Field of the Invention

The present invention relates to methods of manufacturing a packaging insert containing elongate elements, particularly but not exclusively to methods of

manufacturing a packaging insert containing smoking articles, as well as packaging inserts for containing elongate elements.

Background

Many variations of packs for elongate elements, such as smoking articles, are known. Methods of inserting elongate elements into such packs are required. For example, a plurality of smoking articles may be packaged into one pack.

Summary of the Invention

In accordance with embodiments of the invention, there is provided a method of manufacturing a packaging insert containing elongate elements, the packaging insert comprising a first web and a second web, the method comprising:

(i) providing a continuous feed of a first web having grooves running lateral to the direction of travel of the first web, each groove shaped to receive a single elongate element;

(ii) feeding elongate elements into the grooves of the first web;

(iii) providing a continuous feed of a second web over the elongate

elements located in the grooves of the first web resulting in a series of individual pockets each containing a single elongate element.

The elongate elements may be fed into the grooves of the first web by any suitable means including but not limited to providing a rotating drum member that feeds elongate elements to the first web at a rate that matches the rate at which each groove of the first web is fed to the feed of elongate elements.

Elongate elements may be, but are not limited to, any cylindrical article.

Examples of suitable elongate elements include but are not limited to smoking articles and electronic cigarettes. As used herein, the term "smoking article" includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products. The smoking article maybe provided with a filter for the gaseous flow drawn by the smoker. Other suitable elongate elements include any delicate or degradable items such as but not limited to halogen bulbs and glass ampules. Glass test-tubes containing one, two, three or more smoking articles may also be appropriate.

The grooves of the first web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves of the first web may have a V-shaped cross section or a U-shaped cross section.

Alternatively, the grooves of the first web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section.

The first web may be corrugated. That is, the first web may have a series of parallel grooves and ridges running lateral to the direction of travel of the first web. The grooves and ridges of the first web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves and ridges of the first web may have a V-shaped cross section or a U-shaped cross section. Alternatively, the grooves and ridges of the first web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section. The second web may have no grooves and no ridges.

Alternatively, the second web may have grooves running lateral to the direction of travel of the second web. The grooves of the second web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves of the second web may have a V-shaped cross section or a U- shaped cross section. Alternatively, the grooves of the second web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section.

The second web may be corrugated. That is, the second web may have a series of parallel grooves and ridges running lateral to the direction of travel of the second web. The grooves and ridges of the second web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves and ridges of the second web may have a V-shaped cross section or a U- shaped cross section. Alternatively, the grooves and ridges of the second web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section. The second web may be located over the elongate elements such that the grooves of the second web face and align with the grooves of the first web.

The grooves (and ridges) of the first web and the second web may have the same shaped cross section.

For example, the first web and the second web may both have grooves having a three-sided polygonal shaped cross section, wherein the continuous feed of the second web is positioned over the first web so that the grooves of the second web face and align with the grooves of the first web resulting in a series of individual hexagon shaped pockets each containing a single elongate element.

The grooves (and ridges) of the first web and/or the grooves (and ridges) of the second web maybe equally spaced along the direction of travel of each web.

The first and second webs may be made of the same material or of different materials. Any suitable material may be used including but not limited to thin walled card. In embodiments of the invention in which the packaging inserts are further modified in order to individually seal each pocket, the first and second webs maybe impervious to water, moisture and/or air. In such circumstances, the first and second webs maybe made of one material that is impervious to water/moisture/air.

Alternatively, the first/second web may comprise any suitable base material, such as thin walled card, board, film or foil, and further comprise a layer or membrane that is impervious to water, moisture and/or air.

The first web may have a width that is equal to the length of the elongate elements or may have a width that is less than the length of the elongate elements.

The second web may have a width that is equal to the length of the elongate elements or may have a width that is less than the length of the elongate elements.

The width of the first web may be the same as the width of the second web. For example, the width of the first web and the second web may be the same and be equal to the length of the elongate elements. Alternatively, the width of the first web and the second web may be the same and be less than the length of the elongate elements. The width of the first web and the second web may be different. For example, the width of the first web may be less than the width of the second web. In such circumstances, the width of the first web may be the same as the length of the elongate elements. Alternatively, the width of the first web may be less than the length of the elongate elements.

The first and second webs may be joined together. For example, the first and second webs may be bonded together. Any suitable bonding means may be employed including but not limited to adhesive.

The first web and the second web may be joined together where the second web contacts with areas between the grooves of the first web. For example, a first web having grooves and ridges may be joined to a second web where the second web contacts the ridges of the first web facing the second web. A first web having grooves and ridges may be joined to a second web having grooves and ridges where the ridges of the first web contact the ridges of the second web facing the first web.

The method may further comprise sealing one or both ends of the individual pockets. For example, both ends of each pocket may be sealed, wherein at least one of the ends is temporarily sealed, e.g. the seal may be removed allowing individual access to each pocket containing a single elongate element.

