 18 wrapped in the folding portion 36. The folding portion 36 is formed by folding a single sheet 34 made of nonwoven fabric in the width direction Z to reduce its diameter to less than the diameter of the filling element 6, and the sheet 34 constituting the folding portion 36 is subjected to a pressing process that presses at least a portion of it in the width direction Z, and the ratio of the total pressed width Dt1 to the sheet width Ds in the width direction Z is a predetermined ratio.

By adjusting the degree of pressing of the sheet 34, it is possible to form the folded portion 36 having a plurality of different filling densities, and thus the filling element 6, using one type and one sheet 34. Furthermore, when only pressing is performed on the sheet 34, the parameter for managing the filling density of the filling element 6 is only the setting of the pressing degree for one sheet 34. Therefore, the filling density of the filling element 6 can be easily and accurately controlled. Furthermore, by optimizing the filling density of the filling element 6, it is possible to prevent the occurrence of gaps and cavities in the filling element 6, thereby ensuring the quality of the article 1.

In addition, by setting the predetermined ratio of the total pressing width Dt1 to the sheet width Ds to 50% or less, it is possible to leave the raised portion 38 on the sheet 34 that is more than 50% of the sheet width Ds. This prevents the nap density of the sheet 34 from decreasing too much, and more reliably prevents gaps and cavities from occurring in the filling elements 6.

The sheet processing section 54 provided in the manufacturing apparatus 50 of the embodiment includes roller sets 64, 66, and 68, and at least one of the pairs of rollers Ra and Rb constituting each roller set 64, 66, and 68 is formed with a protruding rib 72 that protrudes around the entire circumference of the outer circumferential surface of the roller. The protruding rib 72 is subjected to a pressing process that presses at least a portion of the sheet 34 in the width direction Z, and the ratio of the total pressing width Dt1 to the sheet width Ds in the width direction Z is adjusted to a predetermined ratio.

This pressing process is performed as a pressing process during the conveying process of the sheet 34 in the sheet processing step. This allows the degree of pressing of the sheet 34 to be easily adjusted during the conveying process of the sheet 34. Therefore, the filling density of the filling elements 6 can be easily and accurately controlled. Also, as described above, by setting the predetermined ratio of the total pressing width Dt1 to the sheet width Ds to 50% or less, an extreme decrease in the nap density of the sheet 34 is suppressed, so that the occurrence of gaps and cavities in the filling elements 6 can be more reliably prevented.

In addition, the folding section 56 provided in the manufacturing apparatus 50 of the embodiment includes a preliminary folding guide 80, a transport jet 82, a trumpet guide 84, and a tongue 86. During the conveying process of the sheet 34, the sheet 34 passes through these parts of the folding section 56, thereby reliably forming the desired folding rod 90 and, therefore, the desired filling element 6.

More specifically, the transport jet 82 and the trumpet guide 84 have baffles 88, 92 extending from their inner circumferential surfaces 82c, 84a toward the radial center, respectively. The curved sheet 34 passing through the transport jet 82 and the trumpet guide 84 is folded by air with wind pressure between the baffles 88, 92 to form a folding rod 90.

That is, each of the baffles 88, 92 functions as a portion that starts folding the sheet 34 when the sheet 34 is folded and also maintains the folded state of the sheet 34. Therefore, by providing each of the baffles 88, 92, the desired folding rod 90, and therefore the desired filling element 6, can be formed more reliably.

This concludes the description of the embodiment, but the above embodiment is not limiting and various modifications can be made without departing from the spirit of the invention. For example, the number, shape, and formation range of the ridges 72 are not limited to the described form and various modifications are possible. The ridges 72 may be formed on both rollers Ra and Rb, or may be formed only on roller Ra or roller Rb.

In addition, the number of roller sets provided in the sheet processing section 54 is not limited to the three roller sets 64, 66, and 68 described above, and may be at least multiple in order to perform the stretching process. In addition, the ratio of the total pressing width Dt1 to the sheet width Ds is preferably 50% or less, but may exceed 50% depending on the specifications of the sheet 34 and the required specifications of the filling element 6.

In addition, it is not necessary to subject the sheet 34 to both the stretching process and the pressing process, and the sheet 34 may be subjected to only one of the stretching process and the pressing process depending on the specifications of the sheet 34 and the required specifications of the filling element 6. In addition, depending on the specifications of the sheet 34 and the required specifications of the filling element 6, it may be possible that neither the stretching process nor the pressing process is performed.

In addition, it is not necessary to place both the additive 42 and the capsule 46 inside the folded-in portion 36, and only one of the additive 42 and the capsule 46 may be placed depending on the specifications of the filling element 6. Also, as shown in Figures 6 and 12, depending on the specifications of the filling element 6, there may be cases where nothing is placed inside the folded-in portion 36.

