WO2013149880A2

WO2013149880A2 - Web processing apparatuses, methods and systems

Info

Publication number: WO2013149880A2
Application number: PCT/EP2013/056342
Authority: WO
Inventors: Glen Elgar; Richard VEZEY
Original assignee: British American Tobacco (Investments) Limited
Priority date: 2012-04-04
Filing date: 2013-03-26
Publication date: 2013-10-10
Also published as: GB201206041D0; WO2013149880A3

Abstract

The WEB PROCESSING APPARATUSES, METHODS AND SYSTEMS provides for processing of web material, such as of tipping paper. An exemplary embodiment is an apparatus including a first roller component that manipulates a pair of tipping paper strips having a first lateral separation, where the pair of tipping paper strips traverse a first path. The apparatus further includes a second roller component that is located above the first roller component at a predefined height and has an orientation that is substantially perpendicular to the first roller component. The second roller component is configured to manipulate the pair of tipping paper strips traversing along the first path to a second path that returns the pair of tipping paper strips back to the first roller component. The pair of tipping paper strips returning to the first roller component include a second lateral separation.

Description

WEB PROCESSING APPARATUSES, M ETHODS AND SYSTEMS

The invention relates to apparatus for processing a moving web of material that has been slit to form a pair of paper strips. FIELD

The present invention is directed generally to processing webs of material and web material converting equipment. In some aspects, the present disclosure is directed to the manufacture of smoking articles (e.g., cigarettes), and more particularly, to the processing of paper, such as tipping paper, utilized during the manufacturing of such smoking articles.

BACKGROUND

Paper is used in the manufacture of cigarettes. Tipping paper is used during the manufacture of cigarettes to attach a filter to tobacco rod.

SUMMARY

The purpose and advantages of the present disclosure will be set forth in and become apparent from the description that follows. Additional advantages of the disclosed embodiments will be realized and attained by the methods and systems particularly pointed out in the written description hereof, as well as from the appended drawings.

The present disclosure provides a variety of methods and systems for processing a web of material for a variety of purposes. According to an aspect of the invention there is provided an apparatus for processing a moving web of material that has been slit to form a pair of paper strips, the apparatus including a feeding roller and a receiving roller each having first parallel rotational axes lying adjacent to each other in the same or parallel first plane(s), and an intermediate second roller pair each having a second rotational axis parallel to each other and lying in a second plane parallel to and spaced from the first plane(s), the rotational axis of the second rollers being angled relative to the rotational axis of the feeding and receiving rollers such that each paper strip is fed from the feeding roller, around which they both pass with a first lateral separation, around a respective angled second roller before they are both fed around the receiving roller, so that said strips have a second a lateral separation on the receiving roller which is greater than the first lateral separation.

In some embodiments, the rotational axis of the second rollers may be perpendicular to the rotational axis of the feeding and receiving roller.

The intermediate second roller pair may be movable towards and away from the feeding and receiving rollers.

The apparatus preferably comprises a slitter for slitting a web of material to form a pair of paper strips which are fed around the feeding roller.

The slitter may be configured to slit the web to form a central strip between said pair of paper strips, said central strip being conveyed along a separate path so that only said pair of strips are passed over said feeding roller. In accordance with another aspect, a system for processing a moving web of material is provided. In one embodiment the system includes a frame or other support, a first set of rollers mounted on and extending outwardly from the frame along a first set of parallel axes of rotation and a second set of rollers mounted on and extending outwardly from the frame along a second set of parallel axes of rotation. The first and second sets of axes of rotation may be in displaced, parallel planes. The first and second sets of axes can be oriented substantially perpendicularly with respect to each other. The system further can include a drive configured to pull a web of material over the first set of rollers and the second set of rollers, wherein the first set of rollers, second set of rollers and drive cooperate to define a web path for passage of the web of material.

In accordance with a further aspect, the parallel planes can be displaced from each other along a vertical dimension of the frame. In some implementations, the distance between the first set of rollers and second set of rollers may be adjustable. In some embodiments, the system further includes a slitter for slitting the web of material into a plurality of web portions. The system can further include a feed spindle for receiving a roll of web material. The feed spindle can extend outwardly from the frame, such as in a cantilevered fashion, and can be supported on one end or on both ends, depending on the implementation. The system can further include a plurality of idler rollers disposed along a web path between the feed spindle and the first set of rollers. One or more stabilizing rollers can be provided and disposed in the web path after the idler rollers and before the slitter. A stabilizing roller can be configured to prevent the edges of the web from curling, such as by varying to location of the stabilizing roller relative to a slitter.

The disclosure also provides methods of processing a moving web of material. An exemplary method can include slitting an initial web of material while the material is moving to provide 2 or more additional web portions each having a centerline, a first face and a second face. A first web portion is directed along a first path from a first set of rollers to a second set of rollers oriented substantially orthogonally with respect to the first set of rollers, wherein the first web portion is rotated about ninety degrees along a first angular direction about the centerline of the first web portion as the first web portion passes from the first set of rollers to the second set of rollers. A second web portion is directed along a second path from the first set of rollers to the second set of rollers, the first web portion and second web portion being separated by a first lateral separation as they are directed over the first set of rollers when traversing the first path and second path respectively, wherein the second web portion is rotated about ninety degrees along a second angular direction opposite to the first angular direction about the centerline of the second web portion as the second web portion passes from the first set of rollers to the second set of rollers. The first web portion is directed along a third path from the second set of rollers to the first set of rollers, wherein the first web portion is rotated about ninety degrees along the first angular direction about the centerline of the first web portion as the first web portion passes from the second set of rollers to the first set of rollers. The second web portion is directed along a fourth path from the second set of rollers to the first set of rollers, the first web portion and second web portion being separated by a second lateral separation as the first web portion and second web portion are directed over the first set of rollers when traversing the third path and fourth path respectively, the second web portion is rotated about ninety degrees along the second angular direction about the centerline of the second web portion as the second web portion passes from the second set of rollers to the first set of rollers, and the second lateral separation is different from the first lateral separation. A center web portion from the initial web of material may be formed laterally between the first web portion and the second web portion, each of the web portions traveling faster than 3,ooo mm/minute. A section of material is separated from each of the leading edges of the first web portion, second web portion and center web portion for application to a smoking article.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the embodiments disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying appendices and/or drawings illustrate various non-limiting, example, inventive aspects in accordance with the present disclosure:

