ROLLING UNIT AND ROLLING METHOD FOR FILLER ROD

Abstract

A rolling unit for a filler rod includes a rolling drum that has an outer peripheral surface for holding chip paper and a continuous body and transfers the chip paper and the continuous body in the circumferential direction of the outer peripheral surface; and a rolling block that has a rolling surface facing the outer peripheral surface of the rolling drum, forms a rolling gap between the rolling surface and the outer peripheral surface of the rolling drum, and winds the chip paper around the continuous body by rolling the continuous body while interposing the continuous body in the rolling gap as the rolling drum rotates. A plurality of block-side suction holes is opened on the rolling surface of the rolling block, and the rolling gap is suctioned via the block side suction holes.

Description

TECHNICAL FIELD

The present invention relates to a rolling unit and a rolling method for a filler rod.

BACKGROUND ART

PTL 1 describes a rolling unit used for filter attachment of a tobacco rod. The rolling unit rolls a serial body including a tobacco rod and a filter rod coaxially disposed, and wraps the serial body with a tipping paper during the rolling to connect the serial body to form an intermediate product of a smoking article. The rolling unit includes a rolling drum and a rolling block.

The rolling drum has an outer periphery for holding a tipping paper and a serial body and conveys the tipping paper and the serial body in a circumferential direction of the outer periphery. The rolling block has a rolling surface facing the outer periphery of the rolling drum. A rolling space is formed between the rolling surface and outer periphery of the rolling drum. With the rotation of the rolling drum, the serial body is rolled while being sandwiched in the rolling space to wrap the serial body with the tipping paper.

When the tipping paper and the serial body are held on the outer periphery of the rolling drum and conveyed, part of the serial body in the circumferential direction is affixed to the tipping paper with adhesive in advance. When the serial body is sandwiched in the rolling space and rolled, the serial body contacts with the rolling surface of the rolling block, with the result that frictional force is applied between the rolling surface and the tipping paper to which the serial body is partially bonded. By the application of the frictional force, the tipping paper wraps all around the serial body in the circumferential direction.

CITATION LIST

Patent Literature

PTL 1: Japanese Unexamined Patent Application Publication (Translation of PCT Application) No. 2019-518455

SUMMARY OF INVENTION

Technical Problem

A tobacco rod filled with a tobacco raw material is defined as a filler rod filled with a flavor raw material (there can be a case where a tobacco raw material is not contained) in a broad sense. In this case, a filled part obtained by cutting the filler rod is a component of a heat-not-burn flavor inhaling article. A heater of a device used to use the flavor inhaling article, for example, heats the filled part when inserted into the filled part and generates an aerosol of a flavor component. In this case, in the filled part, when the filling amount of flavor raw material is large for the volume of the heater, the resistance to insert the heater to the filled part increases to make it difficult to insert the heater, with the result that operability during inhalation deteriorates. The resistance to insert the heater may lead to breakage of the heater.

Furthermore, in the filled part, when the filling amount of flavor raw material is large for the volume of the heater, the flavor raw material in the filled part becomes excessively dense as a result of insertion of the heater, so air permeability in the filled part deteriorates, with the result that an inhalation taste may be impaired. To eliminate these inconveniences, the filling amount of flavor raw material that fills the filler rod can be reduced as compared to the existing art. In consideration of a situation in terms of costs for a flavor inhaling article, the filling amount of flavor raw material can be reduced.

For the filler rod, a wrapping machine forms a flavor raw material into a filler and continuously wraps the filler with a wrapping paper. When the filling amount of flavor raw material is reduced, a packing density of flavor raw material in the filler rod decreases. For this reason, the hardness of the filler rod decreases, that is, the filler rod softens. As a result of softening of the filler rod, the reaction force of the filler rod, which is generated at the time when the filler rod is sandwiched in the rolling space and rolled, decreases; in other words, the filler rod is difficult to elastically deform. Therefore, when the serial body rolls in the rolling space, adhesion between the rolling surface and the tipping paper to which the serial body is partially bonded decreases, and frictional force applied between the rolling surface and the tipping paper decreases.