A temporary seal may comprise perforations arranged so as to allow access to each individual pocket.

In one embodiment, one end of each individual pocket is permanently sealed and the other end is temporarily sealed.

The step of sealing one or both ends of the individual pockets may comprise positioning a continuous strip along the (open) ends of the individual pockets and joining the strip to the pockets creating a seal.

The strip may be the same width as the depth of the grooves of the first web or the same width as the combined depth of the grooves of the first and second webs (in embodiments in which the pockets are formed by a first web and a second web both having grooves that face and align with each other). Joining the continuous strip to the end of the individual pockets may be carried out in any suitable way including but not limited to bonding the strip to the ends of the individual pockets. For example, the continuous strip maybe heat bonded to the ends of the individual pockets.

Positioning such a continuous strip at the ends of the individual pockets may create a temporary seal or a permanent seal. For example, a temporary seal may be created by providing a continuous strip having a series of perforated lines arranged lateral to the length of the strip so that perforation of one or more perforated lines allows access to one individual pocket containing an elongate element.

The strip may be made of the same material as the first and/or second webs, or can be different from the first and/or second webs. The strip maybe made from any suitable material including but not limited to thin walled card, foil, opaque foil, or plastic such as transparent or translucent plastic. In some embodiments, the seal is impervious to water, moisture and/or air.

Alternatively, the step of sealing one or both ends of the individual pockets may comprise folding part of the second web such that it covers the ends of the pockets creating a seal. Such a step may be possible when the second web has no grooves and no ridges, and has a width greater than the width of the first web. The second web may be folded along an axis running in the direction of travel of the second web. For example, the width of the first web may be less than the width of the second web, such that the width of the second web extends beyond the width of the first web, providing an additional width of second web in relation to the first web. The second web is then folded such that the additional width of the second web is positioned over one end of the series of individual pockets containing elongate elements thereby sealing one end of the individual pockets. The individual pockets may be sealed in this way at one end or both ends.

The seals may be of any suitable shape including but not limited to semicircular, triangular, and hexagonal. For example, a seal may be the same shape and size as the end of each individual pocket. Alternatively, the seal has a size greater than the end of each individual pocket. The seal would therefore overlap the pocket providing an easy way of removing a temporary seal from the end of an individual pocket.

The steps above may create a permanent seal or a temporary seal.

In the context of a temporary seal, the additional width of the second web may further comprise a series of perforations arranged laterally in relation to the direction of travel of the second web and extending from the edge of each individual pocket (where the first web joins the second web) to the edge of the second web.

Any kind of temporary seal may further comprise a tab for facilitating removal of the seal from the end of the pockets. The tab allows the user to effectively and efficiently remove the seal and gain access to an elongate element inside each pocket. A tab may be of any suitable shape including but not limited to semicircular.

In any embodiment of the invention, the packaging insert prepared by the methods described above may be further processed in order to provide packaging inserts having a variety of different arrangements. For example, any method of the invention described herein may further comprise rolling the resulting packaging insert containing elongate elements. In one embodiment, the packaging insert is rolled such that the first web is positioned on the inside of the roll.

Alternatively, any method of the invention may further comprise folding the packaging insert. For example, the packaging insert may be folded into a triangular configuration in which the first web is located on the inside of the triangular configuration, or in which the first web is located on the outside of the triangular configuration. Alternatively, any method of the invention may further comprise folding the packaging insert such that a first section of individual pockets overlays a second section of individual pockets providing a packaging insert having at least two layers of individual pockets. Preferably, overlaying a section of individual pockets with a different section of individual pockets provides a further series of individual pockets located between them each capable of containing a single elongate element. In one such embodiment, the packaging insert maybe folded further such that a third area of individual pockets overlays the first and second areas providing a further series of individual pockets each capable of containing a single elongate element. In accordance with embodiments of the invention, there is provided a method of manufacturing a packaging insert containing elongate elements, the packaging insert comprising a first web and a second web, the method comprising:

(i) providing a continuous feed of a first web having grooves running lateral to the direction of travel of the first web, each groove shaped to fit a single elongate element;

(ii) providing a continuous feed of a second web;

(iii) arranging the second web and the first web so as to provide a

packaging insert having a series of individual pockets shaped to fit an elongate element; and

(iv) inserting a single elongate element into each individual pocket.

Elongate elements may be, but are not limited to, any cylindrical article.

Examples of suitable elongate elements include but are not limited to smoking articles and electronic cigarettes. As used herein, the term "smoking article" includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products. The smoking article maybe provided with a filter for the gaseous flow drawn by the smoker. Other suitable elongate elements include any delicate or degradable items such as but not limited to halogen bulbs and glass ampules. Glass test-tubes containing one, two, three or more smoking articles may also be appropriate.

The elongate elements may be inserted into the pockets in any suitable way including but not limited to providing a rotating drum roller having a supply of elongate elements located around its circumference, positioning the drum roller laterally alongside the packaging insert having a series of individual pockets, moving laterally an elongate element into each pocket, wherein the drum roller rotates so as to feed elongate elements to the pockets at a rate that matches the rate at which individual pockets are fed to the supply of elongate elements.

