JP7724311B2 - Packing element, packing element manufacturing device, and packing element manufacturing method - Google Patents

Description

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

Patent Document 1 discloses a method for manufacturing filter elements for cigarettes. These filter elements are formed by stacking two or more sheets of filtering material with a certain width offset, folding each sheet into an S or Z shape, and then squeezing and rolling up the sheet into a cylindrical shape.

Special Publication No. 44-3727

The filter element can be used in flavor inhalation articles, including combustion-heating cigarettes as described in Patent Document 1, as well as non-combustion-heating 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 ultimately the smoking experience experienced by the user. If the packing density of the filter element decreases, gaps and cavities will form in the filter element, significantly impairing the smoking experience and appearance of the flavor inhalation article. In other words, the packing density of the filter element is an important factor in ensuring the quality of a 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, it is necessary to prepare multiple sheets and change the number of sheets in order to adjust the packing density of the filter element, adjust the offset width of each stacked sheet, or change the specifications of the sheet itself.

As such, in the past, there were a wide variety of parameters for managing the packing density of filter elements formed by packing sheets, in other words, packing elements used in flavor inhalation articles, making it difficult to easily and accurately control the packing density of the packing elements according to required specifications. Furthermore, the manufacturing method described in Patent Document 1 does not give special consideration to the placement of additives in the packing elements, making it difficult to place additives in the appropriate positions on the packing elements while optimizing the packing density of the packing elements.

The present invention was made in consideration of these problems, and aims to provide a filling element, a filling element manufacturing apparatus, and a filling element manufacturing method that can easily and accurately control the filling density and that can place additives at appropriate positions in the filling element.

In order to achieve the above-mentioned object, one embodiment of a filling element is a filling element used in a flavor inhalation article, and comprises a folded portion formed by folding a single sheet of nonwoven fabric in a width direction intersecting with its longitudinal direction, so that the diameter is reduced to less than the diameter of the filling element, and a wrapping paper wrapped around the folded portion, and the folded portion has an opening in a part of its circumferential direction that opens along the axial direction of the folded portion, and has a recessed stripe with a U-shaped cross section that is connected to the opening and extends to the radial center of the folded portion, and an additive or capsule is placed in the radial center inside the folded portion through the opening.

In one embodiment, a filling element manufacturing device is a filling element manufacturing device for use in flavor inhalation articles, and includes a sheet processing section that processes a single sheet made of nonwoven fabric while transporting it on a transport path, a folding section that folds the sheet processed in the sheet processing section in a width direction intersecting with its longitudinal direction during the sheet transport process on 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 during the sheet folding process, the folding section forms an opening that opens along the axial direction of the folding rod in a part of the circumferential direction of the folding rod, and forms a recessed groove that is connected to the opening and has a U-shaped cross section that is recessed down to the radial center of the folding rod, and further includes a supply unit that supplies additives or capsules to the radial center inside the folding rod through the opening.

A method for manufacturing a filling element according to one embodiment is a method for manufacturing a filling element used in a flavor 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 its longitudinal direction to form a folded rod with a diameter reduced to less 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. In the folding step, during the sheet folding process, an opening is formed in a part of the circumferential direction of the folding rod that opens along the axial direction of the folding rod, and a recessed groove with a U-shaped cross section is formed that is connected to the opening and extends to the radial center of the folding rod, and further, a supply process is performed in which an additive or a capsule is supplied to the radial center inside the folding rod through the opening.

The packing density of the packing elements can be easily and precisely controlled, and additives can be placed in the appropriate positions of the packing elements.

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

<Flavor suction article>
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, from the left side (the tip side of the article 1) as viewed in Fig. 1, a flavor element 2, a tubular element 4, and a filling element 6. The flavor element 2 is formed by filling a flavor raw material 8.

The device (flavor inhaler) used to heat the flavor element 2 includes, for example, a needle-shaped heater 10. Only the heater 10 of the device is shown in Figure 1. The item 1 is placed 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.