FIGURE l illustrates a perspective view of an exemplary tipping paper manufacturing apparatus according to some embodiments;

FIGURE 2 illustrates a more detailed perspective view of an exemplary tipping paper feeder mechanism shown in FIGURE l according to some embodiments;

FIGURE 3 illustrates a more detailed rear perspective view of the tipping paper guide mechanism shown in FIGURE l according to some embodiments; FIGURE 4 illustrates a more detailed perspective view of the tipping paper cutting mechanism shown in FIGURE l according to some embodiments;

FIGURE 5A illustrates a more detailed perspective view of the tipping paper lateral adjustment mechanism shown in FIGURE 1 according to some embodiments; FIGURE 5B illustrates a more detailed perspective view of the generated separation produced by the tipping paper lateral adjustment mechanism according to some embodiments;

FIGURE 5C illustrates a more detailed perspective view of the twisting of the tipping paper during the operation of the tipping paper lateral adjustment mechanism according to some embodiments;

FIGURE 6A illustrates a more detailed perspective view of the tipping paper combiner and feed mechanism shown in FIGURE 1 according to some embodiments;

FIGURE 6B illustrates another more detailed perspective view of the tipping paper combiner and feed mechanism shown in FIGURE 1 according to some embodiments; FIGURES 7 A and & 7B illustrate a perspective view of a cigarette manufacturing apparatus according to some embodiments;

FIGURE 8 illustrates a more detailed perspective view of a cigarette manufacturing apparatus according to some embodiments; and

FIGURES 9A, 9B, 9C and 9D provide additional detail for implementations of some embodiments. DETAILED DESCRIPTION

The disclosed manufacturing apparatuses and methods are germane to many

applications in converting web material, and are not limited to any particular use.

Exemplary embodiments of the disclosure can provide for a system that utilizes a high speed feed mechanism with a low paper-tear disposition for producing multiple strips of web material, such as tipping paper, having an adjustable lateral separation for usage during the cigarette manufacturing stages.

An exemplary manufacturing apparatus may include a web feed (e.g., a spindle feeder), one or more web guides, a slitter, a web lateral adjuster, and a web combiner/driver. According to some embodiments, a unitary paper sheet or web (i.e., a single sheet) is passed through a manufacturing apparatus such that, upon being output therefrom, the leading (or advancing) face or front edge of the unitary web includes a plurality of strips of material that are laterally spaced from each other. For example, although a unitary web is fed into the apparatus, the unitary web can be converted into two, three or more strips in the same plane that are laterally spaced from one another. The overall width of the processed web (the distance between the edges of the outermost strips) can accordingly be greater than the initial width of the unitary web (e.g., the width of the web on a bobbin or other storage mechanism/component). Some embodiments may provide this separation of strips with little, no, or substantially no side-tension applied to the strips of the unitary web.

FIGURE l illustrates an exemplary manufacturing apparatus loo according to some embodiments that can be used for processing tipping paper, among other things. The manufacturing apparatus 100 includes a web feeder 102, a web guide 104, a slitter 106, a web lateral adjuster 108, and a web combiner and driver 110.

As shown in FIGURE 1, some embodiments may include a web feeder 102 that includes a spool or bobbin 112 of web material 116 (in the illustrated implementation, 64mm

5 wide tipping paper) mounted on a cantilevered spindle 111. While a cantilevered spindle 111 is illustrated, a spindle supported on both ends can also be used. The web material 116 is fed from the spool through a series of feed and/or idler rollers that can impart a tension to the web material 116. Such components can include, for example, cork feeder rollers, brake rollers and the like. As illustrated, web feeder 102 delivers the web 116 to

10 a web guide 104 (and/or like guiding mechanisms or systems). As shown, the web feeder 102 (and associated components) provides the appropriate force or tension to the paper web when the web is drawn from the spool 112 and through the apparatus.

FIGURE 2 further illustrates the web feeder 102 of the embodiment shown in FIGURE 1. Referring to FIGURE 2, the web 116 is drawn from the spool 112 and traverses 15 through the feed roller components 114 along the paths depicted by arrows A, B, C, and D, such that the web passes from the spool 112 to a first roller, and downwardly to a second roller (path A), back up again to a third roller (path B), and down again toward a fourth roller (path C) and then past the fourth roller (path D).

Referring back to FIGURE 1, the initial web 116 traverses path D toward the web guide 20 104. At the web guide 104, the web 116 is aligned prior to entering the slitter 106.

