Note: Descriptions are shown in the official language in which they were submitted.
'10 7
¦;BACKGRO~ND O THE INVENTION
.
This invention relates generally to methods and apparatus
for decoratlng sheet material such as, for example, a manufac-
tured cigar wrapper, anal more particularly, to a method and
apparatus for embossin~ a predetermined pattern such as, for
example, a vein pattern, on such sheet material.
The present invention is particularly useful in embossing
a vein pattern, similar to the vein pattern of a naturally~appear-
ing tohacco leaf, on a manufactured cigar wrapper. Cigars
generally are wrapped with either a natural tobacco leaf or
a manufactured wrapp~r which includes a mixture of natural
tobacco, adhesives and cellulosic fibers.
The advantage of using a manufactured cigar wrapper rather
than a natural tobacco'leaf resides in its considerably
lower cost and the increased ability to manipulate both taste
and aroma by the addition of appropriate additives. The'natural
~obacco leaf has, historically, been the symbol o a quality
flgar and, accordingly, it has been a goal of cigar manufacturers
fo simulate the appearance of a natural tobacco leaf wrappers
on man~factured wrappers.
To this end, cigar wrapper manufacturers have; on-
¦ umerous occasions, attempted to print or draw a natural
~ein pattern on a sheet of manufactured cigar wrapper. For
fxample, British Pa~ent No. 14,494, which issued to William
Watson on November ~ 1884, teache~ the embossing, stamping
¦ lor pri~ting of natu~a'1 ~obacco lea~ designs on manufactured
tobacco paper. Similarly, U.S. Patent No. 2,316,785, which
issued to Frederick C. Gladeck on April 20, 1943, discloses
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733(~7
the embossing of a sheet of manufactured tobacco wrapper with a
pattern which simulates leaf tobacco. See also, in this
regard, U.S. Patent No. 3,145,717 which issued to F.H. Osborne,
et al. on August 25, 1964 and which discloses the calendering
or embossing of a sheet of manufactured cigar~wrapper wlth a
leaf design having stems and veins.
A particular problem experienced by cigar wrapper
manufacturers in embossing or engraving such a veined pattern
on the manufactured cigar wrapper is that during subsequent
manufacturing operations and during use, as the sheet is
stretched, the raised vein pattern is stretched flat and is
thus removed. This is particularly true when the humidity of
the wrapper rises. Prior art attempts at embossing or
printing vein patterns on manufact~red cigar wrappers have
not, heretofore, been successful because the generally u~iform
color of the manufactured wrappers did not appear natural
when compared to the landomly colored natural tobacco leaf.
Against the foregoing background, it is a primary objective
of the present invention to provide methods of and apparatus
for decorating sheet material such as, for example, manufac-
tured cigar wrappers.
It is another object o the present invention to provide
methods of and apparatus for embossing a predetermined
pattern on sheet material such as, for example, a manufactured
cigar wrapper, which will not be removed during subsequent
processing operations and during use.
It is still another object of the present invention to
provide a method of and apparatus for imparting a base color
and a shade color pattern on the embossed sheet material-such
as, for example, a manufactured cigar wrapper.
It is a further ~ject of the present inventio~ to provide
a method of and apparatus for imparting a base color and shade
pattern on the embossed sheet material such as, for example, a
,,
- ~Ci7;33()7
manufactured cigar wrapper, and then laminating thereto, in a
symbiotic relationship, a second sheet having similar or dissimilar
properties to that of the embossed and colored sheet.
It is yet still a further object oE the present inven-
tion to provide an efficient, economical and commercially accepted
method of and apparatus for decorating cigar wrapper material.
` According to the present invention there is provided a ~;~
sheet of manufactured cigar wrapper material having opposed sur- ~
faces and à pre-determined cross-sectional thickness, said wrapper
having a vein-like pattern embossed through said cross-sectional
thickness to form a raised vein-like pattern on one of said opposed
surfaces ana a complimentary depressed vein-like pattern on said
opposite surface, wherein the depressed pattern on said oppo ed
surface is filled with a filler material in order to reinforce
said embossed pattern. I
The present invention also provides a cigar ha~ing a ~,
manufactured wrapper with opposed surfaces and a pre-determined r
cross-sectional ~hickness, said wrapper having a vein-like pattern
embossed through said cross-sectional thickness to form a raised
vein-like pattern on one of said opposed surfaces and a complimen-
tary depressed vein-like pattern on said opposite surface t wherein
the depressed pattern on said opposed surface is filled with a
filler material in order to reinforce said embossed pattern.
The cigar wrapper material sheet of the present inven- j
tion may be made in an apparatus which includes a rotatably
mounted center cylinder about which is posi~ioned an embossing r
roller for embossing a pattern on said sheet material at elevated
temperature and pressure; coloring means for coloring said sheet
material a predetermined color; shading means for randomly shading
said sheet material with a predetermined shade pattern; and
reinforcing means for applying a filler material on one side of
the embossed sheet material to fill and thus reinforce the recessed
.~ ,
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.
~ 733~7
portions of the embossed pattern. Staining, coating and humidifying
means may also be provided.
An alternate preferred embodiment uses similar apparatus
to decorate, color, shade and reinforce one sheet and then provides
laminating means to laminate this sheet to a second sheetO Simi-
larly, staining, coating and humidifying means may also be provided.
