AEROSOL-GENERATING ROD SEGMENT AND AEROSOL-GENERATING ARTICLE COMPRISING SUCH A SEGMENT

Abstract

An aerosol-generating rod segment is provided, including: a rod-shaped susceptor casing; and an aerosol-forming gel contained in the rod-shaped susceptor casing, in which the rod-shaped susceptor casing includes a bottom, a side wall, and an opening arranged opposite the bottom, in which the aerosol-forming gel is retained inside the rod-shaped susceptor casing in axial direction of the aerosol-generating rod segment by at least one positive locking means, in which the side wall of the rod-shaped susceptor casing is corrugated, in which at least one of the at least one positive locking means is an inwardly directed seam of the rod-shaped susceptor casing arranged adjacent to an end section of the rod-shaped susceptor casing, the end section being arranged opposite the bottom of the rod-shaped susceptor casing, and in which the inwardly directed seam is formed by an inwardly bent end portion of the side wall of the rod-shaped susceptor casing.

Claims

1-15. (canceled)

16. An aerosol-generating rod segment, comprising: a rod-shaped susceptor casing; and an aerosol-forming gel contained in the rod-shaped susceptor casing, wherein the rod-shaped susceptor casing comprises a bottom, a side wall, and an opening arranged opposite the bottom, wherein the aerosol-forming gel is retained inside the rod-shaped susceptor casing in axial direction of the aerosol-generating rod segment by at least one positive locking means, wherein the side wall of the rod-shaped susceptor casing is corrugated, wherein at least one of the at least one positive locking means is an inwardly directed seam of the rod-shaped susceptor casing arranged adjacent to an end section of the rod-shaped susceptor casing, the end section being arranged opposite the bottom of the rod-shaped susceptor casing, and wherein the inwardly directed seam is formed by an inwardly bent end portion of the side wall of the rod-shaped susceptor casing.

17. The aerosol-generating rod segment according to claim 16, wherein the inwardly directed seam of the rod-shaped susceptor casing is an inwardly arranged flange.

18. The aerosol-generating rod segment according to claim 16, wherein at least one of the at least one positive locking means is a radially inwardly directing protrusion.

19. The aerosol-generating rod segment according to claim 18, wherein the radially inwardly directing protrusion is a radially inwardly directing deformation of the side wall of the rod-shaped susceptor casing.

20. The aerosol-generating rod segment according to claim 16, wherein the aerosol-forming gel is retained in the rod-shaped susceptor casing by the at least one positive locking means with clearance in a longitudinal direction of the rod-shaped susceptor casing.

21. The aerosol-generating rod segment according to claim 16, wherein at least one of the at least one positive locking means is arranged along an entire circumference of the rod-shaped susceptor casing.

22. The aerosol-generating rod segment according to claim 16, wherein at least one of the at least one positive locking means is arranged along an entire circumference of the side wall of the rod-shaped susceptor casing.

23. The aerosol-generating rod segment according to claim 16, wherein at least part of the side wall of the rod-shaped susceptor casing is made of a susceptor material.

24. The aerosol-generating rod segment according to claim 16, wherein corrugations of the corrugated side wall of the rod-shaped susceptor casing converge radially inwardly forming the at least one positive locking means.

25. The aerosol-generating rod segment according to claim 16, wherein corrugations of the corrugated side wall of the rod-shaped susceptor casing are aligned in a longitudinal direction of the rod-shaped susceptor casing.

26. The aerosol-generating rod segment according to claim 16, wherein the bottom of the rod-shaped susceptor casing and the side wall of the rod-shaped susceptor casing are made as a single piece.

27. An aerosol-generating article comprising a plurality of segments arranged in an end-to-end position and wrapped in a wrapper to form a rod, the plurality of segments comprising an aerosol-generating rod segment according to claim 16.

28. The aerosol-generating article according to claim 27, wherein the plurality of segments further comprise at least one of a hollow tube, a filter segment, an airflow directing element, and an empty cavity.

29. The aerosol-generating article according to claim 27, wherein the aerosol-generating rod segment is arranged between a hollow acetate tube and a filter segment.

Description

[0169] Examples will now be further described with reference to the figures in which:

[0170] FIG. 1 shows a cup-shaped susceptor casing;

[0171] FIG. 2 shows a cup-shaped susceptor casing with corrugated side wall;

[0172] FIG. 3 shows a manufacturing series using a cup-cake shaped preformed casing;

[0173] FIGS. 4 to 6 schematically show longitudinal cross sections through a susceptor casing;

[0174] FIG. 7 shows an embodiment of an aerosol-generating article comprising an aerosol-generating rod segment;

[0175] FIG. 8 shows another embodiment of an aerosol-generating article comprising an aerosol-generating rod segment;

[0176] FIG. 9 shows yet another embodiment of an aerosol-generating article comprising an aerosol-generating rod segment;

[0177] FIG. 10 shows a further embodiment of an aerosol-generating article comprising an aerosol-generating rod segment;

[0178] FIG. 11 to FIG. 16 shows a manufacturing process of an aerosol-generating article comprising a cup-shaped susceptor;

[0179] FIGS. 17 and 18 show an embodiment of a folded susceptor casing having a polygon-shaped bottom;

[0180] FIGS. 19 and 20 show further embodiments of folded susceptor casings having a polygon-shaped bottom with a bottom folded inside (FIG. 19) and a bottom folded outside (FIG. 20);

[0181] FIG. 21 shows a bottom view, side view and top view of an aluminium casing with inwardly bent rim;

[0182] FIG. 22 shows part of a set-up of an aerosol-generating article manufacturing process; and

[0183] FIGS. 23 to 25 illustrate a process of forming a cup-shaped aluminium casing.

