CN103403108B - 制备印刷溶液和制造图案化的香烟包装物的方法 - Google Patents
制备印刷溶液和制造图案化的香烟包装物的方法 Download PDFInfo
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Abstract
用于制造图案化的烟草包装物的方法,包括如下步骤:制备印刷溶液,所述步骤包括如下步骤:将至少水和淀粉混合以形成淀粉混合物;将所述淀粉混合物加热到至少大约180℉的温度,优选加热至少大约30分钟以释放支链淀粉和直链淀粉,将丙二醇加入到所述淀粉混合物中,并且将所述淀粉混合物和丙二醇混合以形成印刷溶液,其中所述印刷溶液在高温下(120℉到150℉)维持和施加。该方法还包括提供包装物的基体卷材并以预定图案将印刷溶液施加到包装物上。
Description
相关申请的交叉引用:
根据美国法典第35卷第119(e)节,本申请要求2010年12月13日提交的美国临时申请61/422,525的优先权,该申请的全部内容通过引用结合于本文中。
背景技术
2008年5月23日提交的序列号为12/153,783的美国申请中记述了先前所发展的概念,该申请要求了2007年5月25日所提交的序列号为60/924,676的申请的优先权,每个申请的全部内容都通过引用结合于本文中。
技术领域
本公开大致上涉及一种用于制造包含印刷溶液的图案化的香烟包装物的方法。更具体地,本公开关于一种用于制造图案化的香烟包装物的方法,所述香烟包装物具有特别配制的氧化淀粉印刷溶液。
发明内容
在一个优选的实施方案中,用于制造图案化的香烟包装物的方法包括如下步骤:制备印刷溶液,提供包装物的基体卷材,并且以预定的图案将所述印刷溶液施加到所述包装物上。优选地,制备印刷溶液的步骤包括:在大于大约70℉的温度下将至少水和氧化淀粉混合以形成水状氧化淀粉混合物,将所述水状氧化淀粉混合物加热到至少从大约180℉到大约200℉的范围内的温度,更优选到大约195℉的温度,将所述水状氧化淀粉混合物的温度维持至少大约30分钟、更优选地维持至少大约45分钟来使淀粉颗粒破裂并且释放直链淀粉和/或支链淀粉,将丙二醇加入到所述水状氧化淀粉溶液中,并且将所述水状氧化淀粉溶液和丙二醇混合以形成印刷溶液。优选地,在混合时将所述印刷溶液的温度维持至少大约30分钟。
可选地,所述方法可以包括将碳酸钙加入到所述印刷溶液中。优选地,在加热和混合的步骤之后和在印刷步骤之前将碳酸钙加入到所述印刷溶液中。
在优选的实施方案中,制备步骤还包括将印刷溶液冷却到位于从大约120℉到大约150℉的范围内的温度,更优选从大约120℉到大约140℉的范围内的温度,并且直到在印刷时被使用之前保持该范围。优选地,所述方法还包括在加热和维持的步骤中搅拌所述印刷溶液。
在优选的实施方案中,还在从大约120℉到大约150℉的范围内的温度下,更优选从大约120℉到大约140℉的范围内的温度下将所述印刷溶液施加到包装物上。
在优选的实施方案中,当在120℉下测量时,由每分钟20转(rpm)的具有#1心轴的Brookfield RVDV-2粘度计所测量,所述印刷溶液具有从大约40厘泊(cP)到大约80cP的范围内的粘度。更优选地,可以通过添加热水和/或热量来将所述印刷溶液在印刷机处的粘度调节到大约18.0±1.5秒的粘度水平,所述粘度在大约120℉的温度下,由Zahn#2量杯(cup)来测量。在优选的实施方案中,所述印刷溶液具有处于从大约4到大约8的范围中的pH值。更优选地,在加入碳酸钙后,所述印刷溶液具有从大约7到大约8的pH值。
在优选的实施方案中,所述印刷溶液施加到在相对于机器方向或纵向方向为横向的条带的所述基体卷材上,即所述基体卷材具有横向方向。预定的图案可以包括在所述基体卷材上大致横向延伸的大致平行的条带。优选地,所述基体卷材具有纵向方向。预定的图案可以包括纵向延伸的条纹。还优选地,所述基体卷材具有横向方向和纵向方向。预定的图案还可以包括多个位于基体卷材上的横向间隔开的和纵向间隔开的区域。
在优选的实施方案中,所述印刷方法选自下述组,所述组包括凹版印刷、苯胺印刷、胶版印刷、喷墨印刷、喷涂和模印。优选地,所述印刷方法为凹版印刷。
在优选的实施方案中,所述印刷溶液单层式地施加到所述基体卷材上。
在另一个实施方案中,吸烟用品包括烟草棒和包装物。优选地,所述包装物根据上述方法来构造。
附图说明