The grooves of the first web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves of the first web may have a V-shaped cross section or a U-shaped cross section. Alternatively, the grooves of the first web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section.

The first web may be corrugated. That is, the first web may have a series of parallel grooves and ridges running lateral to the direction of travel of the first web. The grooves and ridges of the first web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves and ridges of the first web may have a V-shaped cross section or a U-shaped cross section. Alternatively, the grooves and ridges of the first web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section.

The second web may have no grooves and no ridges.

Alternatively, the second web may have grooves running lateral to the direction of travel of the second web. The grooves of the second web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves of the second web may have a V-shaped cross section or a U- shaped cross section. Alternatively, the grooves of the second web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section.

The second web may be corrugated. That is, the second web may have a series of parallel grooves and ridges running lateral to the direction of travel of the second web. The grooves and ridges of the second web may have any suitable shaped cross section so that each groove is shaped to receive a single elongate element. For example, the grooves and ridges of the second web may have a V-shaped cross section or a U- shaped cross section. Alternatively, the grooves and ridges of the second web may have a polygonal shaped cross section such as a three-sided polygonal shaped cross section.

The second web may be arranged in relation to the first web such that the grooves of the second web face and align with the grooves of the first web.

The grooves (and ridges) of the first web and the second web may have the same shaped cross section. For example, the first web and the second web may both have grooves having a three-sided polygonal shaped cross section, wherein the second web is joined to the first web so that the grooves of the second web face and align with the grooves of the first web resulting in a series of individual hexagon shaped pockets each containing a single elongate element. The grooves (and ridges) of the first web and/ or the grooves (and ridges) of the second web maybe equally spaced along the direction of travel of each web.

The first and second webs may be made of the same material or of different materials. Any suitable material may be used including but not limited to thin walled card. In embodiments of the invention in which the packaging inserts are further modified in order to individually seal each pocket, the first and second webs maybe impervious to water, moisture and/or air. In such circumstances, the first and second webs maybe made of one material that is impervious to water/moisture/air.

Alternatively, the first/second web may comprise any suitable base material, such as thin walled card, board, film or foil, and further comprise a layer or membrane that is impervious to water, moisture and/or air.

The first web may have a width that is equal to the length of the elongate elements or may have a width that is less than the length of the elongate elements.

The second web may have a width that is equal to the length of the elongate elements or may have a width that is less than the length of the elongate elements.

The width of the first web may be the same as the width of the second web. For example, the width of the first web and the second web may be the same and be equal to the length of the elongate elements. Alternatively, the width of the first web and the second web maybe the same and be less than the length of the elongate elements.

The width of the first web and the second web may be different. For example, the width of the first web may be less than the width of the second web. In such circumstances, the width of the first web may be the same as the length of the elongate elements. Alternatively, the width of the first web may be less than the length of the elongate elements. The first and second webs may be joined together. For example, the first and second webs may be bonded together. Any suitable bonding means may be employed including but not limited to adhesive.

The first web and the second web may be joined together where the second web contacts with areas between the grooves of the first web. For example, a first web having grooves and ridges may be joined to a second web where the second web contacts the ridges of the first web facing the second web. A first web having grooves and ridges may be joined to a second web having grooves and ridges where the ridges of the first web contact the ridges of the second web facing the first web.

The method may further comprise sealing one or both ends of the individual pockets. For example, both ends of each pocket may be sealed, wherein at least one of the ends is temporarily sealed, e.g. the seal may be removed allowing individual access to each pocket containing a single elongate element.

A temporary seal may comprise perforations arranged so as to allow access to each individual pocket. In one embodiment, one end of each individual pocket is permanently sealed and the other end is temporarily sealed.

The step of sealing one or both ends of the individual pockets may comprise positioning a continuous strip along the (open) ends of the individual pockets and joining the strip to the pockets creating a seal.

The strip may be the same width as the depth of the grooves of the first web or the same width as the combined depth of the grooves of the first and second webs (in embodiments in which the pockets are formed by a first web and a second web both having grooves that face and align with each other).

Joining the continuous strip to the end of the individual pockets may be carried out in any suitable way including but not limited to bonding the strip to the ends of the individual pockets. For example, the continuous strip may be heat bonded to the ends of the individual pockets. Positioning such a continuous strip at the ends of the individual pockets may create a temporary seal or a permanent seal. For example, a temporary seal may be created by providing a continuous strip having a series of perforated lines arranged lateral to the length of the strip so that perforation of one or more perforated lines allows access to one individual pocket containing an elongate element.

The strip may be made of the same material as the first and/or second webs, or can be different from the first and/or second webs. The strip maybe made from any suitable material including but not limited to thin walled card, foil, opaque foil, or plastic such as transparent or translucent plastic. In some embodiments, the seal is impervious to water, moisture and/or air.