In addition, 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 also be a sheet made from tobacco-free pulp to which flavoring has been added, a shredded sheet made from a non-tobacco plant, or one of these sheets folded in a gathered shape. The flavor raw material 8 is wrapped around its periphery 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 periphery 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 continuous body. The elements 2, 4, and 6 are connected to each other by wrapping tipping paper 20 around the periphery of the continuous body. Air vents 22 are formed in the tubular element 4 and the tipping paper 20 to allow air to be drawn into the article 1 when the article 1 is inhaled. The air drawn into the article 1 from the outside through the air vents 22 cools the flavor components of the flavor elements 2 and the volatile components of the additives described below, promoting the aerosolization of these components.

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

At this time, the tip filling element 6 prevents the flavor ingredient 8 from spilling from the flavor element 2 onto the base of the heater 10. In other words, the tip filling element 6 functions as a support segment in the product 1, supporting the flavor ingredient 8 filled in the flavor element 2 so that it does not spill onto the heater 10 side. This prevents the spilled flavor ingredient 8 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 product 1. This product 1 is composed of, from the tip side, a flavor element 2 and a filling element 6. When the flavor element 2 is ignited and heated, the flavor components of the flavor raw material 8 are volatilized. Figure 4 shows a cross-sectional view of a combustion-heating product 1 according to a modified example. This product 1 is composed of, 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 wrapper 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 a wrapper paper 32.

Figure 5 shows a cross-sectional view of another modified combustion-heating product 1. This product 1 is composed of, in order from the tip, a flavor element 2, a filler element 6, and a filter element 26. The arrangement of the filter element 26 and filler element 6 in the product 1 in Figure 4 is changed, but the rest of the configuration is the same as that of the product 1 in Figure 4.

<Filling element>
6 shows an end face of the filler element 6. The filler material 16 of the filler element 6 is a single sheet 34, whose main material is a dry nonwoven fabric made of plant pulp bonded together with a water-soluble binder. The plant pulp may be wood pulp, which is not derived from tobacco. Alternatively, the sheet 34 may 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, which uses a sheet 34 made of nonwoven fabric impregnated with tobacco powder or tobacco extract, not only functions as a filter element that serves as a filter body, but also 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 (described below), which 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 wrapping paper 18 and gluing and wrapping both ends of the wrapping paper 18. By folding a single sheet 34 to form the folded-in portion 36 and thus the filling element 6, it is no longer necessary to prepare multiple sheets 34, change the number of sheets 34, adjust the offset between the stacked sheets 34, or change the specifications of the sheets 34 themselves, as was done in the past, in order to adjust the packing density of the filling element 6.

Therefore, compared to conventional methods, the packing density of the packing elements 6 can be controlled more easily and with higher precision. 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 packing material 16, making it possible to more effectively prevent gaps and cavities from occurring in the packing elements 6.

Figure 7 shows a perspective view of the sheet 34 before processing. The 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. The sheet 34 has a thickness t including the raised portions 38.

<Sheet Stretching Treatment>
8 shows a perspective view of a sheet 34 that has been stretched. As the sheet 34 is stretched and lengthened in the longitudinal direction X, the thickness t of the sheet 34 decreases to a smaller value t1. Furthermore, as the sheet 34 lengthens in the longitudinal direction X and the surface area of the sheet 34 increases, the density (raised density) of the raised portions 38 on the front and back surfaces of the sheet 34 decreases. By adjusting the degree of stretching of the sheet 34, the thickness and raised density of the entire sheet 34 can be controlled. Therefore, it is possible to form folded portions 36, and thus filling elements 6, having a variety of packing densities using a single 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 the end face of the sheet 34 in Fig. 9. The sheet 34 is subjected to a pressing process in which at least a portion of the sheet 34 in the width direction Z is pressed. The sheet 34 shown in Fig. 6, which is an example of a pressed 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 incompletely pressed sloped surfaces and completely unpressed flat surfaces. When the total pressed width Dt1 of the sheet 34 is defined as the sum of the widths D1 of the pressed areas S1 where the sheet 34 is pressed in the width direction Z, 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 due to pressing. Furthermore, as the raised portion 38 is crushed, the raised density on the front and back surfaces of the sheet 34 in the pressed area A1 is significantly reduced. Meanwhile, the non-pressed area A2 of the sheet maintains the thickness t1 and raised density almost identical to those after the stretching process.