当结合附图来阅读所述说明书时,本公开的许多目的和优势对于本领域技术人员而言是显而易见的,其中相同的附图标号应用于相同的部件,其中:
图1显示了用于制造印刷溶液的方法步骤;
图2为凹版印刷系统的示意图,其中对基体卷材10应用根据图1的方法所制备的淀粉溶液的预定图案;
图3为具有横向印刷条带的包装物的示意图;
图4为具有纵向印刷条带的包装物的示意图;
图5为具有横向延伸的和纵向间隔开的多个印刷区域的包装物的示意图;
图6为狭缝条带布置的图示;
图7为包括构造有此处所公开的包装物的具有烟草棒的吸烟用品的立体图;
图8为用于实施图1的方法的设备的目前优选的操作布局的示意图;
图9为具有锯齿状条带区域的包装物的示意图。
具体实施方式
在一个优选的实施方案中,用于制造图案化的烟草包装纸的方法包括:制备印刷溶液,提供包装物的基体卷材,并且以预定的图案将所述印刷溶液施加到所述包装物上。所得到的烟草包装物为使用所述烟草包装物的类型的吸烟用品提供了减少的引燃倾向性特征。当阴燃的吸烟用品无意地落在基板上时,减少的引燃倾向性特征反应出降低的未被注意的吸烟用品导致基板点燃的能力。
在优选的实施方案中,预定的图案可以包括至少一个条带或印刷区域,例如横向条带。优选地,可以使用印刷技术,例如凹版印刷、苯胺印刷、胶版印刷、喷墨印刷、喷涂、模印或类似技术来施加该预定图案。最优选地,所使用的印刷技术可以为凹版印刷。优选地,单程式地来施加该预定图案。在实施该优选的实施方案时,例如可以商业可接受的印刷速度来进行淀粉溶液在单程基体上的凹版印刷。
为了改善具有该包装物的吸烟用品的引燃倾向性特征,优选通过一种印刷溶液来施加所述图案,所述印刷溶液包含氧化淀粉并且通过此处所述的方法来形成。可以使用具有从大约40厘泊(cP)到大约80cP的范围内的粘度、更优选地具有处于从大约40cP到大约60cP的范围内的粘度的水状氧化淀粉溶液来实现被加附材料的优选的印刷特征和成膜特征,所述粘度为在120℉下使用每分钟20转(rpm)的具有#1心轴的Brookfield RVDV-2粘度计所测量。在印刷机处或在印刷时,通过添加热水和/或热量来调节所述粘度以达到优选的最终值,所述印刷溶液具有从大约16.5到19.5秒的粘度,更优选地具有从大约17秒到大约19秒的粘度,所述粘度在120℉下由Zahn#2杯(cup)来测量。所述印刷溶液所采用的淀粉可以优选地先与水混合以形成具有从大约29%到大约34%(重量)、更优选从大约30%到大约33%(重量)的固体含量的水状淀粉混合物。可以使用多种淀粉,然而为了本发明的目的优选使用氧化淀粉,但并不限制于此。优选的氧化淀粉包括氧化木薯淀粉,例如可从National Starch,LLC.处获得的FloMax8。这种类型(例如木薯淀粉)和处理(例如氧化)提供了处于优选的分子量范围的淀粉成分(例如直链淀粉和支链淀粉)。
优选地,印刷溶液也包括1,2-丙二醇,所述1,2-丙二醇的量足够减少基体卷材由于在印刷过程中的水状淀粉溶液的施加和干燥而起皱的趋势(丙二醇的“抗皱”效应)。目前理解的是,使得达到此效应的含量水平将导致在最终的包装物中在条带中存在的丙二醇处于从大约0.3到0.5克每平方米或更多的基本重量水平下。针对丙二醇的含量水平的其余理念和其它的“抗皱”剂在2009年3月8日提交的共同拥有的序列号为61/064,439的美国专利申请“具有抗皱剂的图案化的包装物”中有所描述,其内容通过引用结合于本文中。目前优选的溶液可以包括基于溶液总重量的从大约7%到大约10%重量的量的丙二醇,基于溶液总重量的大约21%重量的量的淀粉,以及基于溶液总重量的大约11%重量的量的碳酸钙。
已经进一步发现,在优选的含量水平下,并且在对水状氧化淀粉溶液的烹煮结束时或邻近结束时添加丙二醇,则丙二醇具有额外有益的效果。在烹煮后的水状淀粉溶液中含有丙二醇的情况下,丙二醇可减少淀粉组分的逆向变化或胶化的倾向,从而可用作稳定剂。其也在所得到的印刷溶液中提供了抗菌效应。这两种效应都延长了印刷溶液的贮藏寿命。印刷溶液的延长的贮藏寿命使得可以在远离进行印刷操作的地方制备溶液并运输溶液。正如下文中将进一步解释的,在运输和/或印刷时,通过将印刷溶液维持在从120℉到150℉的范围内、更优选从大约120℉到大约140℉的范围内来进一步延长印刷溶液的操作贮藏寿命。另外,根据所述方法来加入丙二醇也具有如下效果,即,将印刷溶液的粘度减少至可进一步提升其适印性的水平。