Alternatively, the step of sealing one or both ends of the individual pockets may comprise folding part of the second web such that it covers the ends of the pockets creating a seal. Such a step may be possible when the second web has no grooves and no ridges, and has a width greater than the width of the first web. The second web may be folded along an axis running in the direction of travel of the second web.

For example, the width of the first web may be less than the width of the second web, such that the width of the second web extends beyond the width of the first web, providing an additional width of second web in relation to the first web. The second web is then folded such that the additional width of the second web is positioned over one end of the series of individual pockets containing elongate elements thereby sealing one end of the individual pockets. The individual pockets maybe sealed in this way at one end or both ends.

The seals may be of any suitable shape including but not limited to semicircular, triangular, and hexagonal. For example, a seal may be the same shape and size as the end of each individual pocket. Alternatively, the seal has a size greater than the end of each individual pocket. The seal would therefore overlap the pocket providing an easy way of removing a temporary seal from the end of an individual pocket.

The steps above may create a permanent seal or a temporary seal. In the context of a temporary seal, the additional width of the second web may further comprise a series of perforations arranged laterally in relation to the direction of travel of the second web and extending from the edge of each individual pocket (where the first web joins the second web) to the edge of the second web.

Any kind of temporary seal may further comprise a tab for facilitating removal of the seal from the end of the pockets. The tab allows the user to effectively and efficiently remove the seal and gain access to an elongate element inside each pocket.

A tab may be of any suitable shape including but not limited to semicircular. In accordance with embodiments of the invention, there is provided a packaging insert prepared by a method according to any one of the embodiments described herein.

In accordance with embodiments of the invention, there is provided a packet comprising within it a packaging insert of the present invention.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure ι shows an example of a method of the present invention and an apparatus suitable for carrying out such a method of manufacturing a packaging insert.

Figure 2 shows an example of how a method of manufacturing a packaging insert containing two parallel lines of elongate elements can be carried out.

Figure 3 shows an example of a packaging insert obtainable by a method of the present invention.

Figures 4a and 4b show an example of a packaging insert obtainable by a method of the invention and how such a packaging insert may be rolled.

Figure 5 shows an example of how the individual pockets of the packaging insert may be sealed in accordance with one embodiment of the invention.

Figure 6 shows an alternative example of how the individual pockets of the packaging insert may be sealed in accordance with one embodiment of the invention.

Figures 7a and 7b show an alternative example of how the individual pockets of the packaging insert may be sealed in accordance with one embodiment of the invention.

Figure 8 shows an example of a packaging insert in a rolled configuration having individual pockets that are sealed. Figures 9a and 9b show examples of packaging inserts in a triangular configuration having individually sealed pockets.

Figures loa-iod show examples of drum rollers that can be employed in some embodiments of the invention and a cross section of a first web that can be used with the same.

Figures 11a, 11b, 12a and 12b show examples of different packaging inserts in configurations that are designed to be folded.

Figure 13 shows an example of a method of the invention and manufacturing apparatus suitable for carrying out such a method in which a first web having grooves is prepared using a vacuum mould.

Figures 14 and 15 show examples of methods of the invention and manufacturing apparatus for carrying out such methods in which elongate elements are inserted into individual pockets after the pockets have been formed. Detailed Description

It is desirable to package elongate elements in a manner that provides protection from bending and/or crushing during transportation and/or storage of the elements. It is also desirable to package elongate elements, in particular smoking articles, in a manner that improves customer experience both during the opening and withdrawing of the element from its container and preserving the element for longer in its desired state ready for use. In this respect, a packaging insert may be employed that retains one or more elongate elements and improves the protection provided by the packaging as a whole. Such a packaging insert may then be incorporated into a packet, e.g. a cigarette packet.

However, methods for manufacturing a packaging insert containing elongate elements can be complicated, slow and inefficient. In contrast, the methods of the invention provide continuous processes for manufacturing packaging inserts containing elongate elements that are efficient and highly adaptable.

In the following examples, the methods of the invention are described in the context of packaging inserts containing smoking articles, although the methods of the invention should not to be viewed as limited as such. The methods of the invention are applicable to any suitable elongate element. The term "smoking article" includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products.

Figure 1 shows an example of a method in accordance with one embodiment of the invention. A continuous feed of a web 7 is provided and supplied to a pair of corrugating rollers 2 which convert the web 7 to a continuous feed of first web 1 having parallel grooves and ridges running lateral to the direction of travel of the first web 1. The shape of the grooves and ridges is not limited. They may have a V-shaped cross section, a U-shaped cross section, or may have a semi-hexagonal (i.e. half a hexagon) cross section. Figure 1 shows the first web 1 with grooves and ridges that are uniform and shaped to receive a single smoking article. A continuous supply of smoking articles 3 is provided and the smoking articles 3 are fed into each groove on one side of the first web 1. A continuous supply of a second web 4 is provided and the second web 4 is fed over the smoking articles 3 located in the grooves of the first web 1 providing a series of individual pockets 5 each containing a single smoking article 3.