By adjusting the area where the pressed area A1 of the sheet 34 is formed and by setting the ratio of the total pressed width Dt1 to the sheet width Ds to a predetermined ratio, i.e., by adjusting the degree of pressing of the sheet 34, it is possible to control the thickness and raised density of the entire sheet 34. Therefore, it is possible to easily form folded sections 36 with multiple filling densities, and thus filling elements 6, using one type of sheet 34.

Figure 11 shows a perspective view of the folded portion 36. Figure 12 shows a perspective view of the filling element 6 formed by shrinking the diameter from the state shown in Figure 11. As a result of folding the sheet 34, an opening 40 is formed in the axial direction X at a portion of the circumferential direction of the folded portion 36. After shrinking the folded portion 36 with the opening 40 formed, the opening 40 is closed by wrapping it with wrapping paper 18, and the filling element 6 shown in Figure 12 is formed.

In this way, by folding a single 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 past, in order to adjust the packing density of the filling elements 6.

Therefore, the packing density of the packing elements 6 can be easily and precisely controlled. Furthermore, by adjusting the number of folds of a single sheet 34, the folding form, or the degree of diameter reduction of the folded portion 36, it is possible to optimize the packing density of the packing elements 6. Therefore, the occurrence of gaps or cavities in the packing elements 6 can be prevented, ensuring the quality of the product 1.

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

In particular, when pressing the sheet 34, the specified ratio of the total pressing width Dt1 to the sheet width Ds is set to 50% or less. This allows the nap-raised portion 38 to remain on the sheet 34 at 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 gaps and cavities from occurring in the filling elements 6.

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

Furthermore, the folded portion 36 is formed with a U-shaped cross-sectional recess 44 that is connected to the opening 40 and extends to the center of the folded 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 positioned in the center of the folded 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 portion 36 is shrinked and wrapped with the wrapping paper 18, the opening 40 is closed. Therefore, the additive 42 does not protrude from the folded portion 36, and the filling element 6 with the additive 42 disposed inside the folded portion 36 can be easily and reliably formed. Furthermore, when the folded portion 36 is shrinked, the recessed grooves 44 in which the additive 42 is disposed are filled with the sheet 34.

This ensures that the additive 42 is positioned at the center of the fold-in portion 36 in the radial direction Y. Furthermore, the components of the additive 42 can be uniformly evaporated from the center of the packing element 6 in the radial direction Y in the radial direction Y. This improves the reliability of ensuring the quality of the packing element 6 and, ultimately, the article 1. The additive 42 may be a liquid additive that is sorbed into 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 a liquid additive.

Additive 42 may also be a conductive material in the form of a thread or a long, thin plate. Filling element 6, which uses a sheet 34 made of nonwoven fabric impregnated with tobacco grounds or tobacco extract, functions as flavor element 2. The conductive material is heated by an induced current when the device generates a magnetic field, and the heated conductive material heats filling element 6, causing the tobacco plant-derived flavor components contained in filling element 6 to volatilize.

<Capsule placement in the fold-in section>
15 shows a perspective view of the folding portion 36 in which a capsule 46 is placed. The capsule 46 has an outer shell formed from a fragile material, and the outer shell encapsulates an additive. An opening 40 is formed in the folding portion 36, so that the capsule 46 can be placed at a predetermined position inside the folding portion 36 through the opening 40. The capsule 46 is placed, for example, at the center of the folding portion 36 in the axial direction X.

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 portion 36 is shrinked and wrapped with the wrapping paper 18, the opening 40 is closed. Therefore, the capsule 46 does not protrude from the folded portion 36, and the filling element 6 with the capsule 46 disposed inside the folded portion 36 can be easily and reliably formed. Furthermore, when the folded portion 36 is shrinked, the recessed ribs 44 are filled with the sheet 34, and the sheet 34 is tightly attached around the capsule 46.

This ensures that the capsule 46 is securely fixed at a predetermined position in the axial direction X, at the center of the radial direction Y of the folded-in portion 36. Furthermore, the additive components released from the capsule 46 can be uniformly evaporated from the center of the radial direction Y of the filling element 6 in the radial direction Y. This ensures the quality of the filling element 6 and, ultimately, the article 1.