在一个备选的实施方案中,作为丙二醇的附加或替换,也可以使用其它的抗皱剂。适合的抗皱剂包括多元醇,包括但不限于丙三醇、甘油、聚乙二醇、葡萄糖、蔗糖、益寿糖、麦芽糖醇、山梨醇、木糖醇和其它展示出类似功能的试剂。
优选地,在印刷溶液中可以根据需要包含惯用的填充材料、例如碳酸钙来改善印刷材料,以使其在包装物上不那么明显并且提升成品吸烟用品的自熄性能。优选地,如果包含碳酸钙,则可恰好在印刷之前将碳酸钙加入到印刷溶液中。碳酸钙也可以通过减少所施加溶液中的水含量来协助减少包装物的褶皱。优选地,在加入碳酸钙后,印刷溶液具有处于大约4到大约8的范围中的pH值,更优选地从大约7到大约8的pH值。
大致上,可以将印刷溶液的预定图案施加到包装物的基体卷材上,以获得提升的引燃倾向性(“IP”)特征,并且获得提升的自熄性(“SE”)特征。引燃倾向性是如在ASTM E2187--4,即“用于测试吸烟用品的点火强度的标准测试方法”中所记述而进行的标准测试,其全部内容通过引用结合于本文中。引燃倾向性测量这种可能性,即当置于基板上时吸烟用品发出足够的热量以维持烟草棒的稳定燃烧的可能性。期望得到低的IP值,因为这样的值与减少的阴燃吸烟用品导致下部基板点燃的可能性相关。
这里,自熄性或SE是对自由的燃烧条件下吸烟用品的阴燃特征的参照。为了衡量SE,在23℃±3℃的温度下和55%±5%的相对湿度下进行实验测试,温度和相对湿度都由记录温湿计来监测。排放室将在测试中形成的燃烧产物移除。在测试之前,所要测试的吸烟用品在24小时中调节到55%±5%的相对湿度和23℃±3℃。恰在测试之前,吸烟用品置于玻璃烧杯中以保证自由接触空气。
SE测试在封闭件或测试箱内进行。使用单端口的吸烟器件或电引燃器来点燃吸烟用品以测试。在测试中,一个器件或“角度支持器”通过支持住端部而将要测试的吸烟用品支持在0°(水平)、45°和/或90°(竖直)的角度。优选地,分别在0°、45°和90°的位置下对20个吸烟用品进行测试。如果使用了多个器件,则器件优选地布置成使得吸烟用品背向彼此以避免交叉干涉。如果在阴燃煤的前线到达接装纸之前吸烟用品熄灭了,则结果评分为“自熄”;而另一方面,如果直到阴燃煤的前线到达接装纸时,吸烟用品继续阴燃,则结果评分为“非自熄”。因此,例如95%的SE值显示在自由燃烧条件下95%的被测吸烟用品展现出自熄性;而20%的SE值显示在自由燃烧条件下仅20%的被测吸烟用品展现出自熄性。
可以用“0°自熄值”、“45°自熄值”或“90°自熄值”来表示SE值,这些中的每个指代在特定测试角度下的SE值。另外,可以用“自熄平均值”来表示SE值,它指代三个角度位置下的平均值,即(i)“0°自熄值”、(ii)“45°自熄值”和(iii)“90°自熄值”下的平均值。对“自熄值”或“SE值”的引用则不区别0°SE、45°SE、90°SE或SE平均值,并且可以指代它们中的任一个。
另外,印刷溶液的预定图案典型地施加到具有处于大约10到大约80CORESTA单位的范围内的渗透性的基体卷材上。优选地,印刷溶液在基体卷材上形成膜,当干燥时,将扩散率值局部减少到位于0到大约0.25厘米每秒(cm/秒)的范围内是有效的,上述值由Sodim CO2扩散率测试器(可以从法国SodimSAS获得)测得。为了使用扩散率测试器来测量一张纸的扩散率,该纸必须置于夹头中,以使得纸分隔开两个竖直布置的腔体。上部腔体包含运载气体,例如氮气,而下部腔体包含标记气体,例如二氧化碳。由于在两个腔体之间没有压差,任何气体的迁移都是由于气体的浓度差所导致的,并且没有渗透效应,当纸的两个表面之间维持压差的时候才会出现渗透效应。在预定的时间周期(例如大约25秒)之后,在分析器中测量上部腔体的氮气流中的二氧化碳的浓度。而后电脑将浓度转换成扩散率。
需要进行多次平衡或交替来选择用于将膜应用到包装物上的淀粉参数。例如,虽然高分子量的淀粉可以导致有效的扩散率减少,然而这样的高分子量淀粉却是低溶解度的,因此必须以低浓度使用,结果是印刷溶液具有非常高的水含量,这提升了干燥要求并且恶化了基体卷材的褶皱。
