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(11) | EP 3 138 785 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | WAX APPLICATOR |
| (57) The present invention relates to a method of manufacturing a tobacco pouch (80),
the method comprising: - unrolling a film material (33) from a roll (32), - conveying the unrolled film material along an adhesive application station (36) comprising an adhesive nozzle (100A, 100B, 100C) and applying at least one row (70A, 70B, 70C) of bands of adhesive on the film material at regular intervals by ejecting a volume of adhesive from the at least one adhesive nozzle at regular intervals, - folding the film onto itself along at least one bottom fold (3) which extends lengthwise of the film material, - conveying the film material along a first heat welding station (38) and providing a right seam (10A) and a left seam (10B) in the first heat welding station along at least a right side (8A) and a left side (8B) of the tobacco pouch which is to be formed, the left and right seam extending transverse to a main longitudinal direction (7) of the film material, wherein each band of adhesive material ends at the left seam and right seam and does not extend into the left seam and right seam, - conveying the film material along a cutting station (39) and cutting the film material at regular intervals to form individual tobacco pouches. |
Field of the invention
[0001] The present invention relates to tobacco pouches and to a method and system of making tobacco pouches.
Background of the invention
[0002] Traditionally, tobacco pouches are made from a film material which is provided on a roll. The film material on the roll is pre-printed and may be a multi-layer or a single layer film material. The film material is unrolled from the roll and guided through an assembly line (or system) for making the tobacco pouches.
[0003] In the assembly line, the film material is folded onto itself in order to form the compartments of the tobacco pouches. Next, seams are made with a heat welding device. During the heat welding, the film material melts and forms a weld which interconnects two parts of the film material which are folded onto one another. The seams extend transverse to the main direction of the film material and form the left side and right side of a the compartment of each tobacco pouch. Subsequently, the tobacco pouches are cut along predefined cutting lines into individual tobacco pouches. Each cut divides the seams in a first and second seam section, wherein the first seam section forms the left side of a leading pouch and the second seam section forms the right side of a trailing pouch. The making of the tobacco pouches is often integrated with a filling assembly line, so that the tobacco pouches are filled with tobacco directly after they are made.
[0004] The tobacco pouches have a mouth which should be open during filling. Further, the mouth should be closed directly after filling in order to keep the tobacco fresh. Furthermore, a user should be able to open the mouth without too much difficulty when he starts to take tobacco from a new tobacco pouch.
[0005] In order to satisfy these different requirements, a non-permanent seal in the form of wax is generally used to close the mouth. Both sides of the film which engage one another at the mouth are provided with a wax layer. The wax acts as a kind of adhesive and keeps the mouth closed before first use. This keeps the tobacco fresh. However, the adhesive strength is weak enough to allow the user to open the mouth. In this way, the wax creates a non-permanent seal at the mouth.
[0006] The wax is generally applied on the film material upstream of the pouch making assembly line and is often provided on the film material in two long bands, which extend lengthwise of the film. The wax bands are as long as the film itself. The wax bands are generally provided by the manufacturer of the film material which can be a different party as the party which makes the pouches and fills the pouches with tobacco. This method of applying the wax has a proven track record and has been used for a number of years.
[0007] In the present invention, the insight was developed that a problem exists with this kind of tobacco pouch. The wax bands run along the entire length of the film. When the film is folded onto itself to form the pouch, and the seams are made with heat welding, the seams cross the bands of wax. At the crossings, the heat welding does not result in a high quality weld, because the wax prevents a high quality weld. The two parts of the film material may come loose quite easily, resulting in holes in the compartment at the left and right side of the pouch. The crossings form weak spots. This is explained further in the figures relating to the prior art.
[0008] Another aspect of the background of the present invention is that tobacco pouches are subject to increasingly strict legal requirements. In particular, the size of the flap is regulated in the sense that the size of the flap is reduced to a certain maximum size. However, many users wish to fold the flap around the tobacco pouch after first use of the tobacco pouch, and this requires a rather large flap. The limited size of the flap according to health warning regulations therefore may have a negative effect on the user friendliness of the tobacco pouch. It was recognized in the present invention that there is no good solution for this problem with current systems for making tobacco pouches.
[0009] Furthermore, the known method does not allow much variations in the position of the wax bands in the pouch. It was recognized that a different method of applying wax on the film material could result in a more versatile system and method of making tobacco pouches and overcomes the known disadvantage of the prior art.
Object of the invention
[0010] It is an object of the invention to provide a tobacco pouch which is free of any weak spots along the sides.
[0011] It is another object of the present invention to provide a tobacco pouch which has a flap which is relatively short but which may still be folded around the tobacco compartment.
[0012] It is a further object of the invention to provide an alternative tobacco pouch and method and system of making the tobacco pouch.