FIGURE 3 provides a detailed rear perspective view of an embodiment of the web guide 104 shown in FIGURE 1. Referring to FIGURE 3, edges 302a and 302b of the web 116 are aligned via web guide sections 304a and 304b, respectively by way of direct contact between the web 116 and the longitudinal planar surfaces of the web guide sections 304a, 304b.

Referring back to FIGURE 1, the web 116 traverses path E from the web guide mechanism 104 to the web slitter 106. FIGURE 4 provides additional detail via a perspective view of an embodiment of the slitter 106 shown in FIGURE 1. As shown in FIGURE 4, in some embodiments, a slitter 106 can include a pre-cutting stabilizer roller 402. The slitter 106 may include one or more score or shear cutting knives or other knives. In the embodiment shown in FIGURE 4, a cutter station 404 includes a pair of knives 406a and 406b, such as "Tidland" pneumatic cutting units. It is to be understood that other cutters can be used as are known in the art. In operation, the web 116 passes over the pre-cutting stabilizer roller 402, thereby stabilizing the web 116 and preventing edge-curling as the web passes into the cutting unit 404.

For purposes of illustration only, the web 116 is cut into three web portions. These include a pair of relatively narrow first and second web portions 410a, 410b, as compared to the original, or third, web portion from which they are formed, and a fourth, wider, center web portion 412. The path traversed by first and second web portions 410a and 410b is different than that of fourth web portion 412. The narrower first and second web portions 410a, 410b traverse along a substantially horizontal path F towards the web lateral adjustment mechanism 108 (FIGURE 1), while the center, or fourth, web portion 412 traverses along substantially vertical path G toward the web combiner and drive system 110 (FIGURE 1).

FIGURE 5A illustrates a more detailed perspective view of the web lateral adjustment mechanism 108 shown in FIGURE 1 according to some embodiments. The web lateral adjustment mechanism 108 includes, for example, a first roller component 502 including a first set of rollers and an elevated second roller component 504 including a second set of rollers. In some embodiments, roller components 502, 504 include idler rollers. The first roller component 502 may include roller pair 506a and 506b, and return roller 510. The elevated second roller component 504 may include elevated roller pair 508a and 508b. An additional illustration of elevated roller pair 508a and 508b is shown in FIGURE 6A. As the first and second web portions 410a, 410b traverse along substantially horizontal path F, roller pair 506a and 506b receive and direct the first and second web portions 410a, 410b to traverse along inclined path H and subsequently along substantially vertical path I. As illustrated, path I extends from roller 506b to elevated roller component 504, whereas roller 506b and roller pair 508a and 508b of elevated roller component 504 are vertically separated by an adjustable predefined height (h).

Depending on the implementation, the height h can be between about 20 and 120 cm, between about 40 and 80 cm, and can be about 60 cm. The width of the first and second web portions 410a, 410b can accordingly be about 5 mm to 20 mm, such as 11 mm and the fourth web portion 412 can be about 20 mm to 80 mm, such as 42 mm. Accordingly, a dimensionless web aspect ratio R can be defined for each of the first and second web portions 410a, 410b as the height "h" divided by the width of the first or second web portion. The web aspect ratio can thus range from 10 to 240. It will also be appreciated that exemplary devices can be operated moving the web 116 at varying speeds, such as between about 3,000 mm/minute and about 300,000 mm/minute, between about 20,000 mm/minute and about 250,000 mm/minute, between about 30,000 mm/minute and about 200,000 mm/minute, between about 50,000

mm/minute and about 150,000 mm/minute, and between about 75,000 mm/minute and about 100,000 mm/minute, among others.

As the first and second web portions 410a, 410b traverse along path I, at the elevated roller component's 504 roller pair 508a, 508b, the first and second web portions 410a, 410b are manipulated to return back towards roller 506b by traversing in the opposite direction along path J. At the end of path J, the first and second web portions 410a, 410b are directed by the return roller 510 to traverse along path K towards the web combiner and feed mechanism 110 (FIGURE 1).

FIGURE 5A also illustrates the physical orientation of the first roller component 502 relative to the elevated second roller component 504. The first roller component's 502 roller pair 506a, 506b and return roller 510 all include an orientation that are substantially perpendicular to that of the elevated second roller component's 504 roller pair 508a, 508b. For example, roller 506b may have a concentric axis, as depicted by "Axis 1," that includes a first horizontal plane (not shown) that encompasses concentric "Axis 1." Similarly, elevated roller 508b may have a concentric axis, as depicted by "Axis 2," that also includes a second horizontal plane (not shown) that encompasses concentric "Axis 2." The orientation of the first roller component's 502 roller pair 506a, 506b and return roller 510 relative to the elevated second roller component's 504 roller pair 508a, 508b is such that concentric "Axis 1" and concentric "Axis 2" are substantially perpendicular while the respective horizontal planes encompassing concentric "Axis 1" and concentric "Axis 2" are substantially parallel. FIGURE 5B illustrates a more detailed perspective view of the generated separation produced by the web lateral adjustment mechanism 108 according to some

embodiments. As the first and second web portions 410a, 410b traverse along paths H & I, they have a first lateral separation Si. By further traversing back along paths J & K, the first and second web portions 410a, 410b now have an increased, second lateral separation, as depicted by S2. The increased separation of S2 relative Si is created as a result of each of the first and second web portions 410a, 410b twisting along paths I & J as result of the relative orientation between the first roller component 502 and the elevated second roller component 504. Along path I, first web portion 410a is twisted by about 90 degrees in a clockwise first angular direction, as depicted by arrow CW, as it traverses from roller 506b to elevated roller 508a (FIGURE 6A). Second web portion 410b is also twisted by about 90 degrees in an opposing, second, angular, anti-clockwise direction, as depicted by arrow ACW, as it traverses along path I from roller 506b to elevated roller 508b (FIGURE 6A). Also, the magnitude or extent of the separation may be adjusted by varying the vertical separation between roller 506b and elevated rollers 508a and 508b (e.g., predefined height (h) as shown in FIGURE 1).