在优选的实施方案中,如图1所示,通过在批处理中向容器中添加水(步骤100)和添加氧化淀粉(步骤105)来制备印刷溶液。该优选的实施方案提供批处理。在批处理中,在大约75℉下以大约15转每分钟(rpm)的低速将水和氧化淀粉混合(步骤110),以将淀粉颗粒分散在水中,并且形成具有处于大约4到大约5.5的范围内的pH值的水状氧化淀粉混合物。在优选的实施方案中,在加入氧化淀粉(步骤105)之前,可将水加热到大约75℉或更高。在混合(步骤110)中,将氧化淀粉混合物加热(步骤120)到从至少大约180℉到至少大约200℉的范围内的温度,更优选到大约195℉的温度。优选地,以从大约60分钟到大约90分钟的优选的时间区间来升高温度,优选伴随搅拌以确保均匀性。还优选的是,通过在至少大约30分钟、更优选至少大约45分钟的混合的同时将溶液维持(步骤130)在从大约180℉到大约200℉的范围内、优选大约195℉的上述所选温度下来“烹煮”加热的氧化淀粉混合物的温度。在加热和维持步骤中,(可在显微镜下观察到的)淀粉颗粒能够吸水、膨胀、破裂和释放直链淀粉和/或支链淀粉到溶液中。
在加热(步骤120)和维持(步骤130)水状氧化淀粉溶液的温度之后,该方法优选还包括将丙二醇添加(步骤150)到水状氧化淀粉溶液中和混合(步骤160),同时基本上将温度保持为常量,使其处在上述所选择的温度下或更优选地处于或大约为180℉。如果当添加丙二醇时其处于室温下,溶液的温度可能从所述195℉下降到大约180℉的温度。在添加(步骤150)丙二醇后,将水状氧化淀粉溶液混合至少大约30分钟,以彻底在水状氧化淀粉溶液中将丙二醇分散。
优选地,在加热(步骤120)、维持(步骤130)的过程中并且在添加(步骤150)之后,连续地混合水状氧化淀粉溶液。优选地,在将丙二醇添加到水状氧化淀粉溶液中之前,将丙二醇维持在室温或更高的温度。另外,优选尽可能迅速地将丙二醇添加到水状氧化淀粉溶液中。在批量处理中,例如在加热(步骤120)和在维持(步骤130)的过程中,以及在将丙二醇添加到水状氧化淀粉溶液中(步骤150)之后,可以在1000加仑的箱中使用大约150rpm的低速度、低剪切混合来混合水状氧化淀粉混合物。优选地,当溶液处于高温下,优选处于大约180℉或更高时进行混合(步骤160)。
在一个备选的实施方案中,可以通过使用喷射式蒸煮锅来完成加热(步骤120),所述喷射式蒸煮锅“按照需要”基本持续地生产经蒸煮的淀粉,其中被加热到至少大约180℃的液体朝着液体中的淀粉的被打碎的颗粒结构的承压面喷射。
不希望被理论所束缚,可以认为,通过将水状氧化淀粉混合物的温度维持在大约195℉或更高,将导致淀粉颗粒膨胀、破裂并释放出直链淀粉和/或支链淀粉。通过添加丙二醇,可以认为丙二醇基本上减少了重组,使得在延长的时间周期中保持淀粉印刷溶液的成膜能力。另外,丙二醇处于具有淀粉的溶液中,以提供具有小于大约100cP、更优选小于大约60cP、更优选具有从大约40cP到大约60cP的低粘度的基本均质的混合物,上述值在120℉下使用20rpm的具有#1心轴的Brookfield RVDV-2粘度计测得。
另外,可以认为,将丙二醇添加到水状氧化淀粉溶液中会提供稳定性和抗菌效应,并且因此提升了印刷溶液的贮藏寿命。这些效应通过溶液的pH值来证明,在制备出印刷溶液后,溶液的pH值数天都不会改变(即基本为常量)。
在添加丙二醇(步骤160)和混合(步骤110)之后,可以将印刷溶液冷却(步骤140)到从大约120℉到大约140℉的范围内的温度。优选地,将印刷溶液维持在大约120℉或更高的温度下,以避免凝聚和粘度增加。已经发现,当溶液温度下降到大约120℉之下时,逆向变化加速,导致不期望有的溶液胶化。一旦胶化效应开始,溶液的逆向状态不可逆转。
在大约120℉的温度下,在印刷操作开始之前,印刷溶液优选具有大约40cP到大约60cP的粘度,其在120℉下使用20rpm的具有#1心轴的Brookfield RVDV-2粘度计来测量。还优选的是,在大约120℉的温度下,印刷溶液具有大约4到大约5的pH值。在印刷机处,恰在印刷操作开始之前,添加热水或升高温度(不高于150℉)或这两者都可以用来获得所期望的最终印刷粘度(处于从大约16.5到19.5秒的范围内,更优选地从大约17秒到19秒的范围内)。
在一个实施方案中,印刷溶液而后可以存储在筒/装运物中,并且处于从大约120℉到大约140℉的温度下,直到在印刷时供使用。根据需要,可以使用绝缘毯或加热货车来运输筒/装运物,同时将筒维持在至少大约120℉的温度下。筒/装运物也可以储存在加热的条件下。在优选的实施方案中,在存储时也可以低速度连续地搅拌印刷溶液。优选地,印刷溶液在生产后72小时内使用。上述温度的维持以及丙二醇的加入为溶液提供了稳定性,使得能够达到至少2或3天或更长的贮藏寿命。