The present invention will be further illustrated by
way of the accompanying drawings wherein: r
' 10
3Q
- 4a -
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FIG. 1 lllustrates in schematic form the decorating
apparatus of the present inVentiQn;
FIG. 2 illustrates in schematic form an alternate em-
bodiment of the decorating apparatus of FIG~ 1 wherein two
5sheets are laminated together after decoration;
FIG. 3 is an enlarged, side elevational view of the
embossing station of the apparatus of FIGS. 1 and 2, ~
FIG. 3A illustrates in schematic form the aIternative
forms which the embossing roller forming part of the embossing
10station of-FIG 3 may assume;
FIG. 3B is an enlarged, bxeakway sectional view of the
embossing roller;
FIG. 3C is a partial front elevational view illustrating
the cooperating relationship between the embossing roller
15and the center cylinder;
FIG~ 3D is a positive print illustrating the vein
attern which is embossed on the sheet material;
FIG. 4 is an enlarged, general side elevational view of
the base color station of the apparatus of FIGS. 1 and 2;
FIG. 4A is an enlarged, general front elevational view of
the base color station of the apparatus of FIGS~ l and 2,
, FIG. 4B is a front elevational view of the color gravure
roller of the base color station;
FIG. 4C is a front elevational VieW of the color transfer
25roller of the base color station;
FIG. 4D is illustrative of the sheet material after the
vein pattern and base color have been applied;
FIG. 5 is an enlarged, general side elevational view of
the shading station of the apparatus of FIGS. 1 and 2;
FIG. 5A is a front elevational view of the shade gravure
roller of the shadin~ station;
FIG~ 5B is illus-trative of the sheet material after the
~ein pattern, the base color and the shade pattern have been
applied;
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FIG. 6 is an enlarged perspective view of the reinforcing
station of FIGS. l and 2;
FIG. 6A is a side view of the reinforcing station of FIG. 6;
FIG. 6B is a partial bottom view of the distribution plate
used in the reinforcing station of FIG. 6;
FIG 7 is an enlarged, genera1 sicle elevational view of the
laminating station of FIGS. 1 and 2;
FIG. 7A is a front elevational vie.w of the laminating roller;
FIG. 8 is a photograph~of a sheet of cigar wrapper material
decorated using the apparatus of FIGS, 1 and 2;
FIG. 8A is a partial cross-sectional view of a cigar wrapper
decorated using the apparatus of FIGS. 1 and 2;
FIG. 8B is a partial cross-sectional view of a decorated and
laminated cigar wrapper using the apparatus of FIG. 2;
FIG. 9 illustrates a cigar having a decorated laminated
wrappex produced using the apparatus of FIG. 2;
FIG 10 is an enlarged cross-sectional view of the cigar of
FIG. 9 taken along line 10-10 with exaggerated wrapper thickness.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
l .
Referring now to FIG. 1, there is shown schematically the
apparatus and method of the present invention as it is used to
decorate and color manufactured sheet material. In this
embodiment, only one layer of sheet material, having a predetermine( 1
thickness with opposed surfaces A and B, is preferably coated on at
least one side A with a hydrophobic coating prior to processing
through the apparatus of the present invention. This sheet
material, which may, for example, be a sheet of manufactured cigar
wrapper including a mixture of ground tobacco and refined pulp and
which measures about 0.003 inches in thickness, is processed
according to the following methods and using the following
apparatus.
As shown in FIG. 1, identical sheet material is stored on
either a-lower roll 12 or an upper roll 13 in the unwind
station 10 with the coated side A facing outwardly. The
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free end of the undecorated sheet material is first fed
through a splicing unit 14 and toward the center cylinder 24
in such a manner that the uncoated side B is upwardly facing.
Splicing unit 14 permits continuous running of the apparatus
since, as the sheet material on the lower roll 12 is depleted,
similar sheet material from the upper roll 13 may then be
spliced by splicing unit 14 into the material rom the lower
roll 12. Embossing, coloring and shading stations, 20, 40
and 60 respectively, are positioned about the center cylinder
24. The sheet material passes through and about idler take-
up rollers 22A, 22B, 22C and 22D and around center cylinder
24, first passing through the nip between the center cylinder
24 and the embossing roller 26 where a predetermined pattern --
is embossed through the thickness of the sheet, forming a
raised pattern on the coated side A of the sheet. The
embossed sheet then continues around the center cylinder 24,
where the uncoated side B of the sheet is treated with colorants
to simulate a natural tobacco leaf at a base color station
40 and at a shade pattern station 60.
The sheet material, after having passed through the
shade pattern station 60, has a raised, embossed pattern on
the coated surface A thereof, with the uncoated surface B
being colored and shaded. The decorated sheet material is
then removed ~rom the center embossing cylinder 24 at a removal
station 100. The decorated sheet material may, if desiredj
be coated at a coating station 120 and stained at a staining
station 140. When the sheet material is a manufactured
cigar wrapper, it is desirable to pass the decorated wrapper
through a humidifier 160 which increases the moisture l~vel
of the sheet and thus prevents it from tearing or cracking.
The decorated sheet material is then rewound at a rewind
statio~ 180.
FIG. 2 illustrates schematically the method and apparatus
used in decorating one sheet of manufactured sheet material
" ' .
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;' ~ 107330~
and then laminating the decorated sheet to a second, undecorated
sheet. It will be appreciated that this method utilizes
essentially the same apparatus as discussed in FIG. 1 with
certain minor differences. In the apparatus of the embodiment
of FIG. 2j the sheet material to be decorated is stored on
lower rolls 12 and 12A and the sheet material to be laminated
to the decorated sheet is stored on the upper rolls 13 and
13A at the unwind station 10 with both sheets being processed
simultaneously. The sheet from the lower rolls 12 and 12A
is processed in an identical manner as the sheet of FIG. 1,
and, after this decoration, coloring and shading, it is then
laminated to the second undecorated sheet from upper rolls ~
13 and 13A at laminatin~ station 100' of FIG. 2. Two lower rolls 1 2
and 12A and two upper rolls 13 and 13A are prov:ided to
permit splicihg at splicing units 14 and 16 as a roll is
depleted, thus assuring continuous operation of the apparatus.
The detailed description of the various portions of the
apparatus which follows will apply to the apparatus used for
the manufacture of both laminated and non-laminated sheet
materi~l, as shown schematically in FIGS. 1 and 2, any
diferences being specifically noted.
The sheet material to be decorated which, in the embodiment
of FIG. 1 is stored on both the upper and lower rolls 13 and
12, respectively, and, in the embodiment of FIG. 2 is stored
on lower rolls 12 and 12A is first fed from the unwind
station 10 toward the embossing 20, coloring 40 and shading
stations 60, which are positioned about the center cylinder
24. In the embodiment of FIG. 2, whsre two sheets are
laminated together, sheet material from upper rolls 13 or
13A is fed simultanevusly over the top of the center cylinder
24 and is laminated in juxtaposition to the decorated sheet
at laminating station 100'.