Furthermore, by fixing the capsule 46 in close contact with the sheet 34 at the center of the fold-in portion 36 in the radial direction Y, the user can easily crush the capsule 46 with their fingers to release the additive, improving user convenience. The additives constituting the additive 42 sorbed in the grooves 44, the additives impregnated in the threads, and the additives encapsulated in the capsule 46 are, for example, flavoring agents such as menthol, and may further include activated carbon, an aerosol bulking agent, etc.

Instead of the capsule 46, a substantially spherical conductive member may be used. 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 nonwoven fabric impregnated with tobacco powder or tobacco extract, functions as 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.

<Filling element manufacturing apparatus and manufacturing method>
Fig. 17 shows a schematic diagram of a manufacturing apparatus 50 for the packing element 6, and Fig. 18 shows a flowchart 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 production of the filling element 6 begins, the sheet supply section 52 supplies a single 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 along 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, as well as 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 along the transport path 62.

At least one of the rotation shafts of a pair of rollers Ra, Rb that make up 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 signals from the control unit 70.

The control unit 70 adjusts the difference in the rotational speed between each roller set 64, 66, 68, thereby adjusting the difference in the conveying speed of the sheet 34 between each roller set 64, 66, 68. As a result, in the sheet processing step, the sheet 34 is subjected to the stretching process shown in Figure 8 (P1: Stretching process).

Specifically, the rotational speed of the downstream roller set (second roller set 66 or third roller set 68) is made higher than the rotational speed of the upstream roller set (e.g., first roller set 64) on the conveying path 62. This causes the conveying speed of the sheet 34 in the downstream roller set to be higher 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 outer periphery of the roller Ra. Each ridge 72 forms a pressing area A1 on the sheet 34. A number of grooves 74 are formed on the outer periphery of the roller Ra in conjunction with the formation of each ridge 72. Each groove 74 forms a non-pressing 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, thereby unwinding the sheet 34 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 Figure 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.

Figures 21 to 23 show examples of combinations of rollers Ra and Rb that make up each roller set 64, 66, and 68. Figure 21 shows a cross-sectional view of the first roller set 64. In this first roller set 64, as shown in Figure 19, numerous ridges 72 are formed across the entire width direction Z of the roller Ra and around the entire outer periphery of the roller Ra. Figure 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 Figure 21 are formed at both ends of the roller Ra in the width direction Z and around the entire 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 around the entire outer periphery of the roller Ra. Also, 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 around the entire outer periphery of the roller Rb.

In this way, at least one of the pair of rollers Ra, Rb that make up each roller set 64, 66, 68 is formed with a protruding ridge 72 that protrudes around the entire outer surface 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 carrying out the pressing process described above.

Figure 24 shows the edge surface of the sheet 34 that has passed through each of the roller sets 64, 66, and 68 in Figures 21 to 23. When the total width 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.

Meanwhile, at the center of the surface of the sheet 34 in the width direction Z, a pressing area A1 is formed by the ridges 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 ridges 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 ridges 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 rollers Rb of the third roller set 68 is added to the total pressing width Dt1, while the width D1 of the pressing area A1 formed by the ridges 72 of the rollers Ra of the first roller set 64 and the rollers Ra of the third roller set 68 is not added to the total pressing width Dt1. In other words, if 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 used as a representative and added to the total pressing width Dt1.

By pre-adjusting 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 formation range 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. Specifically, in each roller set 64, 66, 68, the area of the pressing surface 76 of the ridges 72, the number of ridges 72, the formation range of the ridges 72, etc. that contribute to the total pressing width Dt1 of the sheet 34 are adjusted, taking into account the formation range of the overlapping ridges 72 in the width direction Z of the sheet 34.