在优选的实施方案中,该方法也可以优选包括将碳酸钙添加(步骤170)到印刷溶液中。在优选的实施方案中,大约300磅的印刷溶液可以与大约40磅的水和大约40磅的碳酸钙混合,并且混合大约15到大约25分钟。优选地,使用涅普顿(Neptune)叶轮以低速度来混合该混合物,以使碳酸钙悬浮在混合物中,避免起泡并且形成印刷溶液。优选地恰在印刷之前添加碳酸钙,使得碳酸钙不会从溶液中沉淀出来。
在转换器/印刷机中,之后可以将印刷溶液泵送到印刷机的运转滚筒处。优选地,最终的印刷溶液(在添加了水和白垩粉之后)具有从大约7到大约8的pH值和大约20cP的粘度,后者是在120℉下使用20rpm的具有#1心轴的BrookfieldRVDV-2粘度计来测得。
在印刷机处,该方法还包括提供包装物的基体卷材(步骤180),以及将印刷溶液施加到基体卷材上以形成烟草包装物(步骤190)。
在优选的实施方案中,印刷溶液允许对基体卷材的较高淀粉负载,使用较少的水,并且丙二醇具有较高的抗皱效应,这是由于丙二醇相对于水含量的较高浓度。这些特征协同地显著减少了基体卷材的褶皱,并且减少了印刷溶液的粘度以加强适印性。例如,在将6.8mm宽的实心条带以27mm的条带周期施加到33CORESTA(烟草科学研究合作中心)基体卷材上之后,大约0.9克每平方米(g/m2)的淀粉、大约0.4g/m2的丙二醇和大约0.4g/m2的碳酸钙布置到基体卷材上。
在优选的实施方案中,通过上述方式制备的印刷溶液也可以使用多种印刷技术中的任一种来施加到基体卷材上,作为示例而非限定性的,所述印刷技术包括下述组,所述组包括凹版印刷、苯胺印刷、胶版印刷、喷墨印刷、喷涂和模印。其它的印刷方法也可能是适合的,并且也处于本申请的范围之内。然而优选地,可以使用凹版印刷来将印刷溶液施加到基体卷材上,以获得图案化的烟草包装物。
如图2所示,在优选的实施方案中,可以将包装物的基体卷材10从滚筒12输送到凹版印刷系统14,在那里将根据上述说明书所制备的印刷溶液的预定图案施加到基体卷材10上。具有新施加的和烘干的预定图案的基体卷材10卷到“压力”辊16上。在其它的惯用步骤中,可以将图案化包装物的“压力”辊16分成多个单独的梭心,这可以用来使烟草棒成形,以用于制造吸烟用品,例如香烟。
凹版印刷系统14可以包括一个或多个印刷操作。上述印刷溶液可以提供到储存器(或储存池)20,从那里印刷溶液被泵送或以其它方式供应到具有与所期望的印刷图案相一致的图案化表面的印刷滚筒22。印刷滚筒22在印刷溶液池中旋转。随着印刷滚筒22旋转,通过刮刀组件23将印刷溶液从辊子表面擦拭掉,使得随着印刷滚筒22在位于印刷滚筒22和具有回弹性表面的承压辊24之间的夹持处与基体卷材10接触,印刷溶液转移到具有印刷滚筒22的表面上的图案的基体卷材上。
优选地,如图3所示,基体卷材10典型地具有横向或横跨卷材的方向(通过箭头30显示)以及纵向或机器方向(通过箭头32显示)。还优选的是,基体卷材10典型地具有横向或横跨卷材的方向,以及纵向或机器方向。如图所示,印刷材料的预定图案可以包括单个地横向定向、大致上平行的区域或条带34。
在另一个实施方案中,基体卷材10可以包括印刷材料的一种预定图案,例如如图4所示的一个纵向延伸的区域或条纹36。如果需要,如图5所示,预定图案也可以包括沿着和/或横向于基体卷材10间隔开的印刷材料的布置在间隔开的周向偏置的列中的区域38的二维阵列(批量图案)。
如图6所示,印刷材料310可以作为带有狭缝的条带构造来施加,例如位于一个组中的两个或更多靠近地间隔开的横向条带,该组与相邻的组以更远的距离间隔开,例如公开号为2008/0295854的共有美国专利申请中所描述的,该申请的全部内容通过引用结合于本文中。
在一个实施方案中,如公开号为2008/0295854的美国专利申请的图49-54所示和如此处所述,一个或两个周向延伸的边缘可以具有锯齿。如图9所示,每个条带区域126的前缘500可以具有锯齿。可选地,条带区域的后缘502也可以具有锯齿。
本领域技术人员可以理解具有锯齿的区域的多种布置,附图中显示了一个示例性的布置。例如(参照图9),条带区域12可以具有前缘500,其中凹部504布置在凸部506之间。在此实施方案中,凸部506在基体卷材140的横向方向上具有一定的尺寸,该尺寸基本上与凹部504在横向方向上的尺寸相同。如所描述的,凸部506和相关联的凹部504可以大致为矩形。然而如果需要的话,凸部506和凹部504可以具有其它的几何形状,包括但不限于四边形、梯形、三角形、六边形和其它的规则或不规则的几何构型。凸部506的顶部和相邻的凹部504的底部之间的距离可以处于从大约2mm到大约5mm的范围内,并且优选可以为大约3mm。在条带区域126的后缘处,也可以设置类似的锯齿布置。