[0013] It is another object of the invention to provide a more versatile method and system for making tobacco pouches, in particular a method and system which is more versatile in the size, shape and locations of non-permanent seals in tobacco pouches.
The invention
[0014] In order to achieve at least one object, the invention provides a method of manufacturing a tobacco pouch, the method comprising:
- unrolling a film material from a roll,
- conveying the unrolled film material along an adhesive application station comprising an adhesive nozzle, and applying at least one row of adhesive regions on the film material at regular intervals by ejecting a volume of adhesive from the at least one adhesive nozzle at regular intervals,
- folding the film onto itself along at least one bottom fold which extends lengthwise of the film material,
- conveying the film material along a first heat welding station and providing a right seam and a left seam in the first heat welding station along at least a right side and a left side of the tobacco pouch which is to be formed, the left and right seam extending transverse to a main longitudinal direction of the film material,
- conveying the film material along a cutting station and cutting the film material at regular intervals to form individual tobacco pouches.
[0015] With the present invention, tobacco pouches can be made without weak spots in the side seams. Alternatively or additionally, the flap can be made to fold onto itself. Further, greater variations in non-permanent seals are possible, because the adhesive nozzles can be configured to apply adhesive in a variety of ways.
[0016] In an embodiment, the adhesive regions of at least one row meet the left seam and right seam or end at a distance from the left seam and right seam and do not extend into the left seam and right seam.
[0017] In an embodiment, each adhesive region of adhesive material comprises opposite ends, wherein the ends meet the right seam and left seam or are located at a distance from the right seam and left seam.
[0018] In an embodiment, each adhesive region is elongate and has a shape of a band, wherein the elongate bands extend parallel to the main longitudinal direction of the film material.
[0019] In an embodiment, the method comprises applying first bands and second bands of adhesive at regular intervals along the film, wherein the first and second bands of adhesive are folded onto each other by the making of the at least one bottom fold.
[0020] In an embodiment, the first bands and second bands of adhesive have a substantially same length and a substantially same width and are provided on either side from the bottom fold at a same distance from the bottom fold.
[0022] In an embodiment, the adhesive is wax. Wax has very good properties for forming non-permanent seals.
[0023] In an embodiment, the adhesive is hot-melted and subsequently applied as hot-melt. The liquid or almost liquid form of the hot-melt adhesive makes it suitable to be applied via nozzles which engage the film material.
[0024] In an embodiment, the method comprises activating the one or more adhesive nozzles for a predetermined first period of time, and de-activating the adhesive nozzles for a predetermined second period of time, and repeating these steps for each tobacco pouch.
[0025] In an embodiment, the method comprises:
- filling a compartment of each tobacco pouch with tobacco in a filling station, and
- conveying the tobacco pouches to a second heat welding station and applying heat at the mouth of the tobacco pouch, thereby melting the adhesive and closing the mouth of the compartment with a non-permanent mouth seal.
[0026] In an embodiment, the method comprises:
- providing at least one row of flap adhesive regions on a flap section of the film material at the adhesive application station, and
- folding the flap onto itself along a flap fold line, and
- fixing a forward flap part to a rear flap part with a non-permanent seal with the one or more flap adhesive regions by applying heat to the flap section.
[0027] In an embodiment, at least one flap adhesive region straddles the cut line along which the film material is cut into individual pouches, the method comprising cutting through the flap adhesive regions during the cutting of the film material to form the individual pouches.
[0028] In an embodiment, the at least one flap adhesive region has the shape of an elongate band, wherein the at least one flap adhesive region extends at right angles to a main longitudinal direction of the film material.
[0029] In an embodiment, the adhesive is applied to the film material while the film material is being conveyed along the at least one adhesive nozzle.
[0030] In an embodiment, the nozzles engage the film material while the film material is being conveyed along the at least one adhesive nozzle. To this end, the nozzles are pressed against the film material. The pressing is carried out gently.
[0031] In an embodiment, the adhesive is applied to the film material while the film material is being conveyed along the at least one adhesive nozzle in an upward direction, in particular vertically upward.
[0032] The present invention further relates to a tobacco pouch making system for making tobacco pouches, the tobacco pouch making system comprising:
- a roll support for supporting a roll of film material,
- multiple guides for guiding the film material,
- an adhesive application station comprising at least one adhesive nozzle for applying one or more rows of adhesive regions onto the film material by ejecting a volume of adhesive from the at least one adhesive nozzle at regular intervals,
- a folding station for folding the film material onto itself along at least one bottom fold which extends lengthwise of the film material,
- a heat welding station comprising at least one heating element for making a right seam and a left seam in the film material for forming a right side and a left side of the tobacco pouches which are to be formed,
- a cutting station for cutting the individual tobacco pouches from the film material.