This allows the ratio of the total pressing width Dt1 to the sheet width Ds to be adjusted. The grip force of the ridges 72 on the sheet 34 can also 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 grip 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 transport of the sheet 34 in the transport path 62, forming a folding rod 90 with a diameter smaller than that 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 into 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 circumference 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, extending 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 comprises a guide roller 80a and a rotation shaft 80b that rotatably supports the guide roller 80a. During the process of transporting the sheet 34 in the transport 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 curve convexly upward in its 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 connected to the large diameter portion 82a. The inner surface 82c of the transport jet 82 tapers 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 radial center. The transport jet 82 uses air pressure to draw in the curved sheet 34 that has passed through the preliminary folding guide 80, folding it a predetermined number of times in the width direction Z between the baffle plate 88, and then reducing 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 whose diameter gradually decreases 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 extends axially inside the transport jet 82 and the trumpet guide 84.

The folding rod 90 that has passed through the transport jet 82 is released into the trumpet guide 84 along with air accompanied by wind pressure, and the air dissipation that accompanies this release unravels and opens the fibers of the folding rod 90. Furthermore, the folding rod 90 formed by the transport jet 82 passes through the trumpet guide 84 while sandwiched between baffles 92. This ensures that the folded state of the folding rod 90 formed by the transport jet 82 is maintained in the trumpet guide 84.

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

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

As shown in FIG. 17, the folding section 56 is equipped with 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 into the interior of the folding rod 90 at least before the folding rod 90 is transported to the tongs 86 (P3: Additive supply process). Specifically, 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, which holds capsules 46. At least before the folding rod 90 is transported to the tongs 86, the capsule supply unit 96 rotates the rotating holder 96a and intermittently drops the capsules 46 held in the rotating holder 96a into the folding rod 90 through the opening 40 to supply them (P4: capsule supply process). Specifically, the capsule supply unit 96 supplies the capsules 46 through the opening 40 to a predetermined position in the axial direction X of the groove 44, for example, to the center position in the axial direction X when the folding section 36 is reached.

17, the wrapping section 58 supplies 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), completing the production of the filling elements 6.

As described above, the filling element 6 of this embodiment comprises a folding portion 36 and a 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. By folding a single sheet 34 to form the folding portion 36, it is no longer necessary to prepare multiple sheets 34, change the number of sheets 34, adjust the offset width of the stacked sheets 34, or change the specifications of the sheets 34 themselves, as was conventionally done, in order to adjust the packing density of the filling element 6.

As a result, the packing density of the packing elements 6 can be controlled more easily and accurately than in conventional cases. Furthermore, by adjusting the number of folds of a single sheet 34, the folding form, or the degree of diameter reduction of the folded portion 36, it is possible to optimize the packing density of the packing elements 6. Therefore, the occurrence of gaps or cavities in the packing elements 6 can be prevented, ensuring the quality of the product 1.

Furthermore, the folded portion 36 has an opening 40 at a portion of its circumferential direction that opens along the axial direction X of the folded portion 36. The additive 42 is placed inside the folded portion 36 through the opening 40. This makes it possible to place the additive 42 in the appropriate position of the packing element 6 while optimizing the packing density of the packing element 6.

Folded section 36 also has a recessed groove 44 that is connected to opening 40 and has a U-shaped cross section that is recessed all the way to the center of folded section 36 in the radial direction Y. Additive 42 is arranged along the axial direction X of recessed groove 44. This ensures that additive 42 is positioned in the center of folded section 36 in the radial direction Y.

In addition, the components of the additive 42 can be uniformly evaporated from the center of the radial direction Y of the packing element 6 in the radial direction Y. This improves the reliability of ensuring the quality of the packing element 6, and ultimately the article 1. The additive 42 may be a liquid additive sorbed in the grooves 44, or may be threads arranged in the grooves 44. When threads are arranged, the threads are impregnated with a liquid additive.

The folding section 56 provided in the manufacturing apparatus 50 of this embodiment forms an opening 40 during the folding process of the sheet 34 and is equipped with an additive supply unit 94. The additive supply unit 94 supplies additives 42 into the inside of the folding rod 90 through the opening 40. The supply of additives 42 by this additive supply unit 94 through the opening 40 is also performed during the additive supply process of the folding step. This makes it possible to easily position the additives 42 in the appropriate position on the filling element 6 while folding the sheet 34 during the folding process of the sheet 34.