When frictional force between the rolling surface and the tipping paper decreases, the rolling resistance of the filler rod decreases in the rolling space. Therefore, the filler rod partially bonded to the tipping paper slips on the tipping paper, and the tipping paper does not properly wrap all around the serial body in the circumferential direction. As a result, for example, a crease occurs in the tipping paper of a completed intermediate product or a step is formed in the tipping paper at a boundary portion between the filler rod of the completed intermediate product and an adjacent rod, such as a filter rod, so the quality of the intermediate product and the smoking article decreases.

The present invention is made in view of such a problem, and it is an object of the present invention to provide a rolling unit and a rolling method for a filler rod, capable of ensuring the quality of an intermediate product and a smoking article even when the filling amount of flavor raw material is reduced.

Solution to Problem

A rolling unit for a filler rod according to an aspect forms a serial body in which a plurality of rods including a filler rod filled with a flavor raw material is disposed so as to be coaxially arranged. The rolling unit forms an intermediate product of a flavor inhaling article by connecting the serial body by rolling the serial body to wrap the serial body with a tipping paper during the rolling. The rolling unit includes: a rolling drum that has an outer periphery holding a tipping paper and a serial body and that conveys the tipping paper and the serial body in a circumferential direction of the outer periphery; and a rolling block that has a rolling surface facing the outer periphery of the rolling drum, the rolling block forming a rolling space between the rolling surface and the outer periphery of the rolling drum, the rolling block wrapping the serial body with the tipping paper by sandwiching and rolling the serial body in the rolling space with rotation of the rolling drum. The rolling block has a plurality of block-side suction holes open at the rolling surface, and the rolling space is sucked via the block-side suction hole.

A rolling method for a filler rod according to an aspect forms a serial body in which a plurality of rods including a filler rod filled with a flavor raw material is disposed so as to be coaxially arranged and forms an intermediate product of a flavor inhaling article by connecting the serial body by rolling the serial body to wrap the serial body with a tipping paper during the rolling. The rolling method includes: a conveying step of, by using a rolling drum that has an outer periphery that holds the tipping paper and the serial body, conveying the tipping paper and the serial body in a circumferential direction of the outer periphery; and a rolling step of, by using a rolling block that has a rolling surface facing the outer periphery of the rolling drum and that forms a rolling space between the rolling surface and the outer periphery of the rolling drum, wrapping the serial body with the tipping paper by sandwiching and rolling the serial body in the rolling space with rotation of the rolling drum. The rolling step includes a suction process of sucking the rolling space via a plurality of block-side suction holes that are open at the rolling surface of the rolling block.

Advantageous Effects of Invention

With the above-described rolling unit and rolling method for a filler rod, even when the filling amount of flavor raw material is reduced, it is possible to ensure the quality of an intermediate product and a smoking article.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic diagram that shows the outline of a filter attachment process.

FIG. 2 is a schematic diagram of a rolling unit.

FIG. 3 is a plan view that shows a positional relationship between a rolling surface of a rolling block and a serial body that contacts with the rolling surface.

FIG. 4 is a plan view that shows another mode of FIG. 3.

FIG. 5 is a flowchart that illustrates a rolling method used for filter attachment of a filler rod.

DESCRIPTION OF EMBODIMENTS

FIG. 1 is a schematic diagram of a filter attachment process for connecting a filler rod FR to a filler rod TR. As shown in (a), the filter attachment process initially prepares a filler rod DTR having a length twice as long as a filled part T of a flavor inhaling article C (hereinafter, also simply referred to as article C). Subsequently, as shown in (b), the center of the filler rod DTR in a longitudinal direction is cut into two equal filler rods TR. In addition, a filter rod FR having a length twice as long as a filter part F of the article C is prepared, and the filter rod FR is disposed between the two filler rods TR.

Subsequently, as shown in (c), a serial body A in which the filler rods TR and the filter rod FR are coaxially arranged to butt against each other is formed.

Subsequently, as shown in (d), the outer periphery of the serial body A including each butted part between the filler rod TR and the filter rod FR is wrapped with the tipping paper P, and is bonded with adhesive. Thus, as shown in (e), an intermediate product B in which the two filler rods TR and the one filter rod FR are connected by the tipping paper P as one is formed.