[0034] In an embodiment, the adhesive application station comprises a control unit configured for activating and de-activating the adhesive nozzle for applying at least one row of elongate bands of adhesive at regular intervals and with adhesive-free zones between the adhesive bands, wherein the at least one row of elongate adhesive bands extends parallel to a main longitudinal direction of the film material.
[0035] In an embodiment, the tobacco pouch making system comprises a first adhesive nozzle and a second adhesive nozzle positioned at a distance from one another and configured for applying a first row of adhesive regions and a second row of adhesive regions at regular intervals along the film, wherein in particular the folding station is configured for folding the first and second adhesive regions onto each other.
[0036] In an embodiment, the first and second adhesive nozzles are configured for applying the first adhesive regions and second adhesive regions with a substantially same length and a substantially same width and at a substantially same distance from the bottom fold.
[0037] In an embodiment, an outflow opening of each nozzle has an elongate shape, having a length and a width, wherein the length of the outflow opening is more than 10 times the width, in particular more than 30 times the width. In an embodiment each nozzle has a single outflow opening.
[0038] In an embodiment, the adhesive application station comprises at least one flap adhesive nozzle configured for providing at least one row of flap adhesive regions on a section of the film material which forms the flap, the tobacco pouch making system comprising a flap folding station for folding a front flap part onto a rear flap part along a flap fold.
[0039] In an embodiment" the tobacco pouch making system comprises a further heating element for heating the flap adhesive regions of the folded flap in order to provide a non-permanent seal which interconnects the front flap part onto the rear flap part of the folded flap.
[0040] In an embodiment, the adhesive application station comprises a reservoir which holds adhesive, such as wax.
[0041] In an embodiment, the heat welding station welds the seams and also heats the adhesive regions to form non-permanent seals.
[0042] In an embodiment, the tobacco pouch making system comprises a second heat welding station positioned downstream from the cutting station and configured for applying heat at the mouth of the tobacco pouch, thereby melting the adhesive and closing the mouth of the compartment with a non-permanent mouth seal.
[0043] In an embodiment, the adhesive application station is configured to apply adhesive while the film material is being conveyed along the at least one adhesive nozzle.
[0044] In an embodiment, the guides are configured to move the film material in an upward direction along the adhesive application station.
[0045] In an embodiment, the adhesive application station comprises an X-direction adjustment device, a Y-direction adjustment device and a Z-direction adjustment device for adjusting the position of the at least one adhesive nozzle in the X, Y and Z-direction.
[0046] The present invention further relates to a tobacco pouch, formed from a piece of a film material, wherein a part of the piece of film material is folded onto itself along at least one bottom fold, the tobacco pouch comprising a right side seam and a left side seam which extend along respectively a right side and a left side of the folded part, thereby forming a tobacco compartment, the tobacco compartment comprising a mouth, the tobacco pouch further comprising a flap, wherein a band of adhesive is present at the mouth, wherein a front part of the pouch is attached to a rear part of the pouch at the mouth via the adhesive band, wherein the adhesive forms a non-permanent seal, wherein the band of adhesive does not extend into the seams.
[0047] The sides of the tobacco pouch are advantageously free of weak spots as are known from the prior art.
[0048] In an embodiment, the band of adhesive meets the right and left seam or ends at a distance from the right or left seam.
[0049] In an embodiment, the at least one band of adhesive extends along the full length of the mouth.
[0050] In an embodiment, the flap is folded onto itself along a flap fold, the flap being divided into a forward flap section and a rear flap section, wherein the tobacco pouch comprises at least one flap adhesive region via which the front section of the flap is attached to the rear flap section, the flap adhesive region forming a non-permanent seal which allows the user to unfold the flap section by tearing the flap seal loose.
[0053] In an embodiment, the right seam and the left seam are free of any weakened zones which result from adhesive material being present in the region of the seam.
[0054] The present invention further relates to a tobacco pouch formed from a piece of a film material, wherein a part of the piece of film material is folded onto itself along at least one bottom fold, the tobacco pouch comprising a right side seam and a left side seam which extend along respectively a right side and a left side of the folded part, thereby forming a tobacco compartment, the tobacco compartment comprising a mouth, the tobacco pouch further comprising a flap, wherein a band of adhesive is present at the mouth and forms a non-permanent seal for closing the mouth, wherein the flap is folded onto itself along a flap fold, the flap being divided into a forward flap section and a rear flap section, wherein the tobacco pouch comprises at least one flap adhesive region via which the front section of the flap is attached to the rear flap section, the flap adhesive region forming a non-permanent seal which allows the user to unfold the flap section by tearing the flap seal loose.