The folding section 56 also forms a recessed groove 44 with a U-shaped cross section that is connected to the opening 40 and extends to the center of the folding rod 90 in the radial direction Y. The additive supply unit 94 supplies additive 42 along the axial direction X of the recessed groove 44 through the opening 40. The supply of additive 42 by the additive supply unit 94 to the recessed groove 44 through the opening 40 is performed during the additive supply process of the folding step. This ensures that the additive 42 is positioned in the center of the folding section 36 in the radial direction Y.

The folding section 56 also includes a preliminary folding guide 80, a transport jet 82, a trumpet guide 84, and a tongue 86. As the sheet 34 passes through these areas of the folding section 56 during the transport process, the desired folding rod 90, and thus the desired filling element 6, can be reliably formed.

More specifically, the transport jet 82 and the trumpet guide 84 have baffles 88 and 92 extending radially from their inner circumferential surfaces 82c and 84a, respectively. The curved sheet 34 passing through the transport jet 82 and the trumpet guide 84 is folded between the baffles 88 and 92 by air with wind pressure, forming a folding rod 90 having an opening 40 and grooves 44.

In other words, each baffle plate 88, 92 functions as a portion that initiates the folding of the sheet 34 when the sheet 34 is being folded, and also functions as a portion that maintains the folded state of the sheet 34. Therefore, by providing each baffle plate 88, 92, the folding rod 90 on which the additive 42 is arranged, and ultimately the filling element 6 on which the additive 42 is arranged, can be formed more reliably.

This concludes the explanation 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.

Furthermore, the number of roller sets provided in the sheet processing section 54 need only be at least multiple in order to carry out the stretching process, and is not limited to the three roller sets 64, 66, and 68 mentioned above. Furthermore, 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.

Furthermore, it is not necessary to subject the sheet 34 to both stretching and pressing processes; the sheet 34 may be subjected to only one of stretching and pressing processes depending on the specifications of the sheet 34 and the required specifications of the filling element 6. Furthermore, depending on the specifications of the sheet 34 and the required specifications of the filling element 6, it may not be necessary to subject both stretching and pressing processes.

Furthermore, it is not necessary to place both the additive 42 and the capsule 46 inside the folded portion 36; only one of the additive 42 and the capsule 46 may be placed depending on the specifications of the filling element 6. Furthermore, as shown in Figures 6 and 12, depending on the specifications of the filling element 6, it may be possible to place nothing inside the folded portion 36.