Subsequently, as shown in (f), the intermediate product B is cut at the center in the longitudinal direction from outside the tipping paper P to finally form two articles C. This filter attachment process is performed by conveying the filler rod DTR, the filler rod TR, the filter rod FR, the tipping paper P, the serial body A, and the intermediate product B on the outer peripheries of drums that make up a train of drums.

A flavor raw material that is a component of a filler of a filler rod TR is, for example, shredded tobacco, an article obtained by shredding a tobacco sheet, or an article obtained by gathering a tobacco sheet. Alternatively, a flavor raw material may be an article obtained by adding a flavoring agent to a sheet made from pulp not containing tobacco, an article obtained by shredding a sheet made from a non-tobacco plant, or an article obtained by gathering a sheet of any one of them.

FIG. 2 is a schematic diagram of a rolling unit 1 according to an embodiment. The rolling unit 1 rolls the serial body A and wraps the serial body A with the tipping paper P during the rolling (the state of (d) in FIG. 1). Thus, the serial body A is connected as one by the tipping paper P, and the intermediate product B of the article C is formed (the state of (e) in FIG. 1). The rolling unit 1 includes a rolling drum 2, a rolling block 4, and a kicking rail 6.

The rolling drum 2 has an outer periphery 2a for holding the tipping paper P and the serial body A and rotates in a direction indicated by the continuous line arrow about a rotary shaft 2b extending parallel to the serial body A. Thus, the serial body A is conveyed in a circumferential direction of the outer periphery 2a, indicated by the dashed line arrows. More specifically, a large number of drum-side suction holes 8 are formed at the outer periphery 2a of the rolling drum 2. Each of the drum-side suction holes 8 is a hole extending parallel to the rotary shaft 2b. The drum-side suction holes 8 are provided at equal intervals in the circumferential direction of the outer periphery 2a and communicate with a suction source (not shown).

A pocket 10 with counter boring is formed at every selected number of the drum-side suction holes 8 formed along the outer periphery 2a, for example, every three drum-side suction holes 8 as shown in the drawing. The tipping paper P is held in a state affixed to the outer periphery 2a by suction from the drum-side suction holes 8 and conveyed in the circumferential direction of the outer periphery 2a. Affixation of the tipping paper P to the outer periphery 2a may be accompanied by static electricity with which the tipping paper P is charged.

The serial body A is held by the outer periphery 2a in a state accommodated in the pocket 10 by suction from the drum-side suction hole 8 in which the pocket 10 is formed, and is conveyed in the circumferential direction of the outer periphery 2a. When the tipping paper P and the serial body A are held by the outer periphery 2a of the rolling drum 2 and conveyed, part of the serial body A in the circumferential direction is affixed in advance to the tipping paper P with adhesive.

The rolling block 4 has a curved rolling surface 4a facing the outer periphery 2a of the rolling drum 2. A rolling space 12 is formed between the rolling surface 4a and the outer periphery 2a of the rolling drum 2. The rolling block 4 sandwiches and rolls the serial body A in the rolling space 12 with rotation of the rolling drum 2 and wraps the serial body A with the tipping paper P all around in the circumferential direction.

More specifically, the kicking rail 6 is provided at the entrance of the rolling space 12 in a conveying direction of the serial body A and protrudes from the rolling surface 4a toward the outer periphery 2a of the rolling drum 2. When the kicking rail 6 contacts with the serial body A to be conveyed, the serial body A temporarily leaves the pocket 10 and starts rolling in the rolling space 12.

The serial body A having started rolling at the entrance of the rolling space 12 rolls while being sandwiched in the rolling space 12 between the rolling surface 4a and the outer periphery 2a at which the drum-side suction hole 8 with no pocket 10 is formed, with rotation of the rolling drum 2. At this time, the tipping paper P held by the outer periphery 2a and partially affixed to the serial body A wraps all over a region of a butted part in the circumferential direction between each filler rod TR and the filter rod FR in the serial body A. The tipping paper P is bonded in a manner such that both end edges are laid on each other with adhesive applied therebetween, and an intermediate product B is formed.