` ~07 33~7
When forming decorated and laminated sheets with the
apparatus of FIG. 2, each sheet should have a thickness of
; preferably about 0.0015 inches and each is preferably
coated on at least one side A or A' with a hydrophobic .
coating material such as, for example, a derivitized cellu-
: losic material. The hydrophobic coating applied to the
coated side A' of the sheet material from the upper rolls 13
and 13A preferably includes a glyceride in an amount sufficient
to lower the melting point of the coating to below about
400F. The sheet material from the lower rolls 12 and 12A
is also preferably coated on side A with a hydrophobic
coating, similar to the hydrophobic coating applied to
sheet material from the upper rolls 13 and 13A, but not including
glyceride.
In the embodiment of FIG. 1,where sheet material from
upper and lower rolls 13 and 12, respectively are used, the
sheet material prefer~bly is about O.Q03 inches thick and is
coated on side A with a hydrophobic coating.
When the sheet material to be decorated is, for example,
a manufactured cigar wrapper, it preferably includes ground
tobacco, refined pulp, filler materials, adhesives, has a
preferable sheet weight of from about l.Og/ft2 to about .
~Og/ft2 and has a moisture level of at least about 19%.
As shown in FIGS. 1 and 2, the coated sheet material to
be decorated is directed through the two rollers 14A and 14B
which comprise splicing unit 14 of unwind station 10 and
toward the embossing 20, coloring 40, shading 60 and reinforcing
. 80 stations positioned about center cylinder 24. 5plicing
: unit 14 permits splicing of the sheet material to be decprated
from one roll to another as the one roll is depleted to insuxe
. a continuous feed ~ ~aterial. A second splicing unit 16 is .
provide~ for use in the embodiment of FIG. 2 and comprises
rollers 16A and 16B which permit splicing of the sheet material
.
.
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Erom one of the upper rolls to the outer roll 13A. Take-up
rollers 22A, 22B, 22C and 22D serve to insure that the sheet
aterial remains taut throughout processing. The take-up
roller 22D! positioned directly beneath the embossing
station 20 may be a bowed roller such as, for example, a
~ount Hope roller, since such a roller maintains the sheet
~aterial flat and taut during processing.
The coated skeet material to be decorated is Eirst
introduced into embossing station 20 where it passes through
he nip between the center cylinder 24 and the embossing
roller 26. Embossing roller 26 is shown in greater detail
in FIGS. 3, 3A, 3B and 3C, FIGS. 3 and 3C illustrating the
ooperation between the center cylinder 24 and the embossing ``'~!
roller 26.
As shown in FIGS. 3B and 3C, center cylinder 24, which
is preferably steel with either a chrome~plated or paper
filled outer surface ~ortion, is rotatably mounted on a
frame 18 by means of hub portions 24A which extend from
opposite ends of the center embossing cylinder 24 and are
rotatably journaled in apertures on opposite sides to the
frame 18. The center cylinder 24 has a female recessed
decorative pattern, preferably a veined pattern, on the ;~
outer surface thereof. When the outer surface of the cylinder
24 is paper filled, a synchronized female or recessed decorative
pattern may be formed on this surface by mounting the embossing
roller 26, which includes a male or raised pattern on its
outer surface, adjacent the cylinder 24 and then rotating
the cylinder 24 and the embossing roller 26 in opposite
directions to cut a pattern synchronized to the pattern of
the embossing roller 26 into its paper filled outer surface.
When the outer surEac~ oE the center cylinder 24 is chrome-
plated steel, the center cylinder 24 and the embossing
roller 26 should be a matched set.
,~ ` ~73~07
The embossing roller 26, shown in FIGS. 3, 3A, 3B and
3C, is rotatably mounted on the frame 18 adjacent to the
center embossing cylinder 24 so as to permit the sheet
P material to pass through the nip between the embossing
roller 26 and the center cylinder 24 when the cylinder 24
and the embossing roller 26 rotate in opposite directions.
The embossing roller 26, which preferably is steel with a
chrome-plated outer surface 26C, includes a male decorative
pattern on the outer surface 26C. Such pattern may be etched
or engraved and is complimentary to the recessed female pattern
on the outer surface of the center cylinder 24. This decorative
pattern is preferably a vein pattern, such as, for example,
the pattern shown in FIG. 3 . As such, when a sheet of
wrapper material is passed through the nip between the embossing
roller 26 and the center cylinder 24, under elevated heat and
pressure, the pattern on the cylinder 24 and roller 26 is
embossed into and through the sheet material. An engraved
pattern is preferred on the outer surface 26C of the embossing
roller 26 since it produces a more pronounced raised pattern
on the wrapper than an etched pattern would. Both left hand
and right hand leaf patterns may be used on the outer surface
of the embossing roller 26, as shown in FIG. 3A.
Referring back to FIG. 3, embossing roller 26 is also
rotatably and adjustably mounted on the rame L8 by means of
stepped, hub portion 26A which extend from opposite
ends of the embossing roller 26 and are rotatably journaled
on adjustable mounting supports 28 whlch are affixed to the
frame 18 at opposite sides thereof. Supports 28, which
permit adjustment of the embossing roller 26 relative to
the center cylinder 24~ include upper and lower plates 28A and
28B, respectively, w~lch rotatably capture the hub portion
26A of the embossing cylinder 26 and which are secured by
~ ~ i73307
retaining or anchor bol-ts 29A and 29B. Mounting shaft 32,
which interconnects both sides o frame 18, is also secured
to support 28 by means of support plates 28B and 29C which
are secured using anchor bolts 29D and 29E~ The pressure
exerted by the embossing roller 26 against the cënter cylinder
24 which determines vein depth, is provided by at least one
conventional, adjustable air cylinder 30 which efects
movement of lower plate 28B toward the center cylinder 24
along a post~29F thus forcing embossing roller 26 against
center cylinder 24. The pressure between the~embossing
roller 26 and the center cylinder 24 may be controlled by the
use of adjusting screws 29G and 29H which control the travel
of lower plate 28B toward center cylinder 24.
Adjusting screws 29G and 29H are set initially to insure
proper registration between the male pattern on the embossing
roller 26 and the female pattern on the center cylinder 24.
The post 29F along which support plate 28B travels, is secured
to the frame 18 by the use of two bolts 29I and 29J.
The embossing roller 26, shown in greater detail in
FIG. 3B, has a substantially hollow center portion 26B, access
to which is available through the hollow, stepped,
hub portions 26A. The embossing roller 26 may be heated by
the introduction of steam through the hub portions 26A and into
the hollow center portion 26B of the embossing roller 26.