[0055] The flap is small when the tobacco pouch is purchased and advantageously complies with legal requirements in this field. After the purchase, the user can unfold the flap by breaking the non-permanent seal and the user can advantageously fold the flap around the compartment.
[0056] These and other aspects of the invention will be more readily appreciated as the same becomes better understood by reference to the following detailed description and considered in connection with the accompanying drawings in which like reference symbols designate like parts.
List of figures
[0057]
Figure 1 shows a top view of a length of film material for making tobacco pouches according to the prior art.
Figure 2 shows an isometric view of a tobacco pouch according to the prior art.
Figures 3A and 3B show isometric views of a tobacco pouch making system according to the invention.
Figure 4A shows an isometric view of an adhesive application station according to the invention.
Figure 4B shows a side view of an adhesive application station according to the invention.
Figure 4C shows an exploded isometric view of an adhesive nozzle according to the invention.
Figure 5 shows a top view of a length of film material according to the invention.
Figure 6A shows a sectional isometric view of an adhesive nozzle for applying flap adhesive regions.
Figure 6B show a top view of a film material according to the invention having an alternative layout of adhesive bands.
Figure 7 shows an isometric view of an embodiment of a tobacco pouch according to the invention.
Figure 8 shows an isometric view of an alternative embodiment of a tobacco pouch according to the invention.
Figure 9 shows a heat welding station for welding the mouth of the tobacco pouch.
Detailed description of the figures
[0058] Turning to figures 1 and 2, a length 1 of film material and a pouch 2 made from the film material according to the prior art are shown. The film material is elongate and generally provided on a roll from which it is unspooled during the making of the tobacco pouches. The film material comprises a longitudinal fold line 3 which is issued to fold a fold section 4 of the film material onto itself. The film material further comprises a flap section 5 which forms the flap in the resulting pouch.
[0059] Cut lines 6 extend transverse to the main longitudinal direction 7 across the film material. The cut lines 6 define the lines along which the individual pouches 2 are cut and mark the right side 8A and left side 8B of the individual pouches.
[0060] Two bands 9A, 9B of wax extend in a direction parallel to the main longitudinal direction 7 of the film material. The bands 9A, 9B are provided on the film material prior to the winding of the film material onto the roll. The bands 9A, 9B have essentially a same length as the length of the film material itself.
[0061] Furthermore, weld regions 10 are indicated with dashed lines. The weld regions 10 are the regions in which heat welds are applied prior to the cutting process. The heat welds interconnect a front part 11A and a rear part 11 B of the folded section 4 and form the compartment 14 of the tobacco pouch. The cutting operation along the cutting lines 6 cut each weld regions 10 in a right weld region 10A and a left weld region 10B.
[0062] The bands 9A, 9B of wax cross the weld regions 10 at crossing zones 13A, 13B. At these crossing zones, the heat welding operation does not work very well, because the wax prevents a proper contact between the two layers of film material which are engaged with one another
[0063] Turning in particular to figure 2, the consequence of the crossing zones is shown. The individual pouch 2 comprises a compartment 14 defined by a front part 15 and a rear part 16, a bottom fold 3' and the right seam 10A and left seam 10B. The pouch has a flap 18 and a mouth 19. After filling of the tobacco pouch, the tobacco pouch 2 is closed by a non-permanent seal 20 at the mouth 19. The non-permanent seal 20 extends along the length of the mouth 19. The non-permanent seal 20 is formed by the two bands 9A, 9B of wax which are folded onto one another and are heated with a heat application device. The wax melts and the front part 15 and the rear part 16 are attached to one another. The wax is strong enough to form a non-permanent seal, yet weak enough to allow a user to open the mouth upon first use.
[0064] Although this works fine, there is a disadvantage in that the crossing zones 13A, 13B produce weak spots 21 at the sides of the tobacco pouch. At the weak spots, the heat welds of the sides have a low quality and may rip open. The weak spots may in particular become a problem after first use of the tobacco pouch, when the mouth is open and the non-permanent seal has been broken.
[0065] Turning to figures 3A and 3B, the tobacco pouch making system 30 according to the invention is shown. The system comprises a roller support 31 for a supporting a roll 32 of film material 33. The system further comprises various guides 35 for guiding the film material through the system. Most guides 35 are rollers. The various parts are mounted on a common frame 34.
[0066] The system comprises an adhesive application station 36. Downstream of the adhesive application station, a folding station 37 is provided. Further downstream, a first heat welding station 38 is provided. Downstream from the first heat welding station 38, a cutting station 39 is provided.
[0067] The adhesive (such as wax) is applied at the adhesive application station. The folding station 37 is used for folding the film material onto itself along at least one bottom fold which extends lengthwise of the film material. The folding station 37 may optionally provide a second fold for folding the flap onto itself, as is further explained below.