A more detailed description of the twisting is illustrated with reference to FIGURE 5C. Along path I, first web portion 410a is twisted about 90 degrees in a clockwise direction, as depicted by arrow 1, as it traverses from roller 506b to elevated roller 508a (FIGURE 6A). Since roller 506b and elevated roller 508a (FIGURE 6A) are perpendicular in orientation relative to each other, a requisite 90 degree twist by the first web portion 410a facilitates the flat surface of the first web portion 410a passing over the elevated roller 508a. As the first web portion 410a returns along path J, due to the return roller 510 and the elevated roller 508a (FIGURE 6A) being perpendicular relative to each other, the first web portion 410a twists again by another 90 degrees in order to facilitate the flat surface of the first web portion 410a passing back under return roller 510 along path K (FIGURE 5A).

Similarly, along path I, second web portion 410b is twisted about 90 degrees in an anticlockwise direction, as depicted by arrow 2, as it traverses from roller 506b to the elevated roller 508b (FIGURE 6A). Since roller 506b and elevated roller 508b (FIGURE 6A) are perpendicular with respect to each other, a requisite 90 degree counter- clockwise twist by the second web portion 410b facilitates the flat surface of the second web portion 410b passing over the elevated roller 508b (FIGURE 6A). As the second web portion 410b returns along path J, due to return roller 510 and the elevated roller 508b (FIGURE 6A) being perpendicular relative to each other, the second web portion 410b twists again by another 90 degrees in order to facilitate the flat surface of the second web portion 410b passing back under return roller 510 along path K

(FIGURE 6A). The relative orientation of the rollers corresponding to the web lateral adjustment mechanism 108 (FIGURE 5A) provide a reduced probability of web tear while operating at high-speed, with an added adjustable lateral separation.

FIGURE 6A illustrates a more detailed perspective view of the web combiner and feed mechanism 110 shown in FIGURE 1 according to some embodiments. The separated first and second web portions 410a, 410b traversing along path J (FIGURE 5C) are manipulated by return roller 510 and traverse along path K to the web combiner and feed mechanism 110. The web combiner and feed mechanism 110 may include feed roller 606, combiner roller 602, feed roller 604, and feed mechanism and rollers 610 (FIGURE 6B). Feed roller 606 manipulates and feeds the wider center fourth web portion 412 traversing along path G towards the combiner roller 602. At the combiner roller 602, the separated first and second web portions 410a, 410b traversing along path K and the wider center fourth web portion 412 traversing along path G are combined and manipulated to traverse along path L, which extends between the combiner roller 602 and feed roller 604. The combined separated first and second web portions 410a, 410b and the wider center fourth web portion 412 traversing along path L are

manipulated by feed roller 604 to traverse along path M towards a cigarette

manufacturing jig or apparatus 700 (FIGURES 7A & 7B). Referring to FIGURE 6B, the path further traversed by the combined first and second web portions 410a, 410b and the center fourth web portion 412 along path M towards the cigarette manufacturing apparatus 700 (FIGURES 7A & 7B), via feed mechanism and rollers 610, is further illustrated. FIGURES 7A and 7B illustrate a perspective view of a cigarette manufacturing apparatus or jig 700 according to some embodiments. In some implementations, a customized web guide may be utilized to facilitate the handling of the webs within a cigarette

manufacturing apparatus, with the guide customized to the relative sizes of and spacing between the web portions within the manufacturing apparatus. In an exemplary embodiment, the cigarette manufacturing apparatus or jig 700 includes a web guide 702, which maintains the separation between the combined first and second web portions 410a, 410b and the center fourth web portion 412 when the cigarette

manufacturing apparatus 700 produces cigarettes. As previously described and illustrated, the manufacturing apparatus (FIGURE 1) generates first and second web portions 410a, 410b, 412 having a desired separation, for example, for cigarette production. Once this separation is set, the web strip guide 702 of the cigarette manufacturing apparatus 700 facilitates maintaining this separation. The cigarette manufacturing apparatus may include additional rollers and/or drums (e.g., cork drums, pin drums, rolling drums) that are configured for the web portions and corresponding spacings. For example, vacuum holes on a cork and/or rolling drum may be configured to be open only where the web portions (e.g., tipping paper) is to contact the surface of the drums. Similarly, support pins on a pin drum may be configured for the particular web portions/spacings. A section from the leading edge of each of the web portions entering the cigarette machine may then be cut from the web portion for application to a smoking article, as discussed below.

FIGURE 8 illustrates a more detailed perspective view of the web strip guide 702 illustrated in FIGURES 7A and 7B according to some embodiments. As shown, the web strip guide 702 includes guide regions 802, 804, and 806, where each of the guide regions are adapted to receive and accommodate the width of a particular web strip. For example, guide region 802 may receive and guide narrower first web portion 410a, guide region 804 may receive and guide narrower second web portion 410b, and guide region 606 may receive and guide the wider center fourth web portion 412. FIGURES 9A and 9B provide detail implementations of some embodiments. As discussed above in FIGURES 5A-5C, a web portion may rotate or twist between respective roller components. FIGURE 9A illustrates an implementation in which the twist or rotation of the web continues in the same direction after passing over the roller 908b. FIGURE 9B illustrates an implementation in which the twist or rotation of the web rotates back or untwists after it passes over the roller 908b.