Condensed water may be removed through, for exampler a conven-
tional rotary joint on one side of the embossing roller 26
(not shown).
Embossing of the sheet material may be accomplished at
temperatures above about 250F and preferably at temperatures
between about 250F ~nd about 350F. An embossing temperature
of about 280F is ~St preferred. An embossing pressure of at
least about 50 psi between the embossing roller 26 and the
center cylinder 24 generated by air cylinder 30, is normally
~ ~ILCI ~3,3C~7
.` . ' ' ' ' .
required to effect satisfactory embossing of the sheet
material and a pressure of about 90 psi is preferred.
Referring back to FIGS. 1 and 2, the embossed sheet
material then passes around the center cylinder 24 toward
the base color station 40 where the shee~ material is treated
!,'' . with a base colorant to simulate the color of a natural
tobacco leaf. In those instances,where the sheet material
is pre-colored prior to processing, the base`color station
may be eliminated and the sheet may be merely embossed or
embossed and shaded. The base color station 40, shown in
greater detail in FIGS. 4, 4A, 4B and 4C includes a color
transfer roller 42, of steel with a rubber or elastomeric
outer surface and a color gravure roller 44 also of steel
with a chrome-plated outer surfacè.
The color gravure roller 44, shown schematically in
FIG. 4B, preferably includes a hollow center portion 44B
with stepped hub portions 44A extending from the opposite
ends thereo,f. The chrome-plated outer surface of the color
gravure roller 44 is patterned, preferably having a 180Q
quadra gravure recessed pyramid shaped pattern formed thereon.
The color gravure roller 44 on the frame 18 ls adjustably
and rotatably mounted by means of an adjustable support 50
mounted on both sides of the frame 18. Hub portions 44A of
~oller 44 are journaled in recessed portions of adjustable
mounting device 50. It is preferred khat the color gravure
roller 44 be cooled and this may be accomplished by passing
cool water through the hollow center portion 44B of the roller
4~.
The color transfer roller 42, shown schematically in
FIG. 4C, includes a rubber or elastomeric outer surface 42C,
a hollow center portQ~n 42B and stepped hub portions 42A
' which e~tend from opposite ends of the color transfer roller
1~ 1()73;307
. 42. The elastomeric outer surface 42C of -the transfer
roller preferably has a hardness of between about 40 and
about 70 Durometer Shore A. It is preferred that the transfer
roller 42 be cooled to retard drying of the coloring agent
which lt transfers to.the sheet material and cooling may be
.. accomplished, for example, by the pumping of cool water into
the hollow center portion 42B through one of the stepped hub
portions 42A.
.. Since in actual operation, the coloring agent is applied
.10 to recessed portions of the color gravure roller 44 and
then transferred to the color transfer roller 42 as the two
rollers contact and rotate in opposite direction, it will be
appreciated that the alignment of and the pressure between
the rollers is important. The cOlor transfer roller 42
transfers the coloring agent in the pattern of the color
gravure roller 44 to the sheet matexial as the sheet material
passes through the nip between the counter rotating center ;~
: cylinder 24 and the color transfer roller 420 Coloring agents
. may include inks and dyes and preferred coloring agents .
20 include carotenoids and annattos; food, drug and cosmetic
dyes including their lake and oil solubilized forms; and
other commercial food grade inks.
As shown in FIG. 4A, the coloring agent is applied
directly to the color gravu~e roller 44 by the use of an
open ink pan 46 positioned adjacent to the color gravure
roller 44, and spaced such that, as the color gravure roller
. 44 rotates, the outer surface of the yravure roller 44 passes .
through the coloring agent contained within the ink pan 46,
thereby "inking" the roller. A doctor blade 48, mounted
tangentially relative ~o the color gravure roller 44 is used to
remove any heavy deposi.ts of the coating agent on the rotating .
color ~ravure roller 44. The coloring agent is introduced
into the open ink pan 46 by conventional means, i.e. by its
: ~1~733~7
.~ . . , - ,
introduction under pressure ~rom an external supply. The
coloring agent should be fed into the ink pan 46 at a
.. sufficient rate to maintain a substantially filled level and an
overflpw return system (not shown) may be provided to ass~re
.5 continuous circulation of the coloring agent.
~::. The doctor blade 48, which may be steel or a plastic
material, includes a bracket 49 which is preferably adjustably
. mounted on frame 18 in order to control its position relative
: to the color gravure roller 44. The doctor blade 48 may bespring or air loaded, such as by air cylinder 49A to generate
. pressure against the color gravure roller 44. It is preferable
that the doctor blade 48 be reciprocating relative to the
. longitudinal extent of the color gravure roller 44 to aid
removing heavy deposits of coloring agents which may accumulate
on the surace of the color gravure roll 44. Reciprocation
: is effected by means of air cylinder 49B, shown in FIG. 4A.
As shown in detail in FIG. 4, the color gravure roller
44, the color transfer roller 42, the ink pan 46 and the
.: doctor blade 48 are adjustably mounted on.and secured to
the frame 18 by use of an adjustable support 50 which
.. includes a plurality of interengaged and adjustable plates
50A, 50B, 50C, 50D and 50E and two screw threaded adjusting
.~. devices 51A and 51B which permit adjustment of the position
. of the plates which control the pressure between the color
~ 25 gravure roller 44 and the color transfer roller 42 and between
. the color transfer roller 42 and the center cylinder 24.
. A conventional adjustable air cylinder 52 is employed
to generate pressure between the transfer roller 42 and the
center cylinder 24 and second conventional air cylinder 54
is used to generate pressure between the transfer roller 42
and the gravure rol.~er 44. Adjusting screw 51A acts as a
stop fQr air cylinder 52 permitting adjustment of the
pressure between the transfer roller 42 and the center
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cylinder 24. Similarly, adjusting screw 51B acts as a stop
for air cylinder 54 and permits adjustment of the spacing
- ~ between the transer roller 42 and the ~ravure roller 44.
~nchor bolts 56A and 56B secure plate 50D to plate 50A in
order to rotatably capture the transfer roller 42 therebetween
and anchor bolts 56C and 56D serve to secure plate 50C to
plate 50B to rotatably capture the gravure roller 44 therebetween.