[0068] The heat welds which form the sides of the pouch are applied in the first heat welding station 38. The first heat welding station 38 comprising at least one heating element 40 for making a right seam 10B and a left seam 10A in the film material for forming a right side 8A and a left side 8B of the tobacco pouches 2 which are to be formed. In this case, four heating elements 40 are provided.
[0069] A first buffer station 41 is provided between the folding station 37 and the first heat welding station 38. The first buffer station 41 turns an essentially continuous movement of the film material upstream of the first buffer station 41 into a start-stop movement of the film material downstream of the first buffer station 41. The first heat welding station applies the heat weld during a stationary time period in which the film material is held stationary at the first heat welding station.
[0070] The system 30 comprises various sensors for measuring the position and speed of the film material.
[0071] Turning to figures 4A and 4B, the adhesive application station 36 is shown in more detail. The adhesive application station 36 comprises three adhesive nozzle assemblies 42A, 42B, 42C, generally indicated with numeral 42. Each adhesive nozzle assembly 42 is mounted on a respective nozzle support 43A, 43B, 43C with a clamp 45. Each nozzle support is mounted on a common support 44. The common support 44 comprises a slider 144 which is guided by guide rods 46 and can slide along the guide rods 46. The guide rods 46 extend between two end blocks 48.
[0072] It is noted that a different number of adhesive nozzles is also possible, such as one or two, or more than three.
[0073] The common support is adjustable in the Z-direction with an adjustment device 47. The nozzle supports can be moved in the Y-direction (which is the direction transverse to the direction 49 of movement of the film material at the adhesive application station) by loosening the clamps 45 and sliding the nozzle supports along a rail 50 in the common support 44. Each adhesive nozzle can also be adjusted in the X-direction, toward and away from the film material, by an X-adjustment device 51.
[0074] Each adhesive nozzle assembly comprises an adhesive inlet 52 via which the adhesive is fed to the nozzle. Each adhesive nozzle assembly 42 comprises a control line connector 53 to which a control line can be connected via which the adhesive nozzle assembly 42 is connected to a control unit 54, schematically indicated in fig. 4B.
[0075] The adhesive application station comprises a first adhesive nozzle assembly 42A and a second adhesive nozzle assembly 42B positioned at a distance from one another.
[0076] The adhesive application station 36 is configured to apply adhesive while the film material is being conveyed along the adhesive nozzle in the direction 49. In other words, the adhesive is applied on a moving surface. The guide 35 is configured to move the film material 33 in an upward direction 49 along the adhesive application station.
[0077] Turning in particular to figures 4B and 4C, each adhesive nozzle assembly 42A, 42B, 42C comprises an adhesive nozzle 100A, 100B,100C, generally indicated as 100.
[0078] Each adhesive nozzle comprises an upper part 105, a lower part 106 and a shim plate 107 which is very thin and which defines a width of the outflow opening of the nozzle between the upper part and the lower part. A channel 107 is provided between the upper and lower part. The shim plate 107 has a recess 108 in the forward side. In the assembled state of the nozzle 100, the recess defines the outflow opening. If the recess needs to be changed, the nozzle can be taken apart and a shim plate of a different shape or thickness can be used.
[0079] The outflow opening is a relatively long and narrow gap. It has a length and a width. The length of the outflow opening is more than 10 times the width, in particular more than 30 times the width. The gap may extend horizontally and may extend at a right angle to the transport direction of the film material.
[0080] Turning to figure 5, the first and second nozzles 42A, 42B are configured for applying a first row 70A of first bands 55A and a second row 70B of second bands 55B of adhesive at regular intervals along the film, wherein the folding station is configured for folding the first and second band of adhesive onto each other. The control unit 54 is configured for activating and de-activating the adhesive nozzles 42 for applying two elongate bands 55A, 55B of adhesive at regular intervals and with adhesive-free zones 56A, 56B between the adhesive bands. The adhesive free zones have a width 57 which is equal than or greater than the width 58 of the weld regions 10. As a result, there are no crossing zones 13.
[0081] The adhesive bands 55A 55B are elongate and extend parallel to a main longitudinal direction 7 of the film material 33, The first bands 55A and second bands 55B of adhesive have a substantially same length 60 and a substantially same width 61 and are located at a substantially same distance 62 from the bottom fold line 3.
[0082] Turning to figures 6A and 6B, in another embodiment, the adhesive application station comprises at least one flap adhesive nozzle 42C (also referred to as a third nozzle 42C) configured for providing at row 70C of bands 63 of flap adhesive on a region 5 of the film material which forms the flap. In this embodiment, the tobacco pouch making system comprises a flap folding station (not shown) for folding a front flap part 64A onto a rear flap part 65B along a flap fold line 65.