The intermediate product B is adsorbed to the pocket 10 again at the exit of the rolling space 12 and conveyed in the conveying direction of the outer periphery 2a to be transferred from the rolling drum 2. In the next step, as shown in (f) of FIG. 1, the intermediate product B is cut at the center in the longitudinal direction from outside the tipping paper P to finally manufacture two articles C.

Here, a large number of block-side suction holes 14 are open at the rolling surface 4a in the rolling block 4 according to the present embodiment, and the rolling space 12 is sucked via the block-side suction holes 14. Each of the block-side suction holes 14 is, for example, a round hole and communicates with the suction source via a suction chamber 16 formed inside the rolling block 4.

FIG. 3 is a plan view of a positional relationship between the rolling surface 4a of the rolling block 4 and the serial body A that is in contact with the rolling surface 4a. The block-side suction holes 14 are open at the rolling surface 4a in regions S1 where the filler rods TR are respectively positioned. A suction force applied from the suction source to each filler rod TR sequentially via the suction chamber 16 and the block-side suction holes 14 is determined by a suction pressure set by the suction source. The suction pressure of the suction source is set to a value with which the rolling resistance of each filler rod TR in the rolling space 12 is a proper value and wrapping of the serial body A with the tipping paper P is properly performed.

FIG. 4 is a plan view of another mode of FIG. 3. In the case of FIG. 4, the block-side suction holes 14 may be open not only at the rolling surface 4a in the regions S1 where the filler rods TR are respectively positioned but also at the rolling surface 4a in a region S2 where the filter rod FR is positioned. The suction pressure of the suction source is set to a value with which the rolling resistance of each filler rod TR and filter rod FR in the rolling space 12 is a proper value and wrapping of the serial body A with the tipping paper P is properly performed.

FIG. 5 is a flowchart that illustrates a rolling method used for filter attachment of the filler rod TR. When rolling of the filler rod TR using the rolling unit 1 is started, the rolling drum 2 rotates about the rotary shaft 2b to convey the tipping paper P and the serial body A in the circumferential direction of the outer periphery 2a of the rolling drum 2 in step S1 (conveying step).

In step S2, with rotation of the rolling drum 2, the serial body A is sandwiched and rolled in the rolling space 12 to wrap the serial body A all around in the circumferential direction with the tipping paper P to which the serial body A is partially affixed (rolling step). In the rolling step, in process P1, the rolling space 12 is sucked via the block-side suction holes 14 open at the rolling surface 4a of the rolling block 4 (suction process).

More specifically, in the suction process, the rolling space 12 is sucked via the block-side suction holes 14 open at the rolling surface 4a in the regions S1 where the filler rods TR are respectively positioned. On the other hand, in the case of the mode shown in FIG. 4, in the suction process, the rolling space 12 is sucked via the block-side suction holes 14 open at the rolling surface 4a in the regions S1 where the filler rods TR are respectively positioned and at the rolling surface 4a in the region S2 where the filter rod FR is positioned.

The rolling method has been described by being separated into step S1, step S2, and process P1 for the sake of description; however, step S1, step S2, and process P1 are performed at the same timing from when rolling of the serial body A is started to when the rolling ends.

As described above, with the rolling unit and the rolling method for the filler rod TR according to the present embodiment, the plurality of block-side suction holes 14 is open at the rolling surface 4a of the rolling block 4, and, in the suction process of the rolling step, the rolling space 12 is sucked via the block-side suction holes 14.

When the filling amount of flavor raw material is reduced as compared to the existing art, the reaction force of the filler rod TR decreases due to softening of the filler rod TR, and frictional force applied between the rolling surface 4a and the tipping paper P to which the serial body A is partially affixed decreases. More specifically, when the hardness of the filler rod TR is lower than 70%, it is difficult to manufacture the filler rod TR, so it has been proved that the hardness of the filler rod TR needs to be higher than or equal to 70% and more preferably higher than or equal to 75%.

The hardness of the filler rod is measured with a measuring instrument (model number: DD60A Densimeter (made by Heinr. Borgwaldt GmbH)). The measuring instrument includes a pusher and applies a load on the filler rod TR by lowering the pusher by a lowering distance d. Where the diameter of the filler rod TR before application of a load is Ds and the diameter of the filler rod TR after a load is applied for a predetermined period of time is Dd, the lowering distance d of the pusher is calculated by the expression Ds−Dd, and the hardness of the filler B is calculated by the expression (Dd/Ds)×100.