In an alternative, the method is carried out but in which the smoking articles are fed into the grooves of the first web from above therefore allowing gravity to aid the placement of the smoking articles into the grooves. The second web is then fed over the smoking articles located in the grooves of the first web providing a series of indivisual pockets each containing a single smoking article.

The smoking article can be placed/ nested inside this purposefully designed and sized shape created by the first web 1 having grooves and ridges thus giving it protection from bending and/ or crushing during transportation and/ or storage of the packet. The nature of the individual pockets 5 and the way in which they are manufactured provides rigidity (and thus protection) in the both the axial and radial directions considered in relation to the longitudinal centreline axis of the smoking article 3.

The series of individual pockets containing smoking articles may subsequently be cut to size and packaged in an appropriate way for storage and/or transport. For example, they could be divided into a selected number of individual pockets and/ or folded. The smoking articles 3 may be fed to the grooves of the first web 1 in a number of ways. For example, as shown in Figure 1 the smoking articles 3 maybe fed to the grooves of the first web 1 by a conveyor belt 6. The conveyor belt 6 feeds the smoking articles 3 to the first web 1 at a rate that matches the rate at which each groove of the first web 1 is fed to the supply of smoking articles 3.

An alternative way of feeding smoking articles to the grooves of the first web is illustrated in Figure 2. In Figure 2, the smoking articles 23 are fed into the grooves using a drum member 212 that feeds smoking articles 23 to the first web 21 at a rate that matches the rate at which each groove of the first web 21 is fed to the supply of smoking articles 23. The smoking articles 23 maybe maintained in place on the drum member 212 using suction.

Not shown in Figure 2 and not limited to the method exemplified in Figure 2, the supply of smoking articles 23 may be fed directly from an apparatus for

manufacturing the smoking articles, e.g. a smoking article maker, or may be fed via a buffer or reservoir holding a supply of smoking articles.

More specifically, Figure 2 illustrates a method in accordance with one embodiment of the invention useful for producing a packaging insert comprising two parallel series of individual pockets 25. A continuous supply of a first web 21 having grooves and ridges running lateral to the direction of travel of the first web 21 is provided. The first web 21 is prepared by feeding a web 213 to a pair of corrugation rollers 22. The corrugation rollers 22 each have three sections along their axial length. A first section 26 and a third section 27 located at each end of corrugated rollers 22 have a corrugated surface. A second section 28 located between the first section 26 and the third section 27 is uncorrugated. The resulting first web 21 having grooves and ridges therefore also has three regions arranged laterally in relation to the direction of travel of the first web 21. Region 29 and region 211 located at each lateral edge of the first web 21 have grooves and ridges (formed by the corrugated sections 26 and 27 respectively). Region 211 of the first web located laterally between section 29 and section 210 has no grooves and ridges (having passed between the uncorrugated second section 28).

A supply of smoking articles 23 is continuously fed into the grooves of the first web 21. As described above, the smoking articles 23 are fed into the grooves using a drum member 212 that feeds smoking articles 23 to the first web 21 at a rate that matches the rate at which each groove of the first web 21 is fed to the supply of smoking articles 23. The smoking articles 23 may be maintained in place on the drum member 212 using suction.

As seen in Figure 2, the width (the lateral dimension in relation to the direction of travel of the first web 21) of each section of the first web 21 having grooves and ridges maybe the same length as the smoking articles 23. A continuous supply of a second web 24 is provided and is fed over the smoking articles 23 located in the grooves of one side of the first web 21.

In Figure 2, the second web 24 has no grooves and no ridges. As a result, the method exemplified in Figure 2 provides two series of parallel individual pockets 25 each containing a single smoking article 23. The two series of individual pockets 25 are parallel and correspond to the grooves and ridges provided by sections 29 and 210 of the first web 21 and are separated by a region corresponding to section 211 of the first web having no grooves and ridges and no smoking articles. A packaging insert comprising a first web and a second web having this type of arrangement may subsequently be folded, for example along the boundary of section 29 and section 211 and/or along the boundary of section 210 and section 211. However, it will be appreciated that the invention as defined in the claims is capable of processing a series of individual pockets in different configurations by simple modification of the methods described herein.

Figure 3 shows an example of a packaging insert obtainable by a method of the present invention. The packaging insert 30 comprises a first web 31 that has grooves and ridges that are uniform in shape and size and a second web 32 that does not have grooves and ridges. Each groove is shaped to receive a single smoking article 33. The first web 31, the second web 32, and the smoking articles 33 are arranged so as to provide a series of parallel individual pockets 34 each containing a single smoking article 33. The first web 31 shown in Figure 3 has a width that is less than the length of the smoking article 33. The second web 32 shown in Figure 3 has a width that is essentially equal to the length of the smoking articles 33. The packaging insert shown in Figure 3 therefore provides support and protection to the smoking articles 33 as well as improved access to the smoking articles 33 and an improved view of the smoking articles 33 when in the packaging insert 30.