如图7所示,吸烟用品包括烟草棒205和滤嘴207,它们通过接装纸209彼此连接。烟草棒205包括根据这里的记述所构造的包装物210。
图8为用于实施此处所记述的制造印刷溶液的方法的设备的目前优选的操作布局的示意图。如图所示,在烹煮设备50中制备印刷溶液,然后将其运输55到一个或多个纸转换器(印刷机)60。在运输过程中,将印刷溶液维持在从大约120℉到大约150℉的温度,更优选从大约120℉到大约140℉的温度,以避免溶液的适印性(粘度)和成膜特征下降。在优选的实施方案中,可以在转换器(印刷机)60处将碳酸钙添加到印刷溶液中以形成印刷溶液。该印刷溶液之后可施加到由纸制造器65所供应的基体卷材上。在将印刷溶液施加到基体卷材上之后,将基体卷材撕开并将所得卷筒输送到烟草制造器70处以用于制造香烟。相应地,单个的烹煮设备50可以支持任何数量的转换器60的操作,这可简化制造,并且节省操作成本和资金。
在一个备选的实施方案中,可以在转换器(印刷机)60处制备印刷溶液,使得溶液的运输并非必要。
在优选的实施方案中,上述用于制造印刷溶液的方法为批量方法。在一个备选实施方案中,该方法可以为连续的工艺。
下面的例子用来展示所述方法的实施方案,并且不应当被认为限制了这些实施方案的范围。
例子1:
将氧化淀粉和水在大约75℉下混合,并在大约45分钟内加热到大约195℉,通过低搅拌(低剪切混合)形成混合物。将该溶液从加热处移开,并加入丙二醇,同时混合大约30多分钟,同时将溶液维持在至少大约180℉的温度。在混合的同时将溶液冷却到大约140℉的温度。之后将溶液打包,并将溶液的温度维持在从大约120℉到大约140℉的范围内的温度,并将溶液输送到印刷位置。
溶液包含大约31%(重量)的淀粉、大约10%(重量)的丙二醇和大约59%(重量)的水。在印刷机处或印刷操作中,大约300磅的溶液与40磅的热水和大约40磅的碳酸钙混合,以形成具有大约21%(重量)的淀粉、大约8%(重量)的丙二醇、大约60%(重量)的水和大约11%(重量)的碳酸钙的印刷溶液,以形成最终的优选的印刷溶液。
该溶液展示了所期望的适印性和成膜特征。
例子2:
将大约51磅的加热到从大约70℉到大约80℉的温度的水与大约31磅的淀粉粉末混合,该粉末例如可从National Starch,LLC.获得的8。将水和淀粉粉末进一步混合,同时加热大约45分钟到大约200℉的温度,以形成水状氧化淀粉溶液。将大约10磅的加热到大约200℉的浓缩蒸汽或另外的水加入到水状氧化淀粉溶液中。水状氧化淀粉溶液使用炉焙方法来测试,并且其具有大约31%的固体含量。在120℉下使用20rpm的具有#1心轴的Brookfield RVDV-2粘度计来测试,发现该水状氧化淀粉溶液具有大约50cP的粘度。水状氧化淀粉溶液具有从大约4到大约5的pH值。
之后将大约8磅的丙二醇加入到水状氧化淀粉溶液中,并且将其在从大约180℉到大约200℉的范围的温度下混合大约30分钟。印刷溶液之后冷却到大约130℉的温度。再次在120℉下使用20rpm的具有#1心轴的Brookfield RVDV-2粘度计来测试粘度,发现该印刷溶液具有大约45cP的粘度。这证明了丙二醇具有减少粘度的有利效果。将印刷溶液保持在基本恒定的搅拌下,搅拌强度取决于箱的大小、尺寸和搅拌器类型。加入碳酸钙,同时混合以使碳酸钙悬浮,并且形成印刷溶液,将该印刷溶液维持在从大约120℉到大约130℉的温度下。该印刷溶液包含大约54.5磅的水、大约24.5磅的淀粉、大约10.5磅的碳酸钙和大约10.5磅的丙二醇;并且其具有从大约17.5秒到大约18.5秒的粘度,所述粘度在120℉下由Zahn#2杯(cup)来测量。
作为一个备选方案,也可以测量水状氧化淀粉和丙二醇溶液的浑浊度,以在通过使用粘度测量而注意到粘度变化之前识别水状氧化淀粉和丙二醇溶液中的变化。浑浊度测量透过给定量材料的光的量,并且因此可以用来作为质量控制工具来决定是否应该在与碳酸钙混合之前使用或丢弃该水状氧化淀粉和丙二醇溶液。因此,可以使用浑浊度测量来确定水状氧化淀粉和丙二醇溶液的成膜能力。