In some embodiments, the twist or rotation of the web as discussed in the exemplary implementations of FIGURES 9A and 9B may allow for various configurations of web material. For example, the implementation illustrated in FIGURE 9A may provide for uniform web section facing - that is, the same surface of the various web sections will be presented when applied to a smoking article. As shown in FIGURE 9C, two tobacco rods and a 2up filter may be placed together and three webs of tipping paper applied. The 2up cigarette may then be sliced or cut to provide 2 cigarettes. In one such embodiment, the face of the webs is uniform (for example, cork patterning on one side of the tipping paper web is presented while the unpatterned side of the tipping paper faces the tobacco rod and filter rod). In such an embodiment, the tipping paper may be a low-porosity paper and the spacing between the webs allows for ventilation of the filter when in use. Some embodiments of the disclosure facilitate the manufacturing of smoking articles that introduce ventilation into the tipping via exposure of a relatively large area of permeable paper (i.e., permeable paper wrapped around the filter material). In some such embodiments, an additional amount of ventilation may be added by laser perforation of the tipping paper.

FIGURE 9D illustrates an alternative embodiment, in which the patterned side of web material is facing outward for one strip of the web material, while the opposite side is facing outward for other strips of the web material. Such an arrangement may be provided by the implementation shown in FIGURE 9B. Although the embodiments discussed in detail above provide for three strips originating from one web, it is to be understood that additional strips may be created and spaced from the unitary web, for example, by utilizing additional roller and roller components. In one such

implementation, an embodiment may utilize tipping paper web material having a patterned side and a plain side to provide strips of tipping paper for application to smoking articles such that one or more strips of the tipping paper have the patterned side facing out while one or more other strips have the opposite side facing out. One such embodiment may provide a tipping paper strip with an external pattern that joins a 2up filter rod to paper wrapped tobacco rods, and additional tipping paper strips that are applied to the tobacco rods such that they lower the ignition propensity of the cigarette, such as is shown in FIGURE 9D. Additional embodiments may be utilized for anti-counterfeiting. For example, the strips may be applied such that a user can pull a strip back to expose a pattern on the underside of the strip and compare it to a strip having an outward-facing pattern.

According to some embodiments, the disclosure provides a system for processing a moving web of material, the system comprising: a support; a first set of rollers mounted on the support and configured thereon along a first set of substantially parallel axes of rotation; a second set of rollers mounted on the support and configured thereon along a second set of substantially parallel axes of rotation, wherein the first and second sets of axes of rotation lay in displaced, substantially parallel planes, and wherein the first and second sets of axes of rotation are oriented substantially perpendicularly with respect to each other; and a drive configured to convey a web of material over the first set of rollers and the second set of rollers, wherein the first set of rollers, second set of rollers and drive cooperate to define a web path for passage of the web of material. In one implementation, the parallel planes are displaced from each other along a vertical dimension of the support. In a further implementation, the distance between the first set of rollers and second set of rollers is adjustable to permit the first set of rollers and second set of rollers be moved toward or away from one another. In one embodiment, the system further comprises a slitter for slitting a web of material into a plurality of web portions. The system may also further comprise a feed spindle mounted on the support for receiving a roll of web material and/or a plurality of idler rollers disposed along a web path between the feed spindle and the first set of rollers. The system may further comprise one or more stabilizing rollers disposed in the web path after the idler rollers and before the slitter, the stabilizing roller being configured to prevent edges of the web from curling.

According to some embodiments of the disclosure, the system further comprises a web of material directed along a web path, wherein the web path includes: a first path after the slitter from the first set of rollers to the second set of rollers, wherein a first web portion is rotated about ninety degrees about its centerline along a first angular direction as the first web portion passes from the first set of rollers to the second set of rollers along the first path, and wherein a first face of the first web portion contacts the first set of rollers along the first path; a second path after the slitter from the first set of rollers to the second set of rollers, wherein a second web portion is rotated about ninety degrees about its centerline along a second angular direction opposite from the first angular direction as the second web portion passes from the first set of rollers to the second set of rollers along the second path, and wherein a first face of the second web portion contacts the first set of rollers along the second path, the second web portion being laterally displaced from the first web portion by a first lateral separation along the first set of rollers when the first web portion and second web portion are traversing the first and second paths, respectively; a third path downstream of the first path from the second set of rollers to the first set of rollers, wherein the first web portion is rotated about ninety degrees about its centerline along the first angular direction as the first web portion passes from the second set of rollers to the first set of rollers along the third path, and wherein a second face of the first web portion contacts the first set of rollers along the third path; and a fourth path downstream of the second path from the second set of rollers to the first set of rollers, wherein the second web portion is rotated about ninety degrees about its centerline along the second angular direction as the second web portion passes from the second set of rollers to the first set of rollers along the fourth path, and wherein a second face of the second web portion contacts the first set of rollers along the fourth path, the second web portion being laterally displaced from the first web portion by a second lateral separation different than the first lateral separation along the first set of rollers when the first web portion and second web portion are traversing the third and fourth paths, respectively. In some implementations, the second lateral separation is larger than the first lateral separation, while in other implementations, the second lateral separation is smaller than the first lateral separation. In some implementations, the first path is substantially parallel to the second path and/or the third path is substantially parallel to the fourth path.