[0083] It is noted that figure 6A is a sectional view. Therefore, only half of the flap adhesive region 63 is shown, and this half has a length L2/2.
[0084] In this embodiment, the tobacco pouch making system will comprise a longer heating element for heating the flap adhesive bands 63 of the folded flap in order to provide a non-permanent seal which interconnects the front flap part 64A onto the rear flap part 64B of the folded flap. It is noted that the heating element for making the seams is also used for welding the adhesive regions into a non-permanent seal. The temperature may also be the same.
[0085] The adhesive application station comprises a reservoir (not shown) which holds the adhesive, for example wax.
[0086] Generally, the tobacco pouch making system will be followed in line by a system which comprises a second heat welding station 120 (also referred to as a mouth welding station) positioned downstream from the cutting station and downstream from a filling station configured for applying heat at the mouth of the tobacco pouch, thereby melting the adhesive and closing the mouth of the compartment with a non-permanent mouth seal. See also figure 9 and the description below.
[0087] Turning to figure 7, the shown tobacco pouch 80 is formed with the layout of the film material shown in figure 5. In this embodiment, the third adhesive nozzle 42C is inactive or may even be removed. The tobacco pouch 80 is made from a piece 81 of a film material. A bottom part of the piece of film material is folded onto itself along at least one bottom fold 3'. The tobacco pouch comprises a right side seam 10A and a left side seam 10B which extend along respectively a right side 8A and a left side 8B of the folded section.
[0088] Similar to the tobacco pouch 2 of the prior art, the tobacco pouch 80 according to the invention comprises a compartment 14 defined by a front part 15 and a rear part 16, a bottom fold 3' and the right seam 10A and left seam 10B. The pouch has a flap 18 and a mouth 19.
[0089] At least one band 55A, 55B of adhesive is present at the mouth. The band 55A is provided on a rear section 16 of the film material, and the band 55B is provided on the front section 15 of film material. The front part of the pouch is attached to a rear part of the pouch at the mouth via the adhesive, wherein the adhesive forms a non-permanent seal, wherein the band of adhesive does not extend into the seams but ends at the left seam and right seam.
[0090] The bands 55A, 55B of adhesive extend almost along the full length of the mouth. A distance L1 of 1-2 millimetre may be present between the ends 75 of the bands 55A, 55B of adhesive and the seams 10A, 10B, but the end may also meet the seams 10A, 10B.
[0091] The right seam 10A and the left seam 10B are free of any weakened zones which result from adhesive material being present in the region of the seam.
[0092] Turning to figures 8, 6A and 6B another embodiment of the tobacco pouch 80 is shown which is manufactured while using the third adhesive nozzle 42C, i.e. the flap adhesive nozzle. The tobacco pouch is made with the layout of the film material shown in figures 6A and 6B.
[0093] Flap adhesive regions 63 have been provided on the flap section 5 of the film material. The flap adhesive regions 63 extend on both sides of the cutting lines 6. The flap adhesive regions 63 extend from the flap fold line 65 over a distance L2 in the direction of the mouth section 19. The flap adhesive regions 63 have a width L3 which corresponds to the width of the seams 10. However, the width L3 may also be different than the width of the seams 10.
[0094] The flap 18 is folded onto itself along a flap fold 84. The flap is divided into a forward flap section 64A and a rear flap section 64B. The tobacco pouch 80 comprises at least one flap adhesive region 63A, 63B via which the front section 64A of the flap is attached to the rear flap section 64b, the flap adhesive region(s) forming a non-permanent seal which allows the user to unfold the flap section by tearing the flap seal loose.
[0095] In the shown embodiment of figure 8, the flap adhesive regions 63A, 63B are provided as elongate bands on the left and right side of the flap. However, different configurations are also possible. For instance, a single central flap adhesive region 86 may be provided as indicated with dashed lines in figure 8. Also, the elongate band 63A,63B may be provided as a series of dots or short bands of adhesive.
[0096] When the user opens the pouch for the first time, he can simply tear loose the front section 64A from the rear section, in order to extend the effective length of the flap 18. The flap may increase 30-70 percent in length. In the extended state the flap may be folded over the entire compartment of the tobacco pouch.
[0097] Turning to figure 9, a heat welding station 120 for closing the mouth of the tobacco pouch 80 is shown. The tobacco pouches are moved in front of a heating element 121 in a start stop movement. When the tobacco pouch has stopped in front of the heat welding station 120, the heat welding element 121 is pressed against the mouth 19 and the wax melts. The heat welding element 121 is subsequently retracted and the wax solidifies, thereby forming the non-permanent seal.
[0098] The heat welding station 120 comprises a base 123 which can be mounted to the frame, a horizontal arm 124 and a vertical arm 125 which supports the heating element 121. Obviously different arrangements are possible.