Furthermore, the folding section 56 is not limited to the configuration described above, so long as it is capable of forming a folding rod 90. Furthermore, the additive supply unit 94 is not limited to the configuration described above, so long as it is capable of performing an additive supply process. Furthermore, the capsule supply unit 96 is not limited to the configuration described above, so long as it is capable of performing a capsule supply process. Furthermore, the configuration of the article 1 and the position and number of the filling elements 6 in the article 1 are not limited to the forms described.

REFERENCE SIGNS LIST 1 flavor suction article 6 filling element 18 wrapping paper 34 sheet 36 folding section 50 manufacturing device 54 sheet processing section 56 folding section 58 wrapping section 60 cutting section 62 conveying path 64, 66, 68 roller set 70 control unit 80 preliminary folding guide 82 transport jet 84 trumpet guide 86 tongs 88, 92 baffle plate 90 folding rod 98 filling rod Ra, Rb roller X longitudinal direction Z width direction

Claims (8)

A filling element for use in a flavor inhalation article, comprising:
A folded portion in which a single sheet made of a nonwoven fabric is folded in a width direction intersecting with the longitudinal direction thereof to reduce its diameter to less than or equal to the diameter of the filling element;
and a wrapping paper wrapped around the folded portion,
The sheet is subjected to a pressing process to press at least a portion of the sheet in the width direction, and when the total width of the sheet pressed in the width direction is defined as the total pressed width of the sheet, the ratio of the total pressed width to the sheet width of the sheet in the width direction is a predetermined ratio. The filling element of claim 1, wherein the predetermined percentage is 50% or less. An apparatus for manufacturing a filling element for use in a flavor inhalation article, comprising:
a sheet processing section for processing a single sheet made of nonwoven fabric while conveying the sheet along a conveying path;
A folding section that folds the sheet processed in the sheet processing section in a width direction intersecting with a longitudinal direction of the sheet during the sheet transport process in the transport path to form a folding rod having a diameter reduced to less than a diameter of the filling element;
a wrapping section for wrapping the folded rod formed in the folding section with a wrapping paper to form a stuffed rod;
a cutting section for cutting the filler rod formed in the wrapping section into the filler elements;
The sheet processing section includes a plurality of roller sets each including a pair of rollers, and each pair of rollers sandwiches and transports the sheet along the transport path;
At least one of the pair of rollers constituting each of the roller sets has a protruding ridge formed on an outer circumferential surface of the roller,
The protrusions are formed by performing a pressing process to press at least a part of the sheet in the width direction,
A filling element manufacturing apparatus, wherein when the sum of the widths of the pressing areas in which the sheet is pressed by the convex ribs in the width direction is defined as the total pressing width of the sheet, the ratio of the total pressing width to the sheet width of the sheet in the width direction is adjusted to a predetermined ratio. The filling element manufacturing apparatus of claim 3, wherein the specified percentage is 50% or less. The fold-in section comprises:
a preliminary folding guide that curves the sheet in a thickness direction during the sheet conveyance process in the conveyance path;
a cylindrical transport jet that draws in the curved sheet that has passed through the preliminary folding guide by air with wind pressure and folds the sheet a predetermined number of times in the width direction to form the folding rod;
A cylindrical trumpet guide in which the folding rod that has passed through the transport jet is released together with the air accompanied by the wind pressure, and the fibers of the folding rod are loosened and opened by the dissipation of the air accompanying this release;
The filling element manufacturing apparatus according to claim 3 or 4, further comprising a cylindrical tong for reducing the diameter of the folding rod that has passed through the trumpet guide to less than the diameter of the filling element. The transport jet and the trumpet guide each have a baffle plate extending from an inner peripheral surface of the transport jet and the trumpet guide toward a radial center thereof,
The apparatus for manufacturing a filling element according to claim 5, wherein the curved sheet passing through the transport jet and the trumpet guide is folded between the baffles by air accompanied by the wind pressure to form the folded rod. A method for producing a filling element for use in a flavor inhalation article, comprising the steps of:
a sheet processing step of processing a single sheet made of nonwoven fabric while conveying it;
A folding step in which, during the conveying process of the sheet, the sheet processed in the sheet processing step is folded in a width direction intersecting with the longitudinal direction to form a folded rod having a diameter reduced to less than the diameter of the filling element;
a wrapping step of wrapping the folded rod formed in the folding step with a wrapping paper to form a stuffed rod;
and a cutting step of cutting the filler rod formed in the wrapping step into the filler elements.
In the sheet processing step, a pressing process is performed in a process of conveying the sheet, in which at least a part of the sheet in the width direction is pressed,
A method for manufacturing a filling element, wherein in the pressing process, when the sum of the widths of the pressing areas where the sheet is pressed is defined as the total pressing width of the sheet, the ratio of the total pressing width to the sheet width of the sheet in the width direction is adjusted to a predetermined ratio. The method for producing a packing element according to claim 7 , wherein the predetermined percentage is 50% or less.

Images