Support shaft 58 is rotatably captured between plates 50E
and 50A which are secured thereto by anchor bolts 56E and
56F.
The embossed sheet material, after passing through the
` base color station 40 where a base coloring agent is applied
in the pattern of the color gravure roller 44 then proceeds
through a shade pattern station 60 as shown in FIGS. 5 and
5A where a random or otherwise irregular color pattern is
applied.
As previously stated, when the sheet material is pre-colored
prior to processing, the sheet may pass directly from the
embossing station 20 to the shade pattern station 60, thus
bypassing the base color station 40. When the sheet material
isj for example, a cigar wrapper, a random "cloud-pattern"
may be applied using contrasting colors to further simulate-
~he irregular or random color patterns of a natu~ally occuring
tobacco Ieaf. The shade pattern station 60, shown in detail
as FIGS. 5 and 5A, lncludes a shade transfer roller 62 of
similar construction to color transfer roller 42
and a shade gravure
roller 64, also of similar construction to the color gravure
roller 44, but for the pattern on the outer surface thereof.
The shade gravure roller 64, shown schematically in
FIG. 5A, which is p~e erably made from steel, is hollow and
include~ on its outer, preferably chrome-plated steel surface,
a randomly diffused, 120Q screen pattern. An open ink pan 66
. and a doctor blade 68, similar to the open ink pan 46 and
-16- ~
. I ~73~07
the doctor blade 48 of the base color station 40, are provided
with.a similar supply and circulation.system. An adjustable
. support 70 is provided for mounting the elements of the
.-.
shade color station 60 to the frame 18, the adjustable support
70 being similar to the adjustable support S0 used in the
base color sta,tion 40. In this regard, adjustable support
70 includes a plurality of plates 71A-H and two adjustable
air cylinders 72 and 74 positioned on adjacent sides of the
. support 70 to provide pressure, respectively, between the
.10 shade tranSfer roller 62 and the center cylinder 24 and
between the shade transfer roller 62 and the gravure roller
64. Adjusting screws 75A and 75B are provided to respectively
controlthe amount of pressure between the rubber transfer
roller 62 and the cen~er cylinder 24 and between the shade
gravure rolLer 64 and the shade transfer roller 62. A
plurality of.anchor bolts 76A-H serve to secure the p~ates
7lA-H together.
. As in the base color station 40, an adjustable bracket
69 is provided, including a pressure piston 69A to adjustably .
mount the doctor blade 68 relative to the gravure roller 64
and an air cylinder 69B to permit reciprocation of the
doctor blade 68 across the longitudinal extent of the outer
_~ surface of the shade gravure roller 64.
A shading agent is applied to the embossed and colored
sheet material by the shade transfer roller 62 which, by
: ~ contacting and rotating in an opposite direction from the
. shade gravure roller 64 receives the shading agent in the
shade pattern of the shade gravure roller 64, then transfers
it to the sheet material as it passes through the nip between
the center cylinder 24 and the transfer roller 62. The
shade transfer rollef 62, which is of a similar cons-truction .
to the-color transfer roller 42, may be cooled in a similar
manner as the color transfer roller is cooled, i.e. by
-17- J
'` ~ : . 1073307
introducing cool water into its center.
.The shading age~t used may be an ink or a dye, preferably
of contrasting color to the coloxing agent. Preferred
shading agents include carotenoids and annattos; food, drug
and cosmetic dyes including their lake and oil solubilized
forms: and other commercial food grade inks. The decorated,
colored and shaded sheet material, as it emerges from the
shade station 60, is shown in FIG. 5B.
The now embossed, colored and shaded sheet material
then proceeds around the center embossing cvlinder 24 to a ..
reinforcing station 80 where a filler material is introduced
onto the top uncoated surface B of the sheet material as
shown in FIGS. 6 and 6~. Reinforcing station 80 includes .a ~`
hopper 82 which is mounted on frame 18 (not shown) adjacent
to the center cylinder 24 in which may be added filler
material for distribution onto the sheet material as it
passes around the cylinder 24. The hopper 82 includes a wire
screen 83 above a slotted distribution plate 84 through
which the filler material is introduced onto the uncoated .
surface B of the sheet material. A rubber blade-like device 88
is adjustably mounted to the bottom edge of the hopper 82 by a
plurality of screws 86 and, when properly adjusted and upon ~;
rotation of the cylinder 24, serves to force the filler
material into the recessed portions of the embossed pattern
on uncoated surface B of the sheet and to remove any excess
filler material from the nonrecessed portions of the sheet
material~ Blade.88 may be replaced by a roller or other
similar device (not shown). A rotatably mounted doffer 87
is provided to prevent agglomeration oE the filler mate~ial
in the hopper 82 and a rotary blade feed~r 89 is provided to aid .
.in forcing the filler material through slotted distribution
plate ~4 and onto the sheet material. The rate of distribution
of the feeder material is controlled by the rate of rotation
of the blade feeder 89.
.1 R-~
~73~6~7
Filler materials may be either in powder or paste form,
the powder including a mixture of ground tobacco suitable binding
agents and fillers including diatomaceous earths, clays and
whitening agents. Preferred diatomaceous earths include the
product marketed by Grefco f Inc. of Los Angeles under the
trademark Dicalite~ and the product marketed by Johns-
Manville of Denver under the mark Celite~. Preferred clays
include Bentonite~, marketed by N~ Industries of New York,
~ Kaolin and monmorillonite and preferred whitening agents,
which serve to give the filled vein pattern a more naturally
colored look, may be selected from the group consisting of
titanium dioxide, calcium carbonate and dolomite.
In certain instances, it may be desirable to use a
paste type filler material rather than a powder, particularly
in the embodiment where only one, non-laminated layer is
used. In order to form such a paste, the powder described
above may be mixed with suitable vehicles, and wetting
agents.
In the embodiment of FIG. 2, whexe two sheets are
laminated together, the sheet material from the lower rolls
12 and 12A, which has then been embossed, colored, shaded
and reinforced, is then mated with and laminated in juxtaposition
to the undecorated sheet material from the upper rolls 13
and 13A of the unwind station 10 which is passed over the
center cylinder 24 by take-up rollers 90A and 90~. The two
layers are mated in such a manner that the coated side A' of
the undecorated sheet material is in juxtaposition with the
uncoated side B of the embossed sheet material and are then
fed into and through a laminating station 100' where they
are laminated or otherwise bonded together to form a~unitary
embossed and lamina~ecl sheet.