According to some embodiments of the system, the first web portion and second web portion are formed by slitting a third web portion, the third web portion traversing a fifth path of the web path upstream of the slitter. In some implementations, the web path further includes a sixth path after the slitter, wherein a fourth web portion traverses the sixth path, the fourth web portion being separated from the first web portion and second web portion by the slitter. In further implementations, the fourth web portion includes a center strip formed laterally between the first web portion and the second web portion from the third web portion.

In a further implementation, the third web portion includes tipping paper, and the fourth web portion is directed into a cigarette manufacturing jig that is adapted and configured to attach a filter material having a first end and a second end to first and second tobacco filled paper rods, wherein the first end of the filter material is attached to the first tobacco filled paper rod using a portion of the fourth web portion, and the second end of the filter material is attached to the second tobacco-filled paper rod using the portion the fourth web portion. A portion of the first web portion may then be circumferentially wrapped around a first region of the first tobacco filled paper rod for providing a low ignition propensity region. The portion of the web material may be separated by a blade, knife or other cutter used in for cutting tipping paper in smoking article manufacture. Glue or other adhesive or adhering substance may be applied to the portion to attach it to the respective filter rod or tobacco rod. In some implementations, the lateral displacement between the fourth web portion and the first web portion can be adjusted by changing the distance between the first set of rollers and second set of rollers. In some implementations, the second web portion is circumferentially wrapped around a first region of the second tobacco filled paper rod for providing a low ignition propensity region. In another implementation, the first, second, and fourth web portions are directed into a cigarette manufacturing jig that is adapted and configured to attach a filter material rod having a first end and a second end to first and second tobacco filled paper rods, wherein the first end of the filter material is attached to the first tobacco filled paper rod using a piece of the first web portion, and the second end of the filter material is attached to the second tobacco-filled paper rod using a piece of the second web portion. A piece of the fourth web portion may be circumferentially wrapped around the filter material between the first and second web portions, providing a split tipping paper. The portions or pieces of the web material may be separated by blade, knife or other cutter used in for cutting tipping or like paper in smoking article manufacture. Glue or other adhesive or adhering substance may be applied to the portion to attach it to the respective filter rod or tobacco rod. Once the filter rod with attached tobacco rods is split into two smoking articles, the gap or space between the web portions applied to the filter rod may define a ventilation region for each filter of the respective smoking article. In some implementations, the lateral displacement between the fourth web portion and the first and second web portions can be adjusted by changing the distance between the first set of rollers and second set of rollers. In some embodiments, the distance between the first set of rollers and second set of rollers is adjustable to permit the magnitude of the second lateral separation to change relative to the magnitude of the first lateral separation.

The disclosure also provides methods of processing a moving web of material. In one embodiment, the method comprises: providing a first web portion, the first web portion having a centerline, a first face and a second face; directing the first web portion along a first path from a first set of rollers to a second set of rollers oriented substantially orthogonally with respect to the first set of rollers, wherein the first web portion is rotated about ninety degrees along a first angular direction about the centerline of the first web portion as the first web portion passes from the first set of rollers to the second set of rollers; providing a second web portion, the second web portion having a centerline, a first face and a second face; directing the second web portion along a second path from the first set of rollers to the second set of rollers, the first web portion and second web portion being separated by a first lateral separation as they are directed over the first set of rollers when traversing the first path and second path respectively, wherein the second web portion is rotated about ninety degrees along a second angular direction opposite to the first angular direction about the centerline of the second web portion as the second web portion passes from the first set of rollers to the second set of rollers; directing the first web portion along a third path from the second set of rollers to the first set of rollers, wherein the first web portion is rotated about ninety degrees along the first angular direction about the centerline of the first web portion as the first web portion passes from the second set of rollers to the first set of rollers; and directing the second web portion along a fourth path from the second set of rollers to the first set of rollers, the first web portion and second web portion being separated by a second lateral separation as the first web portion and second web portion are directed over the first set of rollers when traversing the third path and fourth path respectively, wherein the second web portion is rotated about ninety degrees along the second angular direction about the centerline of the second web portion as the second web portion passes from the second set of rollers to the first set of rollers, and wherein the second lateral separation is different from the first lateral separation. In some implementations, the first, second, third and fourth paths are substantially vertical. In one implementation, the method further comprises adjusting the second lateral separation by adjusting the distance between the first set of rollers and the second set of rollers. In one

implementation, the second lateral separation is greater than the first lateral separation, while in another implementation, the second lateral separation is less than the first lateral separation.

In some embodiments, the first face of the first web portion contacts the first set of rollers before the first web portion passes over the second set of rollers, and the second face of the first web portion contacts the first set of rollers after the first web portion passes over the second set of rollers. In some embodiments, the first face of the second web portion contacts the first set of rollers before the second web portion passes over the second set of rollers, and the second face of the second web portion contacts the first set of rollers after the second web portion passes over the second set of rollers. In some implementations, the method further comprises forming the first web portion and second web portion by slitting a third web portion while the web of material is moving. In one implementation, the third web portion is slit to form the first web portion, the second web portion and a fourth web portion while the web of material is moving. The fourth web portion may be a center strip formed laterally between the first web portion and second web portion. In some implementations, the third web portion includes tipping paper, and the fourth web portion is used to attach a filter material having a first end and a second end to first and second tobacco filled paper rods, such that the first end of the filter material is attached to the first tobacco filled paper rod using the fourth web portion, and the second end of the filter material is attached to the second tobacco-filled paper rod using the fourth web portion (e.g., by feeding the first, second and fourth web portions into a cigarette assembly device that can cut pieces from each, apply an adhesive or glue, and attach them to a filter rod and/or tobacco rod as appropriate). The first web and second web portions may be circumferentially wrapped around a first region of the first tobacco filled paper rod for providing a low ignition propensity region. The lateral displacement between the fourth web portion and first web portion may, in some implementations, be adjusted by adjusting the distance between the first set of rollers and the second set of rollers. Alternatively, the first and second web portions may be used to attach paper wrapped tobacco rods to a filter rod, with the center or fourth web portion