Operation
[0099] In operation, a roll 32 is positioned on the support 31, and the film material 33 is pulled through the assembly line. The film material 33 on the roll may be free of any bands of adhesive.
[0100] The film material is conveying by a number of guides and is moved along the adhesive application station 36 in a continuous motion.
[0101] At the adhesive application station 36, a first row of bands 55A of adhesive is applied on the film material at regular intervals by ejecting a volume of adhesive from at least one adhesive nozzle 42A at regular intervals. A second row of bands 55B of adhesive is applied from a second nozzle 42B. The adhesive may be wax. The adhesive is applied to the film material 33 while the film material is being conveyed along the at least one adhesive nozzle in an upward direction 49, in particular vertically upward.
[0102] Each band 55A, 55B of adhesive material ends at the left seam and right seam and does not extend into the left seam and right seam, as it does in the prior art. Each band 55a, 55B of adhesive material comprises opposite ends 75 which meet the right seam and the left seam. Alternatively, the ends 75 may be located at a distance from the right and left seam. The distance may be between zero and 3 mm.
[0104] The intervals between the bands 55A, 55B are achieved by activating the one or more adhesive nozzles 42A, 42B, 42C for a predetermined first period of time, and de-activating the adhesive nozzles for a predetermined second period of time, and repeating these steps for each tobacco pouch which is to be made.
[0105] The first bands 55A and second bands 55B of adhesive have a substantially same length 60 and a substantially same width 61 and are provided on either side from the bottom fold line 3 at a same distance 62 from the bottom fold line 3.
[0107] Next, the film material 33 is transported to the folding station 37 where it folded onto itself along at least one bottom fold 3 which extends lengthwise of the film material. The first bands 55A and second bands 55B of adhesive are folded onto each other by the making of the at least one bottom fold 3.
[0108] Subsequently, the film material is conveyed along a first heat welding station 38. The first heat welding station welds a right seam 10A and a left seam 10B with heat. These seams are actually welded as a single seam 10, and later cut into two separate seams at the cutting station
[0109] The right seam 10A extends along a right side 8A of the pouch which is to be formed and the left seam 10B extends along a left side 8B of the tobacco pouch which is to be formed. The left and right seam 10A, 10B extend transverse to a main longitudinal direction 7 of the film material, in particular at right angles to the main longitudinal direction.
[0110] The bands 55A, 55B of adhesive are elongate and extend parallel to the main longitudinal direction 7 of the film material.
[0111] The film material subsequently passes a second buffer station 72. The buffer changes the pitch distance of the start-stop movement of the film material.
[0112] The film material is subsequently conveyed along a cutting station 39 where the film material is cut at regular intervals along the cutting lines 6 to form individual tobacco pouches. Each tobacco pouch comprises a compartment and a flap.
[0113] The filling line may follow directly after the making of the tobacco pouches. The pouches are transported along a conveyor to a filing station where a compartment of each tobacco pouch is filled with tobacco.
[0114] Next, the tobacco pouches may be conveyed to a mouth heat welding station, where heat is applied at the mouth of the tobacco pouch, in the area of the first band 55A and second band 55B of adhesive. The adhesive melts and upon solidifying, the adhesive forms a non-permanent mouth seal which closes the mouth of the tobacco pouch.
[0115] In an alternative embodiment, the method comprises:
- providing one or more flap adhesive regions 63 on a flap section 5 of the film material at the adhesive application station 36, and
- folding the flap onto itself along a flap fold line 65 in the folding station 37 and
- fixing a forward flap part 64A to a rear flap part 64B with a non-permanent seal with the one or more flap adhesive regions by applying heat to the flap section.
[0116] Each flap adhesive region 63 may straddle the cut line 6 along which the film material is cut into individual pouches, and each flap adhesive region may be cut in two parts by the cutting operation.
[0117] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the invention.
[0118] The terms "a" or "an", as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language, not excluding other elements or steps). Any reference signs in the claims should not be construed as limiting the scope of the claims or the invention.
1. Method of manufacturing a tobacco pouch (80), the method comprising:
- unrolling a film material (33) from a roll (32),
- conveying the unrolled film material along an adhesive application station (36) comprising an adhesive nozzle (100A, 100B, 100C), and applying at least one row (70A, 70B, 70C) of adhesive regions (55A, 55B, 63) on the film material at regular intervals by ejecting a volume of adhesive from the at least one adhesive nozzle at regular intervals,
- folding the film onto itself along at least one bottom fold (3) which extends lengthwise of the film material,
- conveying the film material along a first heat welding station (38) and providing a right seam (10A) and a left seam (10B) in the first heat welding station along at least a right side (8A) and a left side (8B) of the tobacco pouch which is to be formed, the left and right seam extending transverse to a main longitudinal direction (7) of the film material,
- conveying the film material along a cutting station (39) and cutting the film material at regular intervals to form individual tobacco pouches.