The laminating station 100', as shown in FIGS. 7 and 7A,
includes a laminating roller 101, preferably of chromeplated
steel,and having a hollow center portion lOlB and two hub
-19- )
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portions lOlA extending from opposite ends thereof. As
shown in FIG. 7, the laminating roller 101 is journaled on
an adjustable support 110 which includes plates llOA, llOB
and llOC. Anchor bolts 112A and 112B rotatably capture and
mount the hub portions lOlA of the laminating roller 101
between plates llOA and llOB. Air cylinder 114 serves to
generate a constant pressure between the laminating roller ;
101 and the center embossing cylinder'24,the amount of pressure
being controlled by adjusting screw 115 and adjusting wheel 116.
' The t~o sheets are laminated together as they pass through
the nip between the laminating roller 101 and the center
embossing cylinder 24 at elevated temperature and pressure.
Lamination should be accomplished at a temperature sufficient
to soften the hydrophobic coating'on the coated surface A'
oE the top, undecorated sheet and thus laminate the undecorated
~; sheet to the embossed and colored 'sheet. Since it is not
; desirable'to have the coating on the embossed sheet soften,
lamination is preferably effected at a temperature of between
about 250F and about 350F, with a temperature of about
280F being most preferred. This temperature may be achieved
by the introduction of steam into the hollow center portion
lOlB of the laminating roller 101 through the hollow tubular
end portion lOlA. The pressure exerted between the laminating
roller 101 and the center cylinder 24 by air cylinder 114
should be between about 50 psi and about 150 psi, and preferably
between about 75 psi and about 100 p9i. A laminating pressure
of about 90 psi is most preferred.
In the embodiment of FIG. 1 where the decorated sheet
is not laminated to a second sheet, the laminating roller
101 is maintained at room temperature and merely serves as a
removal roll for r~o~ing the embossed, colored, shaded and
reinforced sheet from -the center cylinder 24~
If desired, a secondary coating may be applied to the
~ 73~,07
sheet material of either FIG. 1 or FIG. 2, preferably at
. coating station 120 which is located adjacent laminating
.: roller 101. Coating station 120 includes a coating transfer
. roller 122 and a coating gravure roller 12~, shown in greater
: 5 detail in FIG. 7. Coa.ting station 120 is similar to both
the base color station 40 and the shade color s~ation 60 in
that the coating is applied to the sheet material by the
transfer roller 122 as it passes through the nip between the
~ transfer roller 122 and the laminating.roller 101. The
: .10 coating transfer roller 122 and the coating gravure roller
. . 124, which are similar in design to the color transfer roller
42 and the:color gravure roller 44 are rotatably mounted on
an adjustable support 130 which includes inter-engaged
plates 130A-130E which are secured to one another by a
plurality of anchor bolts 131A-131F. Air cylinders 132 and
. . 133 provide pressure respectively between the coating transfer
: . roller 122 and the cclor gravure roller 124 and between the
transfer roller 122 and the laminating roller 101. Pressure
generated by air cylinder 132 between the gravure rollex 124 .
and the coating transfer roller 122 is adjusted by adjusting
screw 134 and the pressure generated between the transfer
roller 122 and the laminating roller 101 is controlled by
adjusting screw 135. The coating applied at the coating
. station 120 may be, for example, a hydrophobic coating and
is applied to the sheet material in a similar manner as the
base color and shading were applied. The secondary coating
is applied to the coating gravure roller 124 as it rotates
through an open pan 126. A reciprocating doctor blade 128, .
. adjustably mounted on support 130 and powered by air cylinder
129, is also provided. The coating is transferred to the
sheet material fro~ ~.he coating gravure roller 124 by the
oppositely rotating coating transfer roller 122 as the sheet
material passes throu~h the nip between the oppositely
rotating laminating roller 101 and transfer roll 1220
1~7337
. An addLtional staining step at staining station 140 may
also.be incorporated into the processes oE FIGS. 1 and 2,
- staining being done after the decorated sheet passes xom
the coating station 120 over a take-up roller 138. Staining
station 140 is of similar design to base color station 40
and shading station 60 and lS shown schematically in FIGS. 1
. and 2. Staining is used to further delineate the pattern
being embo~ed on the sheet material. Suitable staining
agents include both saturated and unsaturated, synthetic or
natural vegetable oils, such as, for example, glycerides.
Staining station 140 includes an upper, internally
heated, roller 141 preferably o chrome-plated steel, which
is in direct contact with an oppositely rotating transfer
roller 142 which is of similar constr~ction to color transfer
roller 42. Stain is applied to the transfer roller 142 by
an oppositely rotating stain gravure roller 144 which includes
an open pan 146 for applying stain to the gravure roller 144
and a doctor blade 148 for removing excess heavy deposi.ts of
. ¦stain from the gravure roller 144. Stain is introduced into .
pan 126 by circulation means similar to the system used for
introducing and circulating the coloring and shading agents.
As the decorated sheet material travels between the upper,
._~ heated roller 141 and the stain transfer roller 142, the
stain is applied to the xaised, decorated side of the decorated
sheet material by the stain transfer roller 144. The upper
heated roller 141, like the laminating roller 101, has a
.. hollow center portion through which steam is passed to~
elevate the temperature of the upper roller 141 to thus
accomplish staining at elevated temperatures. Preferably,
the upper heated roller 141 i~ maintained at a temperature .
of at least about gOa~ with a temperature within the range
of from about 100F to about 120F being most preferred.
The staining station 140, which includes rollers 141,
142 and 144, stain containing pan 146 and doctor blade 146,
-22- I
~733~7
is rotatably and adjustably mounted on a frame (not shown)
of similar design to frame 18 which supports the embossing,
coloring, shading and laminating stations.
The decorated sheet material may after passing through
the staining station 140 ! be introduced into a humidi~ier 160
; o conventional design where the moisture level of ~he sheet
; material is raised to a pre-determined level. This is
particularly recommended when the sheet material is a cigar
wrapper where after processing, the wrapper should have a
moisture lçvel of at least about 25% and preferably between
about 28% and about 35%. A moisture level of abou~ 30% for
the final product is most preferred. Humidification is
preferably accomplished by the simultaneous introduction of
steam through a plurality of jets onto both surfaces of the
sheet material as it passes through the humidifier 160.