therebetween, and once cut at in the middle, providing two smoking articles with split tipping paper. Smoking articles with such split tipping paper may allow for relatively uniform ventilation across a variety of draw strengths. The methods and systems may be operated at a variety of high speeds, as discussed above, and provide for reduced tearing or splitting of the web material while allowing for spacing the material webs in a relative compact environment or small manufacturing floor footprint. Additionally, in some embodiments, use of a single initial web source for the various web portions allows for efficient use of resources and may reduce waste from cutting or trimming, as well as decreased machinery maintenance. It is to be understood that, where a range of values is provided each

intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein. It is also noted that as used herein and in the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior web material manipulation and adjustment. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It should be understood that they are not representative of all claimed inventions. As such, certain aspects of the disclosure have not been discussed herein. That alternate embodiments may not have been presented for a specific portion of the invention or that further undescribed alternate embodiments may be available for a portion is not to be considered a disclaimer of those alternate embodiments. It will be appreciated that many of those undescribed embodiments incorporate the same principles of the invention and others are equivalent. Thus, it is to be understood that other embodiments may be utilized and modifications may be made without departing from the scope and/or spirit of the disclosure. As such, all examples, implementations, and/or embodiments are deemed to be non-limiting throughout this disclosure. Also, no inference should be drawn regarding those embodiments discussed herein relative to those not discussed herein other than it is as such for purposes of reducing space and repetition. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. Some of the disclosed features, elements, implementation, etc., may be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the disclosure, and inapplicable to others. In addition, the disclosure includes other inventions not presently claimed. Applicant reserves all rights in those presently unclaimed inventions including the right to claim such inventions, file additional applications, continuations, continuations in part, divisions, and/ or the like thereof. As such, it should be understood that

advantages, embodiments, examples, function, features, structural, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims.

Claims

CLAI MS

What is claimed is:

l. Apparatus for processing a moving web of material that has been slit to form a pair of paper strips, the apparatus including a feeding roller and a receiving roller each having first parallel rotational axes lying adjacent to each other in the same or parallel first plane(s), and an intermediate second roller pair each having a second rotational axis parallel to each other and lying in a second plane parallel to and spaced from the first plane(s), the rotational axis of the second rollers being angled relative to the rotational axis of the feeding and receiving rollers such that each paper strip is fed from the feeding roller, around which they both pass with a first lateral separation, around a respective angled second roller before they are both fed around the receiving roller, so that said strips have a second a lateral separation on the receiving roller which is greater than the first lateral separation.

2. The apparatus of claim l, wherein rotational axis of the second rollers is perpendicular to the rotational axis of the feeding and receiving roller.

3. The apparatus of claim 1 or 2, wherein the intermediate second roller pair are movable towards and away from the feeding and receiving rollers.

4. The apparatus of any preceding claim, comprising a slitter for slitting a web of material to form a pair of paper strips which are fed around the feeding roller.

5. The apparatus of claim 4, wherein the slitter is configured to slit the web to form a central strip between said pair of paper strips, said central strip being conveyed along a separate path so that only said pair of strips are passed over said feeding roller.

6. A system for processing a moving web of material, the system comprising:

a support;

a first set of rollers mounted on the support and configured thereon along a first set of substantially parallel axes of rotation;

a second set of rollers mounted on the support and configured thereon along a second set of substantially parallel axes of rotation, wherein the first and second sets of axes of rotation lay in displaced, substantially parallel planes, and wherein the first and second sets of axes of rotation are oriented substantially perpendicularly with respect to each other;

a drive configured to convey a web of material over the first set of rollers and the second set of rollers at a speed of approximately 3,000 mm/minute to 300,000 mm/minute, wherein the first set of rollers, second set of rollers and drive cooperate to define a web path for passage of the web of material.

7. The system of claim 6, wherein the distance between the first set of rollers and second set of rollers is adjustable to permit the first set of rollers and second set of rollers be moved toward or away from one another.

8. The system of claim 6, further comprising a slitter for slitting a web of material into a plurality of web portions.

9. The system of claim 8, further comprising a plurality of idler rollers disposed along a web path between a feed spindle and the first set of rollers and a stabilizing roller disposed in the web path after the idler rollers and before the slitter, the stabilizing roller being configured to prevent edges of the web from curling.