Furthermore, the folding section 56 is not limited to the above-described configuration as long as it can form the folding rod 90. Furthermore, the additive supply unit 94 is not limited to the above-described configuration as long as it can perform the additive supply process. Furthermore, the capsule supply unit 96 is not limited to the above-described configuration as long as it can perform the capsule supply process. Furthermore, the configuration of the article 1 and the positions and number of the filling elements 6 in the article 1 are not limited to the forms described above.
The claims of this application as filed are set forth below.
[Appendix 1]
A filling element for use in a flavor inhalation article, comprising:
A folded portion in which a single sheet made of nonwoven fabric is folded in a width direction intersecting with its longitudinal direction to reduce its diameter to less than the diameter of the filling element;
a wrapping paper wrapped around the folded portion;
Equipped with
The folding portion has an opening that opens in the axial direction of the folding portion in a part of its circumferential direction, and an additive is placed inside the folding portion through the opening. A filling element.
[Appendix 2]
The folding portion has a recessed stripe having a U-shaped cross section that is connected to the opening and recessed to the center of the folding portion in the radial direction,
The packing element of claim 1, wherein the additive is arranged along the axial direction of the groove.
[Appendix 3]
3. The packing element of claim 2, wherein the additive is a liquid additive that is sorbed into the grooves.
[Appendix 4]
the additive is a thread disposed in the groove;
4. The packing element of claim 2 or 3, wherein the thread is impregnated with a liquid additive.
[Appendix 5]
An apparatus for manufacturing a filling element for use in a flavor inhalation article, comprising:
a sheet processing section that processes a single sheet made 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 a longitudinal direction thereof during the sheet conveyance process in the conveying path to form a folding rod having a diameter reduced to a diameter equal to or smaller than that of the filling element;
a wrapping section for wrapping the folded rod formed in the folding section with a wrapping paper to form a filled rod;
a cutting section for cutting the filler rod formed in the wrapping section into the filler elements;
Equipped with
The folding section forms an opening that opens in the axial direction of the folding rod in a portion of the circumferential direction of the folding rod during the sheet folding process, and further includes an additive supply unit that supplies additives to the inside of the folding rod through the opening.
[Appendix 6]
The folding section forms a recessed line having a U-shaped cross section that is connected to the opening and reaches the radial center of the folding rod during the folding process of the sheet,
The filling element manufacturing apparatus described in Appendix 5, wherein the additive supply unit supplies the additive along the axial direction of the groove through the opening.
[Appendix 7]
The fold-in section comprises:
a preliminary folding guide that bends the sheet in its thickness direction during the sheet conveyance process in the conveyance path;
a cylindrical transport jet that uses air with wind pressure to draw in the curved sheet that has passed through the preliminary folding guide and folds it a predetermined number of times in the width direction to form the folding rod;
a cylindrical trumpet guide through which the folding rods that have passed through the transport jet are released together with the air accompanied by the wind pressure, and the fibers of the folding rods are unraveled and opened by the dissipation of the air accompanying this release;
a cylindrical tongue that reduces the diameter of the folding rod that has passed through the trumpet guide to a diameter equal to or smaller than the diameter of the filling element;
7. An apparatus for manufacturing a packing element according to claim 6, comprising:
[Appendix 8]
the transport jet and the trumpet guide each have a baffle plate extending from an inner peripheral surface thereof toward a radial center thereof,
The curved sheet passing through the transport jet and the trumpet guide is folded between the baffles by the air accompanied by the wind pressure, and is formed into the folding rod having the opening and the grooves.
[Appendix 9]
A method for manufacturing a filling element for use in a flavor inhalation article, comprising:
a sheet processing step of processing a single sheet made of nonwoven fabric while conveying it;
a folding step in which, during the sheet conveying process, the sheet processed in the sheet processing step is folded in a width direction intersecting with the longitudinal direction thereof to form a folding rod having a diameter reduced to or 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;
a cutting step of cutting the filler rod formed in the wrapping step into the filler elements;
Including,
In the folding step, during the folding process of the sheet, an opening is formed in a portion of the circumferential direction of the folding rod that opens in the axial direction of the folding rod, and further, an additive supply process is performed to supply additives into the inside of the folding rod through the opening. A method for manufacturing a filling element.
[Supplementary Note 10]
In the folding step, a recess having a U-shaped cross section is formed in the folding process of the sheet, the recess being connected to the opening and extending to the radial center of the folding rod,
A method for manufacturing a packing element as described in Appendix 9, wherein the additive supply process supplies the additive through the opening along the axial direction of the groove.

1 Flavor inhalation article 6 Filling element 18 Wrapping paper 34 Sheet 36 Fold-in portion 40 Opening 42 Additive (additive, thread)
44 Groove 50 Manufacturing device 54 Sheet processing section 56 Folding section 58 Wrapping section 60 Cutting section 62 Conveying path 80 Preliminary folding guide 82 Transport jet 84 Trumpet guide 86 Tongs 88, 92 Baffle plate 90 Folding rod 94 Additive supply unit 98 Filling rod X Axial direction Y Radial direction Z Width direction

Claims (19)