When the hardness of the filler rod is lower than 70%, frictional force between the rolling surface 4a and the tipping paper P decreases, and the rolling resistance of the filler rod TR in the rolling space 12 also decreases. Therefore, the filler rod TR slips on the tipping paper P, and the tipping paper P does not properly wrap the filler rod TR all around in the circumferential direction. As a result, for example, a crease occurs in the tipping paper of a completed intermediate product B or a step is formed at a boundary portion between the filler rod TR and filter rod FR of the completed intermediate product B, so the quality of the intermediate product B and the article C decreases.

On the other hand, in the present embodiment, the amount of decrease in frictional force applied between the rolling surface 4a and the tipping paper P is compensated by suction force applied via the block-side suction holes 14. Thus, even when the filling amount of flavor raw material is reduced as compared to the existing art, it is possible to enhance adhesion between the rolling surface 4a and the tipping paper P to which the serial body A is partially affixed in the rolling space 12, so it is possible to properly perform wrapping of the filler rod TR with the tipping paper P all around the region in the circumferential direction.

Therefore, it is possible to suppress a crease or a step that occurs in the tipping paper P of the intermediate product B. In other words, irrespective of the filling amount and packing density of flavor raw material or irrespective of the hardness of the filler rod TR, the quality of the intermediate product B and the article C can be ensured. More specifically, as shown in FIG. 3, the block-side suction holes 14 are open at the rolling surface 4a in the regions S1 where the filler rods TR are respectively positioned.

In this case, in the suction process, the rolling space 12 is sucked via the block-side suction holes 14 open in the regions S1. Thus, suction force from the suction source can be further effectively applied to the filler rods TR. Therefore, the amount of decrease in frictional force applied between the rolling surface 4a and the tipping paper P is further effectively compensated by suction force applied via the block-side suction holes 14.

On the other hand, in consideration of the filtration capacity of the filter part F that is a component of the article C, the filling amount of filter material, such as nonwoven fabric sheet, may be reduced in the filter rod FR. In this case, as in the case of the filler rod TR, the packing density of the filter rod FR decreases, with the result that the filter rod FR softens. As a result of softening of the filter rod FR, the reaction force of the filter rod FR, which occurs at the time when the filter rod FR is sandwiched and rolled in the rolling space 12, decreases, so frictional force applied between the rolling surface 4a and the tipping paper P decreases.

When frictional force between the rolling surface 4a and the tipping paper P decreases, it is difficult to properly wrap the filter rod FR with the tipping paper P. As a result, a crease or a step occurs in the tipping paper P of the intermediate product B, and the quality of the intermediate product B and the article C decreases. When the filter rod FR softens, as shown in FIG. 4, the block-side suction holes 14 are formed not only at the rolling surface 4a in the regions S1 where the filler rods TR are respectively positioned but also at the rolling surface 4a in the region S2 where the filter rod FR is positioned.

In this case, in the suction process, the rolling space 12 is sucked via the block-side suction holes 14 open in the regions S1 and the region S2. Thus, at both positions of each filler rod TR and the filter rod FR, the amount of decrease in frictional force applied between the rolling surface 4a and the tipping paper P can be compensated by suction force applied via the block-side suction holes 14. Therefore, not only when the filling amount of flavor raw material is reduced but also when the filling amount of filter raw material is reduced, the quality of the intermediate product B and the article C can be ensured.

The description of the embodiment has been described above; however, the above-described embodiment is not restrictive and may be modified into various forms without departing from the purport. For example, each of the block-side suction holes 14 may have a shape other than a round hole, and the number of holes and the size of the holes in the regions S1, S2 may be changed. Alternatively, a mechanism of varying suction force applied via the block-side suction holes 14 in the regions S1 and suction force applied via the block-side suction holes 14 in the region S2 may be provided. Thus, it is possible to apply a suction force according to a difference in hardness between the filler rod TR and the filter rod FR.