在实施本发明的优选实施方案时,将溶液温度维持在从大约120℉到大约150℉的范围内的步骤提供了多个优势,包括但不限于:允许在水状溶液中获得并维持高淀粉含量,并且降低水状溶液的粘度。相应地,通过使用温度维持步骤直到印刷步骤,得到了所期望的印刷溶液,该溶液适合于单程式地应用于基体卷材。
当根据本说明书将丙二醇作为抗皱剂来使用时,在从大约120℉到大约150℉的范围的温度下,丙二醇也抵消掉特定的微生物在淀粉溶液中繁盛的趋势。
对于凹版印刷应用而言,说明书中所使用的用语“单程”意图指代使用一个滚筒进行印刷。对于其它的印刷应用,用语“单程”意指整个条带或图案只施加一次的方法。
当在说明书中关于数值使用“大约”一词时,其指相关数值关于所述数值包含±10%的公差。另外,当在说明书中涉及百分比时,其指那些百分比基于重量,即重量百分比。
另外,当关于几何形状使用词语“大致”和“基本”时,其意为并不要求该几何形状的精度,而是该形状的机动幅度处于本公开的范围内。当关于几何术语使用时,用语“大致”和“基本”意为不仅包括满足严格定义的特征,而是还有相当逼近严格定义的特征。
很明显,在本文中以详细地足以使本领域普通技术人员能够理解的方式描述了一种新的改进的和非显而易见的用于制造图案化的包装物的方法。另外,对于本领域技术人员而言显而易见的是,本发明的特征存在多种修改、变化、代替物和等效物,它们实质上并不偏离本发明的精神和范围。相应地,明显意图通过所附权利要求来包含落入由所附权利要求所限定的本发明的精神和范围之内的这些修改、变化、代替物和等效物。
Claims (18)
1.一种制备适用于印刷的水状淀粉的能够印刷的溶液的方法,包括如下步骤:
将至少水和淀粉混合以形成水状淀粉溶液;
将所述水状淀粉溶液加热到至少180℉的温度下,并将所述水状淀粉溶液维持在所述温度来烹煮所述水状淀粉溶液至少30分钟的时间,所述时间足以释放直链淀粉和支链淀粉中的至少一种;
将丙二醇与所烹煮的水状淀粉溶液混合,所述丙二醇的量为所述能够印刷的溶液的7%到10%重量,其足以提供抗皱能力和抗菌能力,从而得到了能够印刷的溶液;
在印刷之前进一步向所述能够印刷的溶液中添加碳酸钙,其中,在所述加热和所述维持的步骤之后和在印刷步骤之前向能够印刷的溶液中添加碳酸钙;并且将所述能够印刷的溶液冷却到从120℉到150℉的范围内的温度。
2.一种用于制造吸烟用品的图案化的包装物的方法,包括如下步骤:
根据权利要求1所述的方法制备能够印刷的溶液;并且
提供包装物的基体卷材;
以预定的图案将所述能够印刷的溶液施加到所述包装物上;并且
在所述制备步骤和所述施加步骤之间,将所述能够印刷的溶液维持在位于从120℉到150℉的范围内的温度。
3.根据权利要求1或2所述的方法,其特征在于,所述将至少水和淀粉混合的步骤包括加入氧化淀粉。
4.根据权利要求1或2所述的方法,其特征在于,还包括在加热步骤中搅拌所述水状淀粉溶液。
5.根据权利要求2所述的方法,其特征在于,所述能够印刷的溶液以横向延伸的条带施加到具有纵向方向的基体卷材上。
6.根据权利要求2所述的方法,其特征在于,在加入丙二醇后,所述能够印刷的溶液具有处于从4±4×10%到5±5×10%的范围中的pH值。
7.根据权利要求2所述的方法,其特征在于,所述基体卷材具有纵向方向,并且其中所述预定图案包括纵向延伸的条纹。
8.根据权利要求2所述的方法,其特征在于,所述基体卷材具有横向方向和纵向方向,并且其中所述预定图案包括位于所述基体卷材上的多个横向延伸并且纵向间隔开的区域。
9.根据权利要求2所述的方法,其特征在于,所述施加选自下述组,所述组包括凹版印刷、苯胺印刷、胶版印刷、喷墨印刷、喷涂和模印。
10.根据权利要求2所述的方法,其特征在于,所述能够印刷的溶液单程式地施加到所述基体卷材上。
11.根据权利要求1或2所述的方法,其特征在于,在冷却步骤之后,所述能够印刷的溶液具有从40cP到60cP的范围内的粘度,所述粘度在120℉下使用20rpm的具有#1心轴的Brookfield RVDV-2粘度计来测量。
12.根据权利要求2所述的方法,其特征在于,在将所述能够印刷的溶液维持在位于从120℉到150℉的范围内的温度的步骤中,将温度维持至少30分钟或更多。
13.根据权利要求1或2所述的方法,其特征在于,所述至少水和淀粉在75℉±75×10%的温度下混合。
14.根据权利要求3所述的方法,其特征在于,在加热步骤之后,所述水状淀粉溶液具有从50cP到80cP的粘度,所述粘度在120℉下使用20rpm的具有#1心轴的Brookfield RVDV-2粘度计来测量。