It has been found that humidification is most effective
when the temperature ~f the sheet material is maintained at
a temperature of about 110F and this may be accomplished by
maintaining a constant circulation of air around the sheet
material. The application of a very fine spray of cool
water applied to the sheet material through water jets 165
positioned immediately adjacent to the humidifier 160 results
in greater moisture levels in the final, humidified product.
The water on the wrapper functions a~ a heat sink and prevents
drying of the sheet material during humidification 160.
After humidification, the sheet material is drawn into
a rewind station 180, as shown in FIGS. 1 and 2, first
passing over an idler roller 182 and then through a driva
assembly lB4 which includes upper and lower puller rollers
184A and 184Bt respectively, which serve to pull the sheet
material through the ~pparatus. It is then fed over take-up
rollers-186A, 186B and 186C and rewound around either top or
bottom rewind rollers 188A and 188B. Take-up roller 186B
is a moisture detection roller and monitors the moisture of
~73307
, '
the sheet material prior to re-rolling on rollers 188A and
188B, thus permitting increased or decre~sed humidification
by humidifier 160, if necessary.
The apparatus of FIGS. 1 and 2 may be powered by conven-
tional means (not shown) and preferably by coordinated D.C.
motors. It is preferred that three separate D.C. motors be
used~ with one master motor to rotatab:Ly drive the center
cylinder 24 with the rollers comprising the embossing coloring,
shading, relnforciny and laminating stations 100', beiny
geared to the center cylinder 24 by conventional gearing.
Secondary motors are provided at the rewind station 180 and
at the staining station 140 and are subordinate to the
master motor driving the center cylinder 24, with their ,,?
drive speed being dependent upon the speed at which the
master motor operates.
It will be appreciated that the tension of the sheet
material must be maintained at a relatively constant level
duxing processing t~ prevent teaxing or pulling of the sheet
material and irregular laminatioh. This may be accomplished
by the use of conventional take-up rollers or dancer rollers
positioned at various points throughout the apparatus. For
example, dancer rollers may be positioned between the laminating
station 100' and the staining station 140 and between the
staining station 140 and the humidifier 160. A potentionmeter
may be employed on one or more o~ the danc~r rollers to both
change the speed of the drive assembly 184 automatically and
to control the speed of rewind rollers 188A and 188B in
order to maintain proper tension of the sheet material.
As previously stated, when the sheet material is, ~or
example, a cigar wrapper, the moisture level of the sheet
material must be m~intained above a mini~um moisture level
to prevent the sheet material from -tearing or cracking. It
is therefore preferred that the sheet material have, prior
to processing, a moisture level of at least about 19~ with a
: ~73307
moisture level of at least about 22% being most preerred. When
the sheet material is at such a moisture level, prior to processing
it will be more resistant to drying from the heat generated during
the processing, thus making the sheet material less prone to
tearing and cracking.
The resultant embossed, colored and shaded cigar wrapper
sheet is shown in FIGS. 8, 8A and 8B; FIG. 8 being a photograph of
the decorated surface of the wrapper; FIG. 8A being a partial
cross-sectional view of a non-laminated wrapper; and FIG.8B being
a partial cross-sectional view of a laminated wrapper having two
layers of sheet material.
The cigar wrappers which are decorated in both the laminated
and non~laminated embodiments of FIGS. 1 and 2 may be sheets of
conventional, manufactured cigar wrapper material. In general,
the sheets of manufactured ciyar wrapper are a mixture of ground
tobacco, reined pulp, Eiller materials, adhesives and other
functional ingredients and preerably have a sheet weight within
the range of from about 1.0 g/ft2 to about 6.0 g/ft2 and a
moisture level of at least about 19%. The sheet of cigar wrapper
material in the non-lamlnated embodiment of FIG. 8A preferably has
a thickness of between about .002 inches and about .006 inches.
While, in the laminated embodiment, of FIG. 8B, two layers of sheet
material, each between about 0,001 inches to about .003 inches
thick, are laminated together to produce a finished laminated
sheet with a thickness of between about 0.002 inches and about
.006 inches. In certain instances, it may be desirable to use
sheets of differing thicknesses or compositions to achieve a
desired result.
As shown in the photograph of FIG. 8, the cigar wrapper 200
has a raised vein-like pattern embossed on its coated surface A
and is colored and shaded on uncoated surface B to simulate the
appearance of a natur~l tobacco leaf. As shown best in FIGS. 8A
and 8B,-the vein-like pattern embossed on the sheet is raised from
the coated outer surface of the wrapper 201. While the height of th, ,
1~73307
raised vein pattern may vary widely, it has been found that a
height for the main vein 202 of between about 0.010 and about
0.020 inches from the otherwise planar outer surface 201 most
closely simulates the appearance of the main vein of a natural
to~acco leaf and accordingly, such a height is preferred. A
most preerred height for the main vein 202 is between about 0.014
and about 0.016 inches. Similarly, it has been found that the
- height of the smaller vein 203 should preferably be between about0.002 and about 0.009 inches and, most preferably between about
0.004 and about 0.008 inches.
As shown in FIGS. 8A and 8B, the complimentary depressed
portions of the vein-like pattern Z02A and 203A on the uncoated
side of the decorated sheet are preferably filled with a filler
material in order to aid in reinforcing the raised pattern on the
outer surface 201 when the cigar wrapper is stretched taut and,
particularly, when the moisture level of the wrapper increases
above about 25~. Filler materials may either be in powder or
paste form, the powder including a mixture of ground to~acco,
binding agents and fillers including diatomaceous earths, clays
and whitening agents. Preferred diatomaceous earths include the
product marketed by ~refco, Inc. of Los Angeles, California under
the trademark Dicalite~ and the product marketed by Johns-
Manville of Denver, Colorado under the mark Celite~. Preferred
_ clays include Bentonite~, marketed by NL Industries, Inc. of
New York, Kaolin and monmorillonite and preferred whitening
agents, which serve to give the filled vein pattern a more natural,
colored appearance, may be selected from the group consisting
of titanium dio~ide, calcium carbonate and dolomite. Flavoring
and aromatic additives, coloring agents, preservatives, burn
modifiers and ash improvers may also be incorporated in ~he filler
materials.