Figures 4a and 4b show how a packaging insert 30 similar to that shown in Figure 3 having a first web 31 with grooves and ridges and a second web 32 arranged so as to provide a series of individual pockets 34 each containing a single smoking article 33 maybe rolled. In particular, the packaging insert maybe rolled such that the first web 31 having a width less than the width of the second web 32 is positioned on the inside of the roll. Figure 4b shows the packaging insert 30 in rolled form. The packaging insert 30 provides improved support and protection for the smoking articles 33·

As previously explained, the method may further comprise a step of sealing one or both ends of the individual pockets. For example, the pockets maybe individually sealed at both ends. Complete sealing of each pocket in this way provides a way of keeping the smoking article in its optimised environment to which it is best suited. In particular, the state of the smoking article just after manufacture may be maintained. Environmental factors such as moisture and humidity can adversely affect a smoking article over time. Sealing the individual pockets containing a smoking article helps avoid the negative effects such environmental factors can cause. By preserving the individual smoking articles in their own individual pocket/environment until they are smoked allows each smoking article to be at its optimised and intended state when it is smoked. Smoking articles that have been left for a period of time in an unsealed packet during which time they have been subjected to varying humidity and other

environmental conditions, can when smoked lead to a harsher taste and hence a degraded smoking experience.

The seals for use in the present invention may be made out of any suitable material including, but not limited to, opaque foil and transparent or translucent plastic. The seals may also be made out of the same material as the first and/or second webs.

For example, Figure 5 shows one possible method of sealing individual pockets 54 in accordance with one embodiment of the invention. A series of individual pockets 54 is provided formed by a first web 51 having grooves and ridges and a second web 52 (which is shown in Figure 5 as having no grooves and ridges) each pocket containing a single smoking article 53. The series of individual pockets 54 may be prepared according to any suitable embodiment of the invention, such as the embodiment exemplified in Figure 1. To this series of individual pockets 54 are supplied two continuous strips 55 which are positioned over each end of the individual pockets 54. The resulting arrangement is then fed to a means 58 of heat sealing the continuous strip 56 to the ends of the individual pockets 54. Although it will be appreciated that other means of bonding the continuous strips to the ends of the pockets are possible.

Any seal added to the packaging insert may have perforations so that each individual pocket containing a smoking article can be accessed independently. For example, in Figure 5, each strip has equally spaced perforations 56 arranged lateral to the length of the strip 55 so that perforation of a pair of adjacent perforations 56 allows access to one individual pocket 54 containing a single smoking article 53. The strip 55 is fed to each end of the series of individual pockets 54 so that a pair of adjacent perforations 56 align with the beginning and end of one pocket 54 and the next. As a result, perforation of a pair of adjacent perforations 56 allows access to one individual pocket 54 containing a single smoking article 53.

Figure 5 illustrates one embodiment of the method of the invention in which a strip 55 is fed to each end of the individual pockets 54. However, in an alternative, the strip 55 could be fed to just one end of the individual pockets. Likewise, in one embodiment the individual pockets may be permanently sealed at one end and temporarily sealed at the other using a method of sealing as illustrated in Figure 5. In general however a strip may be joined to the end of a series of individual pockets in any suitable way. For example, Figure 6 shows a reel containing a continuous strip 61 that is supplied to and positioned at one end of a series of individual pockets 60 each containing a single smoking article (not shown). The strip of sealing material 61 may be joined to the ends of the individual pockets by any suitable means, for example using an adhesive.

The strip of sealing material 61 shown in Figure 6 also has equally spaced perforations 62 arranged laterally along the length of the strip 61. The strip 61 is fed to one end of the individual pockets 60 so that a pair of adjacent perforations 62 align with the beginning and end of one pocket and the next. As a result, perforation of a pair of adjacent perforations 62 allows access to one individual pocket 60 containing a single smoking article (not shown).

In accordance with some embodiments of the invention, the individual pockets containing smoking articles may be sealed at least at one end and possibly at both ends. These seals may be permanent and/ or temporary. As explained above, temporary seals may further comprise a tab. A seal with a tab provides improved access to each smoking article positioned in each individual pocket. For example, the strip 61 shown in Figure 6 has a tab 63 located between every pair of perforations 62. The tab 63 provides an effective way of pulling the seal 61 away from the end of each individual pocket 60, thus perforating a pair of adjacent perforations 62 and allowing access to a smoking article.