2. Method according to claim 1, wherein the adhesive regions (55A, 55B) of at least one
row (70A, 70B) meet the left seam and right seam or end at a distance from the left
seam and right seam and do not extend into the left seam and right seam.
3. Method according to any of claims 1 - 2, wherein each adhesive region is elongate
and has a shape of a band, wherein the elongate bands extend parallel to the main
longitudinal direction (7) of the film material, the method comprising applying first
bands (55A) and second bands (55B) of adhesive at regular intervals along the film,
wherein the first and second bands of adhesive are folded onto each other by the making
of the at least one bottom fold.
4. Method according to any of the preceding claims, wherein the adhesive is wax.
5. Method according to any of the preceding claims, comprising:
- filling a compartment (14) of each tobacco pouch with tobacco in a filling station, and
- conveying the tobacco pouches to a second heat welding station and applying heat at the mouth of the tobacco pouch, thereby melting the adhesive and closing the mouth of the compartment with a non-permanent mouth seal.
6. Method according to any of the preceding claims, comprising:
- providing at least one row (70C) of flap adhesive regions (63) on a flap section (5) of the film material at the adhesive application station (36), and
- folding the flap onto itself along a flap fold line (65), and
- fixing a forward flap part (64A) to a rear flap part (64B) with a non-permanent seal with the one or more flap adhesive regions by applying heat to the flap section.
7. Method according to any of the preceding claims, wherein the adhesive is applied to
the film material while the film material is being conveyed along the at least one
adhesive nozzle, and wherein in particular the adhesive is applied to the film material
while the film material is being conveyed along the at least one adhesive nozzle in
an upward direction, more in particular vertically upward.
8. Tobacco pouch making system (30) for making tobacco pouches (80), the tobacco pouch
making system comprising:
- a roll support (31) for supporting a roll (32) of film material (33),
- multiple guides (35) for guiding the film material,
- an adhesive application station (36) comprising at least one adhesive nozzle (100A, 100B, 100C) for applying one or more rows (70A, 70B, 70C) of adhesive regions (55A, 55B, 63) onto the film material by ejecting a volume of adhesive from the at least one adhesive nozzle at regular intervals,
- a folding station (37) for folding the film material onto itself along at least one bottom fold (3') which extends lengthwise of the film material,
- a heat welding station (38) comprising at least one heating element (40) for making a right seam (10A) and a left seam (10B) in the film material for forming a right side (8A) and a left side (8B) of the tobacco pouches which are to be formed,
- a cutting station (39) for cutting the individual tobacco pouches (80) from the film material.
9. Tobacco pouch making system according to claim 8, wherein the adhesive application
station comprises a control unit (54) configured for activating and de-activating
the adhesive nozzle for applying at least one row of elongate bands (55A, 55B, 63)
of adhesive at regular intervals and with adhesive-free zones (56A, 56B) between the
adhesive bands, wherein the at least one row of elongate adhesive bands extends parallel
to a main longitudinal direction (7) of the film material.
10. Tobacco pouch making system according claim 8 - 9, comprising a first adhesive nozzle
(100A) and a second adhesive nozzle (100B) positioned at a distance from one another
and configured for applying a first row of adhesive regions and a second row of adhesive
regions at regular intervals along the film, wherein in particular the folding station
is configured for folding the first and second adhesive regions onto each other.
11. Tobacco pouch making system according to any of claims 8 - 10, wherein the adhesive
application station comprises at least one flap adhesive nozzle (100C) configured
for providing at least one row (70C) of flap adhesive regions (63) on a section of
the film material which forms the flap, the tobacco pouch making system comprising
a flap folding station for folding a front flap part onto a rear flap part along a
flap fold.
12. Tobacco pouch making system according to any of claims 8 - 11, wherein an outflow
opening of each nozzle has an elongate shape, having a length and a width, wherein
the length of the outflow opening is more than 10 times the width, in particular more
than 30 times the width.
13. Tobacco pouch making system according to any of claims 8 - 12, wherein the nozzles
are configured to engage the film material.
14. Tobacco pouch making system according to any of claims 8 - 13, comprising a second
heat welding station positioned downstream from the cutting station and configured
for applying heat at the mouth (19) of the tobacco pouch, thereby melting the adhesive
and closing the mouth of the compartment with a non-permanent mouth seal.
15. Tobacco pouch making system according to any of claims 8 - 14, wherein the adhesive
application station is configured to apply adhesive while the film material is being
conveyed along the at least one adhesive nozzle, and wherein in particular the guides
are configured to move the film material in an upward direction (49) along the adhesive
application station.