~ ~ ~ 1073307
As illustrated in the photograph of FIG. 8, the decorated
igar wrapper includes a base color which is applied to its
ncoated surface B, and which is clearly visible from the opposite
oated surface A. A random shade pattexn of contrasting color is
also applied to uncoated surface B and is also visible from coated
surface A. The base color applied to the uncoated surface B is
one with a coloring agent, including in~s and dyes and,
preferably selected from the group including carotenoids and
annattos; ood, drug and cosmetic dyes including the lake and
solubili~ed forms; and other commercial food grade inks. A
particulaxly preferred coloring agent is a misture of an alcohol
soluble cellulose ester and a pigment.
The shade color pattern is a second random color coating
selectively applied to the uncoated surface B of the cigar wrapper
USinCJ a shading agent. Preferred shading agents are drawn from
khe same class as the base coloriny agents although the shading
agent should be of a contrasting color to effect the random shade
or c~oud pattern.
As previously stated, the cigar wrapper may have either two
layers of sheet material laminated together, as shown in FIG. 8B,
or be a single-layered, non-laminated wrapper as shown in FIG. 8A.
The two layered, laminated wrapper is preferable, since it further
reinforces the embossed pattern and is thus more resistant to
stretching and resultant obli~eration of the embossed vein pattern.
Additionally, the use of a laminated wrapper permits the use of
layers of different types and thicknesses and provides the
opportunity to create, by combining la~ers of diferent properties
but having a symbiotic relationship with respect to one another,
cigar wrappers having flavors, aromas and other physical properties
such as strength, burn characteristics and surface appea~ances not
heretofore possible from a single layered wrapperO
`"" ~733~7
In the laminated wrapper of FIG. 8B, the second or laminating
layer 300 is laminated to the decorated layer 200 on the uncoated
side B of the decorated layer 200 which has the filled, depressed
pattern. The laminating layer 300 is a second, undecorated sheet
of manufactured cigar wrapper material. While in most cases, the
laminating layer 300 is similar in all respects, except decoration,
to the decorated sheet 200 to which it is laminated, it is forseen
that layers of different thickness and/or composition may be
laminated together. Lamination, which is generally accomplished
at elevated temperature and pressure, results in the physical
bonding of the decorated layer 200 to the laminating layer 300.
; The cigar wrapper of FIG. 8 may then be wrapped around the
binder 400 and the bunch portion 500 of a cigar in a conventional
anner in order to prodce the cigar of FIGS. 9 and 10.
In an alternate embodiment of the present invention (not
shown), the decorated layer 200 is laminated directly to the
binder 400, thus eliminating the need for this additional layer
; and ~rapping step. Such an embodiment is particularly useful inhigh speed rod-making machines and a preferred application is in
the manufacture of tipped cigars.
The following example serves to illustrate the present
invention and should not be construed as limiting its scope.
EXAMPLE
In order to more clearly illustrate the properties of a
decorated cigar wrapper which was decorated according to the
ethod and using the apparatus of the present invention, a sheet
of conventional manufactured cigar wrapper was decorated and
then laminated to a second sheet of conventional manufactured
cigar wrapper. Each of the two sheets had a thickness of
_ .
~ 73307
. '
about 0.0015 inches, a tobacco content in excess of 65~ and
the ~ollowing physical properties:
. LAMINATING SHEET (Prior to processing~
dry long strength: 540 g/in
dry transverse strength: 135 g/in
Mullen strength: ` 1.45 lb/in2
smoothness - top: ~ . 25 seconds/25cc/in2
. smoathness - bottom: 32 seconds/25cc/in2
sheet veight: 155 g/ft. 2
sheet ~oisture: 24.84%
DECORATING SHEET (Prior to processing)
..
dry long strength: 650 g/in
dry transverse strength: 410 g/in
Mullen strength: 1.95 lb/in2
smoothness - top: .60 seconds/25cc/in2
.smoothness ~ bottom: 100 seconds/25cc/in2
sheet weight: 1.40 g/ft2
sheet moisture: 25.30% - .
.
The decorating sheet was coated on one surface with
the following coating:
- Ingredients Percent By Weight
cellulose-acetate-propionate 10~
ethyl alcohol 63%
ethyl acetate 27%
The laminating sheet had originally been coated on its
. underside with the following coating:
Ingredients - Percent By Wei~ht
. cellulose-acet2ie--propionate 5.0% .
acetylated monoylyceride 5.0%
ethyl alcohol 63.0%
: eth~1 acetate 27.0%
``` 1~ 10733()7
Each sheet was coated at a level of about 80 mg/ft2 measured
on a dry weight basis~
The laminating and decorating sheets were simultaneously
processed through the apparatus of FIG. 2, the decorating
sheet first having a raised, vein-like pattern embossed through
its thickness at a pressure of 60 psi and at a temperature
of 262F.
Base color was applied ~t a base color station at a
temperature of 80F with an alcohol soluble ink and a shade
color patt-ern was applied at a temperature of 84F at a
shade-color station, also using an alcohol soluble ink of
a contrasting color to the base color ink. The decorating
sheet was then laminated to the laminating sheet at a temperature
of 281F and at a pressure o 60 psi.
The resultant decorated, laminated cigar wrapper, was
humidified and rewound. Subsequent testing indicated that
the wrapper had the following physical properties:
dry long strength 700 g/in
dry transverse strength 330 g~in
Mullen Strength 1.65 lb/in2
smoothness top 80 seconds/25cc~in2
sheet weight 3 38 y~ft2
_ sheet moisture 30.4~
:''
The resultant decorated cigar wrapper, although being a
manufactured cigar wrapper, had the appearance of a natural
tobacco leaf and the physical properties of a commercially
acceptable cigar wrapper.
Although the foregoing example illustrates the for~ation
of a decorated, lami~ated cigar wrapper, using the apparatus
and methods of the ~ese~t inVentions, it will be appreciated
that the presently disclosed apparatus and method may be
used to manufacture sheet material for use in numerous other
applications. Accordingly, the present invention should be
limited only by the true scope of the appended claims.
J