Alternatively, a seal may be incorporated into a packaging insert as illustrated in Figures 7a and 7b. Figures 7a and 7b show a packaging insert 71 made up of a series of parallel individual pockets 72 each pocket containing a single smoking article 73. The packaging insert is made up of two webs. The first web 75 has grooves and ridges having a V-shaped cross section and the second web 74 is flat. The second web 74 is wider than the first web 75 and therefore a portion of the second web 74 extends beyond each pocket 72 and beyond the smoking article 73 within each pocket 72. The portion of the second web 74 extending beyond each pocket 72 is folded along an axis 76 (shown in Figure 7a) running the length of the second web 74 and along the ends of the individual pockets 72. When folded (as shown by the arrows in Figures 7a and 7b), the extension of the second web 74 provides a seal over the ends of the individual pockets 72. Each individual pocket can then be opened as shown in Figure 7b by pulling the seal away from the end of individual pocket 72 and allowing access to the smoking article 73 contained within it. Figures 8, 9a and 9b illustrate other ways in which seals can be added to a packaging insert. For example, Figure 8 shows a packaging insert 80 comprising a first web 81 having grooves and ridges and a second web 82 providing a series of individual pockets 84 each pocket 84 containing a single smoking article 83. Although not essential, the packaging insert 80 of Figure 8 is shown in a rolled configuration. Each individual pocket 84 also has a seal 85 attached to one end allowing access to each smoking article 83 in each pocket 84. The seal 85 in Figure 8 also comprises a tab 86 to facilitate removal of the seal 85 from the end of the pocket 84.

Figures 9a and 9b show packaging inserts 90 obtainable by methods of the present invention. The packaging inserts 90 comprise a first web 91 having grooves and ridges and a second web 92 arranged so as to provide a series of individual pockets 94, each pocket containing a single smoking article 93. The second web 92 in both cases has no grooves or ridges. In Figure 9a the grooves and ridges of the first web 91 have a V-shaped cross section, whereas in Figure 9b they have a U-shaped cross section. The individual pockets 94 each have a seal 95 that covers one end of the pockets 94. In both cases the shape of the seal 95 corresponds to the shape of the cross section of the individual pockets 94. In these Figure, the seals 95 are temporary and may be removed to allow access to the smoking articles 93 contained within them. Furthermore, the seals 95 of Figures 9a and 9b further comprise a tab 96 to facilitate the removal of the seals 95 from the ends of the pockets 94.

Figures 9a and 9b also illustrated how the packaging inserts obtained by the present invention maybe modified into different configurations. For example, the packaging inserts 90 of Figures 9a and 9b are both folded into triangular

configurations. However, in Figure 9a the packaging insert 90 is folded such that the individual pockets 94 are located on the inside of the triangular configuration, whereas in Figure 9b the packing insert 90 is folded such that the individual pockets 94 are located on the outside of the triangular configuration. As exemplified above, the methods of the invention are capable of being adapted to provide packaging inserts of various configurations that provide improved support and protection. Further modification of these packaging inserts can provide an array of different configurations, and the reference herein to just a few of the configurations made possible by the present invention should not be viewed as limiting the invention.

Accordingly, the methods of the invention are capable of being adapted so as to provide packaging inserts that optimise their ability to be further modified, e.g. folded or rolled. Packaging inserts obtainniable by the methods of the invention can be configured in a number of different ways providing improved support and protection, as well as improved customer experience. In this respect, the methods of the invention may provide packaging inserts comprising different sections arranged along its length in relation to the direction of travel of the web materials, such as discrete sections having individual pockets each pocket containing a single smoking article separated by a discrete section having no individual pockets. These arrangements allow the packaging inserts to be folded, usually along an axis formed by the boundary of a discrete section having individual pockets and a discrete section without.

For example, Figure 10a shows a drum member 100 that may be employed to feed smoking articles 103 into the grooves 104 of a first web 101 as shown in Figure 10b. Figure 10b shows the first web 101 having discrete regions 102 that do not have grooves and ridges. The discrete regions 102 are arranged along the direction of travel of the first web 101. The drum member 100 also has corresponding discrete regions 104 that do not provide a feed of smoking articles 103. The smoking articles 103 are fed into the grooves 107 using a drum member 100 that feeds the smoking articles 103 to the first web 101 at a rate that matches the rate at which each groove 107 of the first web 101 is fed to the supply of smoking articles 103. The discrete regions 104 located on the drum roll 100 ensure that the feed of smoking articles 103 does not continue when there are no grooves 107 on the first web 101 to receive the smoking articles.

Figures 10c and lod show a similar arrangement as Figures 10a and 10b however roller 105 in Figure 10c comprises two continuous feeds of smoking articles 103. Each feed of smoking articles on roller 105 is the same as the roller 100 shown in Figure 10a. As such, roller 105 comprises two feeds of smoking articles 103 separated by a region 106 that does not provide a feed of smoking articles. A roller 105 could be employed in the method shown in Figure 2.

Figures 11a and 11b show how a packaging insert 110 obtainable from a method as illustrated in Figures 10a and 10b may be further modified. The packaging insert 110 comprises a first web 111 having grooves and ridges and a second web 112 that has no grooves and no ridges. The two webs 111 and 112 are arranged so that they provide a series of individual pockets 115. A single smoking article 113 is located in each pocket 115. Similar to that shown in Figure 3, the packaging insert 110 shown in Figure 11a has at least one discrete region 116 that does not have a series of individual pockets each containing a single smoking article and two regions 117 having pockets 115 either side of region 116. Figure 11a shows how additional smoking articles 114 may be placed in the grooves provided on the outer side of the first web 111. The packaging insert may then be folded as shown in Figures na and lib such that the grooves and ridges of the first web in align with the grooves and ridges of second web 112. The packaging insert 110 is shown in Figure lib in folded form. The packaging insert 110 provides support and protection for all the smoking articles 113 and 114 contained within it.