10. The system of claim 8, further comprising a web of material directed along a web path, wherein the web path includes:

a first path after the slitter from the first set of rollers to the second set of rollers, wherein a first web portion is rotated about ninety degrees about its centerline along a first angular direction as the first web portion passes from the first set of rollers to the second set of rollers along the first path, and wherein a first face of the first web portion contacts the first set of rollers along the first path;

a second path after the slitter from the first set of rollers to the second set of rollers, wherein a second web portion is rotated about ninety degrees about its centerline along a second angular direction opposite from the first angular direction as the second web portion passes from the first set of rollers to the second set of rollers along the second path, and wherein a first face of the second web portion contacts the first set of rollers along the second path, the second web portion being laterally displaced from the first web portion by a first lateral separation along the first set of rollers when the first web portion and second web portion are traversing the first and second paths, respectively; a third path downstream of the first path from the second set of rollers to the first set of rollers, wherein the first web portion is rotated about ninety degrees about its centerline along the first angular direction as the first web portion passes from the second set of rollers to the first set of rollers along the third path, and wherein a second

5 face of the first web portion contacts the first set of rollers along the third path; and

a fourth path downstream of the second path from the second set of rollers to the first set of rollers, wherein the second web portion is rotated about ninety degrees about its centerline along the second angular direction as the second web portion passes from the second set of rollers to the first set of rollers along the fourth path, and wherein a io second face of the second web portion contacts the first set of rollers along the fourth path, the second web portion being laterally displaced from the first web portion by a second lateral separation different than the first lateral separation along the first set of rollers when the first web portion and second web portion are traversing the third and fourth paths, respectively, wherein the web aspect ratio of each of the first web portion is and the second web portion ranges from io to 240.

11. The system of claim 10, wherein the first path is substantially parallel to the second path and/or the third path is substantially parallel to the fourth path.

20 12. The system of claim 10, wherein the first web portion and second web portion are formed by slitting a third web portion, the third web portion traversing a fifth path of the web path upstream of the slitter.

13. The system of claim 12, wherein the web path further includes a sixth path after the slitter, wherein a fourth web portion traverses the sixth path, the fourth web portion being separated from the first web portion and second web portion by the slitter.

14. The system of claim 13, wherein the fourth web portion includes a center strip formed laterally between the first web portion and the second web portion from the third web portion.

15. The system of claim 14, wherein the third web portion includes tipping paper, and the fourth web portion is directed into a cigarette manufacturing jig that is adapted and configured to attach a filter material rod having a first end and a second end to first and second tobacco filled paper rods, wherein the first end of the filter material is attached to the first tobacco filled paper rod using the fourth web portion, and the second end of the filter material is attached to the second tobacco-filled paper rod using the fourth web portion.

16. The system of claim 15, wherein the first web portion is circumferentially wrapped around a first region of the first tobacco filled paper rod to provide a low ignition propensity region thereon, and the second web portion is circumferentially wrapped around a first region of the second tobacco filled paper rod to provide a low ignition propensity region thereon.

17. The system of claim 16, wherein the lateral displacement between the fourth web portion and the first web portion can be adjusted by changing the distance between the first set of rollers and second set of rollers.

18. The system of claim 14, wherein the third web portion includes tipping paper, and the first, second and fourth web portions are directed into a cigarette manufacturing jig adapted and configured to attach a filter material rod having a first end and a second end to first and second tobacco filled paper rods, wherein the first end of the filter material is attached to the first tobacco filled paper rod using the first web portion, the second end of the filter material is attached to the second tobacco-filled paper rod using the second web portion, and the fourth web portion is attached to the filter rod between the first and second web portion, wherein the displacement between or gap defined by the first web portion and the fourth web portion and the displacement between or gap defined by the second web portion and the fourth web portion provides ventilation of the filter material rod.

19. A method of processing a web of material for manufacturing a smoking article, the method comprising:

slitting an initial web of material while the material is moving to provide web portions;

providing a first web portion from the initial web of material, the first web portion having a centerline, a first face and a second face;

providing a second web portion from the initial web of material, the second web portion having a centerline, a first face and a second face; directing the first web portion along a first path from a first set of rollers to a second set of rollers oriented substantially orthogonally with respect to the first set of rollers, wherein the first web portion is rotated about ninety degrees along a first angular direction about the centerline of the first web portion as the first web portion passes from the first set of rollers to the second set of rollers;

directing the second web portion along a second path from the first set of rollers to the second set of rollers, the first web portion and second web portion being separated by a first lateral separation as they are directed over the first set of rollers when traversing the first path and second path respectively, wherein the second web portion is rotated about ninety degrees along a second angular direction opposite to the first angular direction about the centerline of the second web portion as the second web portion passes from the first set of rollers to the second set of rollers;

directing the first web portion along a third path from the second set of rollers to the first set of rollers, wherein the first web portion is rotated about ninety degrees along the first angular direction about the centerline of the first web portion as the first web portion passes from the second set of rollers to the first set of rollers;

directing the second web portion along a fourth path from the second set of rollers to the first set of rollers, the first web portion and second web portion being separated by a second lateral separation as the first web portion and second web portion are directed over the first set of rollers when traversing the third path and fourth path respectively, wherein the second web portion is rotated about ninety degrees along the second angular direction about the centerline of the second web portion as the second web portion passes from the second set of rollers to the first set of rollers, and wherein the second lateral separation is different from the first lateral separation; providing a center web portion from the initial web of material, the center web portion formed laterally between the first web portion and the second web portion, each of the web portions traveling at faster than 3,000 mm/minute; and

separating a section of material from each of the leading edges of the first web portion, second web portion and center web portion for application to a smoking article.

20. The method of claim 19, wherein the initial web of material comprises tipping paper, further comprising

attaching two wrapped tobacco rods to a filter rod therebetween by applying the separated sections of the first web portion and the second web portion;

applying the separated section of the center web portion to the filter rod such that a gap is defined between each of the applied first and second web portion sections and the applied center web portion section, the gap providing filter rod ventilation; and

cutting the filter rod with attached tobacco rods along the center of the applied center web portion to form two smoking articles.