A filling element for use in a flavor inhalation article, comprising:
A folded portion in which a single sheet made of nonwoven fabric is folded in a width direction intersecting with its longitudinal direction to reduce its diameter to less than the diameter of the filling element;
a wrapping paper wrapped around the folded-in portion,
The folding portion has an opening in a part of its circumferential direction that opens in the axial direction of the folding portion, and has a recessed groove that is connected to the opening and has a U-shaped cross section that is recessed up to the radial center of the folding portion, and an additive or capsule is placed in the radial center inside the folding portion through the opening. The filling element according to claim 1 , wherein the folded portion has the additive disposed therein. The filling element according to claim 1 , wherein the fold-in portion has the capsule disposed therein. The filling element according to claim 1 , wherein the folded portion is formed by folding the single sheet so that the folded portions overlap in the radial direction of the folded portion and extend in the circumferential direction of the folded portion. The filling element according to claim 1 , wherein the folded portion has the additive or capsule arranged along the axial direction of the groove. 6. The packing element according to claim 5 , wherein the additive is a liquid additive that is sorbed into the grooves. the additive is a thread disposed in the groove;
7. A packing element according to claim 5 or 6 , wherein the thread is impregnated with a liquid additive. An apparatus for manufacturing a filling element for use in a flavor inhalation article, comprising:
a sheet processing section that processes a single sheet made 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 a longitudinal direction thereof during the sheet conveyance process in the conveying path to form a folding rod having a diameter reduced to a diameter equal to or smaller than that of the filling element;
a wrapping section for wrapping the folded rod formed in the folding section with a wrapping paper to form a filled rod;
a cutting section that cuts the filler rod formed in the wrapping section into the filler elements;
The folding section forms an opening that opens in the axial direction of the folding rod in a portion of the circumferential direction of the folding rod during the sheet folding process, and forms a recessed rib that is connected to the opening and has a U-shaped cross section that is recessed and extends to the radial center of the folding rod, and further includes a supply unit that supplies additives or capsules to the radial center inside the folding rod through the opening. The device for manufacturing a filling element according to claim 8 , wherein the supply unit supplies the additive to the inside of the folding rod. 9. The device for manufacturing filling elements according to claim 8, wherein the feeding unit feeds the capsules into the inside of the folding rod. The filling element manufacturing apparatus described in claim 8, wherein the folding section folds the single sheet to overlap along the radial direction of the folding portion and extend along the circumferential direction of the folding portion during the sheet folding process to form the folding rod. The apparatus for manufacturing a filling element according to claim 8 , wherein the supply unit supplies the additive or capsule through the opening along the axial direction of the groove. The fold-in section comprises:
a preliminary folding guide that bends the sheet in its thickness direction during the sheet conveyance process in the conveyance path;
a cylindrical transport jet that uses air with wind pressure to draw in the curved sheet that has passed through the preliminary folding guide and folds it a predetermined number of times in the width direction to form the folding rod;
a cylindrical trumpet guide through which the folding rods that have passed through the transport jet are released together with the air accompanied by the wind pressure, and the fibers of the folding rods are unraveled and opened by the dissipation of the air accompanying this release;
The stuffing element manufacturing apparatus according to claim 12 , further comprising a cylindrical tongue that reduces the diameter of the folding rod that has passed through the trumpet guide to a diameter equal to or less than the diameter of the stuffing element. the transport jet and the trumpet guide each have a baffle plate extending from an inner peripheral surface thereof toward a radial center thereof,
The curved sheet passing through the transport jet and the trumpet guide is subjected to air accompanied by the wind pressure and folded between the baffles to form the folding rod having the opening and the grooves. The filling element manufacturing apparatus of claim 13 . A method for manufacturing a filling element for use in a flavor inhalation article, comprising:
a sheet processing step of processing a single sheet made of nonwoven fabric while conveying it;
a folding step in which, during the sheet conveying process, the sheet processed in the sheet processing step is folded in a width direction intersecting with the longitudinal direction thereof to form a folding rod having a diameter reduced to or 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;
a cutting step of cutting the filler rod formed in the wrapping step into the filler elements;
In the folding step, during the folding process of the sheet, an opening is formed in a part of the circumferential direction of the folding rod that opens in the axial direction of the folding rod, a recessed groove with a U-shaped cross section is formed that is connected to the opening and extends to the radial center of the folding rod, and further, a supply process is performed to supply additives or capsules to the radial center inside the folding rod through the opening. 16. The method for manufacturing a filler element according to claim 15, wherein the supplying process supplies the additive inside the folding rod. 16. The method for manufacturing a packing element according to claim 15, wherein the feeding process feeds the capsules inside the folding rod. The method for manufacturing a filling element according to claim 15, wherein the folding step forms the folded rod by folding the single sheet so that the folded portions overlap along the radial direction of the folded portion and extend along the circumferential direction of the folded portion during the folding process. The method for manufacturing a packing element according to claim 15 , wherein the supplying process supplies the additive or capsule through the opening along the axial direction of the groove.