Figures 12a and 12b show a packaging insert 120 that is similar to that shown in Figures 11a and lib. However, in Figures 12a and 12b the packaging insert 120 has three discrete regions 127, 128, 129 having individual pockets 125 and two discrete regions 126, 1210 that do not have individual pockets. Additional smoking articles may be placed in the grooves provided on the outer surface of sections 128 and 129. The packaging insert 120 may then be folded as shown in Figures 12a and 12b (see arrows). For example, the packaging insert 120 may be folded along the boundary of sections 127 and 126, the boundary of sections 126 and 128, the boundary of sections 128 and 1210, and then the boundary of sections 1210 and 129, such that the grooves provided by the outside surface of section 127 are positioned over the additional smoking articles 1241 located in the grooves provided on the outer surface of section 128 resulting in a series of individual pockets each pocket containing a single smoking article 1241, and the outer surface of section 127 having no grooves and ridges is brought into contact with the grooves containing additional smoking articles 1242 located on the outer surface of section 129 resulting in a further series of individual pockets each pocket containing a single smoking article 1242.

A cross section of the packaging insert 120 in folded form is shown in Figure 12b. The packaging insert 120 provides support and protection to all the smoking articles 123, 1241, 1242 contained within the packaging insert.

Figure 13 shows an embodiment of the invention in which a continuous supply of a first web 131 is provided and fed to a means (not shown) for shaping the first web 131 into a groove shaped for receiving a single smoking article 133. For example, the first web 131 may be shaped using a vacuum mould. A continuous supply of smoking articles 133 is provided and the smoking articles 133 are positioned in the grooves. A continuous supply of a second web 132 is provided over the smoking articles 133 located in the grooves 134 of the first web resulting in a series of parallel individual pockets 135 each containing a single smoking article 133. The second web 132 shown in Figure 13 is made of a transparent material, although it will be appreciated that any suitable material may be employed. The first web 131 may also optionally be made of a transparent material although it will be appreciated that the first web 131 may be made of any suitable material.

Although not explicitly shown in Figure 13, it is also possible to use a first web 131 that is wider (in a lateral direction relative to the direction of travel of the first web 131) than the second web 132. The first web 131 would therefore extend beyond the width of the second web 132 providing an additional width of the first web 131. The additional width of the first web 131 may then be positioned over the ends of the individual pockets 134 creating a seal. In practice, this method of sealing the ends of the pockets maybe carried out at one end or both ends of the individual pockets.

The method illustrated in Figure 13 may therefore be used to prepare individually sealed smoking articles. Sealing smoking articles individually improves the articles shelf life, retains the product's quality in terms of, for example, taste, and improves the consumer's experience.

Any individually sealed elongate element/smoking article may further benefit from being stored in an inert atmosphere. The methods of the invention therefore may further comprise adding an inert gas to the individual pockets before sealing the pockets. For example, nitrogen gas maybe added to the pockets. In some

circumstances, it maybe appropriate to add the inert gas under positive pressure. Adding an inert gas may take place before, during and/ or after the elongate

elements/smoking articles are fed to the grooves/pockets.

Figure 14 shows an example of a method in accordance with one embodiment of the invention. A continuous feed of a web 148 is provided and supplied to a pair of corrugation rollers 146 which convert the web 148 to a continuous feed of a first web 141 having grooves and ridges running lateral to the direction of travel of the first web 141. The shape of the grooves and ridges is not limited. They may have a V-shaped cross section, a U-shaped cross section, or may have a semi-hexagonal (i.e. half a hexagon) cross section. Figure 14 shows the first web 141 with grooves and ridges that are uniform and shaped to receive a single smoking article. A second web 142 is provided and fed to the first web 141 providing a packaging insert 140 having a series of individual pockets 145, each pocket 145 shaped to receive a single smoking article. Smoking articles 143 are then inserted into the pockets 145. A rotating drum 147 is provided having a supply of smoking articles 143 located around its circumference and positioned laterally alongside the packaging insert having a series of individual pockets. A smoking article 143 is moved laterally (see arrow) into each pocket 145. The drum roller 147 rotates so as to feed smoking articles 143 to the pockets 143 at a rate that matches the rate at which the individual pockets 145 of the packaging insert 140 are fed to the supply of smoking articles 143.

Figure 15 shows how the method illustrated in Figure 14 may be modified so as to include a cigarette maker 150 in the apparatus that directly provides a feed of cigarettes 151.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior methods for manufacturing packaging inserts containing elongate elements. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/ or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and

modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.