15.根据权利要求2所述的方法,其特征在于,在施加到基体卷材上时,所述能够印刷的溶液的粘度为18秒±18×10%,所述粘度在120℉下使用Zahn#2杯来测量。
16.根据权利要求2所述的方法,其特征在于,在施加时所述能够印刷的溶液的固体含量为21%±21%×10%,在120℉下由Zahn#2杯来测量,所述能够印刷的溶液的粘度处于从16.5秒±16.5×10%到19.5秒±19.5×10%的范围内,并且所述能够印刷的溶液单程式地施加到基体卷材上。
17.根据权利要求1所述的方法,其特征在于,将所述能够印刷的溶液保持在恒定的搅拌下。
18.通过权利要求2所述的方法形成的图案化的包装。
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- 2011-12-13 MX MX2013006665A patent/MX2013006665A/es not_active Application Discontinuation
- 2011-12-13 US US13/324,747 patent/US9302522B2/en active Active
- 2011-12-13 PL PL17197328T patent/PL3287016T3/pl unknown
- 2011-12-13 KR KR1020137018178A patent/KR20140018213A/ko not_active Application Discontinuation
- 2011-12-13 BR BR112013014848A patent/BR112013014848A2/pt not_active Application Discontinuation
- 2011-12-13 CN CN201510524184.6A patent/CN105238128A/zh active Pending
- 2011-12-13 WO PCT/US2011/064676 patent/WO2012082757A2/en active Application Filing
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Also Published As
Publication number | Publication date |
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CN103403108A (zh) | 2013-11-20 |
JP5942206B2 (ja) | 2016-06-29 |
EP3287016B1 (en) | 2021-08-18 |
PL3287016T3 (pl) | 2022-02-21 |
EP3287016A1 (en) | 2018-02-28 |
WO2012082757A3 (en) | 2013-10-10 |
US20120285477A1 (en) | 2012-11-15 |
EP2651255A2 (en) | 2013-10-23 |
EP2651255A4 (en) | 2014-10-29 |
CA2821282A1 (en) | 2012-06-21 |
RU2013132160A (ru) | 2015-01-20 |
RU2592017C2 (ru) | 2016-07-20 |
EP2651255B1 (en) | 2017-11-15 |
CN105238128A (zh) | 2016-01-13 |
BR112013014848A2 (pt) | 2016-07-19 |
CA2821282C (en) | 2019-02-19 |
WO2012082757A2 (en) | 2012-06-21 |
KR20140018213A (ko) | 2014-02-12 |
US9302522B2 (en) | 2016-04-05 |
MX2013006665A (es) | 2013-11-06 |
JP2014507122A (ja) | 2014-03-27 |
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