In the embodiment, the serial body A is formed by disposing one filter rod FR between two filler rods TR; however, the configuration is not limited thereto. The rolling unit and the rolling method according to the embodiment may be applied to a case where a plurality of rods including a filler rod TR is disposed so as to be coaxially arranged. For example, the serial body A may be formed by disposing one filler rod TR between two filter rods FR.

The serial body A may include a rod different from the filter rod FR, for example, a paper core, as a rod other than the filler rod TR. The rolling unit and the rolling method according to the embodiment may be applied to a case when a different intermediate product B is formed step by step, for example, a case where the intermediate product B is formed from the serial body A in which a paper core is disposed adjacent to the filler rod TR, then the serial body A in which the filter rod FR is disposed adjacent to the intermediate product B is formed, and a new intermediate product B is formed from the serial body A.

The rolling unit and the rolling method according to the embodiment are not limited to manufacturing the intermediate product B of a heat-not-burn flavor inhaling article C and may also be applied to manufacturing of an intermediate product B of a heat-burn flavor inhaling article.

REFERENCE SIGNS LIST

• • 1 rolling unit
  • 2 rolling drum
  • 2a outer periphery
  • 4 rolling block
  • 4a rolling surface
  • 12 rolling space
  • 14 block-side suction hole
  • A serial body
  • B intermediate product
  • C smoking article
  • P tipping paper
  • TR filler rod
  • FR filter rod (rod other than the filler rod)
  • S1 region on a rolling surface where the filler rod is positioned
  • S2 region on the rolling surface where the filter rod (rod other than the filler rod) is positioned

Claims

1. A rolling unit for a filler rod, the rolling unit forming a serial body in which a plurality of rods including a filler rod filled with a flavor raw material is disposed so as to be coaxially arranged, the rolling unit forming an intermediate product of a flavor inhaling article by connecting the serial body by rolling the serial body to wrap the serial body with a tipping paper during the rolling, the rolling unit comprising:

a rolling drum that has an outer periphery holding the tipping paper and the serial body and that conveys the tipping paper and the serial body in a circumferential direction of the outer periphery; and

a rolling block that has a rolling surface facing the outer periphery of the rolling drum, the rolling block forming a rolling space between the rolling surface and the outer periphery of the rolling drum, the rolling block wrapping the serial body with the tipping paper by sandwiching and rolling the serial body in the rolling space with rotation of the rolling drum, wherein

the rolling block has a plurality of block-side suction holes open at the rolling surface, the rolling space is sucked via the block-side suction holes.

2. The rolling unit for a filler rod according to claim 1, wherein the block-side suction holes are open at the rolling surface in a region where the filler rod is positioned.

3. The rolling unit for a filler rod according to claim 2, wherein the block-side suction holes are open at the rolling surface in a region where the rod other than the filler rod is positioned.

4. A rolling method for a filler rod, the rolling method forming a serial body in which a plurality of rods including a filler rod filled with a flavor raw material is disposed so as to be coaxially arranged, the rolling method forming an intermediate product of a flavor inhaling article by connecting the serial body by rolling the serial body to wrap the serial body with a tipping paper during the rolling, the rolling method comprising:

a conveying step of conveying the tipping paper and the serial body in a circumferential direction of the outer periphery by using a rolling drum that has an outer periphery that holds the tipping paper and the serial body; and

a rolling step of, by using a rolling block that has a rolling surface facing the outer periphery of the rolling drum and that forms a rolling space between the rolling surface and the outer periphery of the rolling drum, wrapping the serial body with the tipping paper by sandwiching and rolling the serial body in the rolling space with rotation of the rolling drum, wherein

the rolling step includes a suction process of sucking the rolling space via a plurality of block-side suction holes that are open at the rolling surface of the rolling block.

5. The rolling method for a filler rod according to claim 4, wherein, in the suction process, the rolling space is sucked via the block-side suction holes that are open at the rolling surface in a region where the filler rod is positioned.

6. The rolling method for a filler rod according to claim 5, wherein, in the suction process, the rolling space is sucked via the block-side suction holes that are open at the rolling surface in a region where the rod other than the filler rod is positioned.