[0184] In FIGS. 1 and 2 embodiments of susceptor casings are shown that are not yet provided with positive locking means.

[0185] In FIG. 1 a perspective side view of a cup-shaped casing 1 is shown. The casing has a bottom 11 and a side wall 12 extending from the bottom 11. The casing 1 has an opening 13 arranged opposite the bottom 11. The casing has the form of an open cylinder with a circular cross section, which cross section is substantially constant over the entire length of the casing. The casing 1 is partly or preferably entirely made of a susceptor material, for example stainless steel. The casing 1 is filled partly or entirely with an aerosol-forming gel (not shown).

[0186] An exemplary eddy current flow in the susceptor casing 1 induced by an inductor, in particular an induction coil arranged around the casing, is indicated with arrows.

[0187] In FIG. 2 a perspective side view of a cup-shaped casing 1 with a corrugated side wall 12 is shown. The corrugations 120 extend from the bottom 11 to the opposite end of the casing 1. The corrugations 120 get continuously more expressed from the bottom 11 into the direction of the opposite opening end. An exemplary eddy current flow in the susceptor casing 1 induced by an inductor, in particular an induction coil arranged around the casing, is indicated with arrows.

[0188] Positive locking means are not shown in FIGS. 1 and 2.

[0189] Exemplary data for casings as shown in FIGS. 1 and 2 are: 12 mg to 75 mg susceptor material; 160 mg aerosol-forming gel; intended temperature for the aerosol-forming gel: about 190 degree Celsius to about 200 degree Celsius. Aerosol-generating rod segments with the mentioned parameters may achieve a vaping experience of a duration of about 360 seconds.

[0190] In FIG. 3 an example of a step by step manufacturing of a casing as shown in FIG. 2 is illustrated. A susceptor sheet material may be preformed into a cup-cake shape as shown in the left drawing of FIG. 3. The radially outwardly directing side wall 12 of the cup-cake shaped casing is pressed radially inwardly until the casing 1 has a substantially same diameter over the entire length of the casing 1.

[0191] The positive locking means for retaining the gel in the casing may subsequently be provided in the casing 1, for example in one of more further manufacturing steps. Preferably, one or more positive locking means are provided in the casing in one further manufacturing step.

[0192] In FIGS. 4 to 6 examples of positive locking means are shown. In FIG. 4 the ends of the side wall 12 of the susceptor casing 1 opposite the bottom 11 of the casing direct inwardly. Preferably, this is achieved by bending the end portion 125 of the side wall 12 of the casing radially inwardly. The end portion 125 then forms a rim diminishing the opening 13 of the casing. The plug of aerosol-forming gel 2 inside the casing 1 may not fall out or be forced out of the opening 13 of the casing 1 as a diameter of the gel plug is larger than the diameter of the opening 13. The inwardly bent end portion 125 of the side wall 12 forms a positive lock for the gel 2 and has a retaining action for the gel in axial direction 4 of the casing 1. In FIG. 4 the susceptor casing 1 is entirely filled with aerosol-forming gel.

[0193] In FIG. 5 next to the inwardly bent end portion 125 of the side wall 12, the casing comprises radially inwardly directing protrusions 126. The protrusions 126 are formed by deformation of the side wall 12. The protrusions 126 are arranged in an intermediate section 128 of the casing 1, in about 40 percent to 60 percent of the length or height of the casing. In FIG. 5 the protrusion is arranged at about 40 percent of the length of the casing 1. Preferably, the protrusion 126 forms a rib that extends partially or entirely around the circumference of the casing. In FIG. 5 about half of the susceptor casing 1 is filled with aerosol-forming gel to about half the height of the casing 1. The protrusion 126 forms a positive lock for the gel 2 without clearance. The inwardly bent end portions 125 form a positive lock with clearance due to the distance between the filling height of the aerosol-forming gel and the inwardly bent end portions 125.

[0194] In FIG. 6 positive locking means are formed in the susceptor casing 1 by radially inwardly directing protrusions 126 arranged at different length positions of the casing 1. A first protrusion 126 is arranged at about 20 percent of the length of the casing 1, while a second protrusion 126 is arranged at about 80 percent of the length of the casing 1 counting from the bottom 11 of the casing 1. The protrusions 126 are formed by deformation of the side wall 12 and form ribs that extend partially or entirely around the circumference of the casing 1. The opening 13 of the casing 1 shown in FIG. 6 has as same diameter as the bottom 11 of the casing 1.

[0195] In the shown examples of FIGS. 4 to 6, protrusions 126 are arranged opposite each other in the casing 1. However, protrusions may also be arranged, for example, in a staggered manner over the height of the casing 1. Several protrusions, for example 3 to 10 protrusions, may be arranged in the casing 1. The sum of protrusions and further positive locking means retain the gel 2 in the casing 1 in axial direction.

[0196] FIG. 7 schematically shows an aerosol-forming article 5 comprising an aerosol-generating rod element 10 according to the invention. The aerosol-generating rod element 10 is a rod element having a corrugated side wall 12. The positive locking means are not shown in FIG. 7.

[0197] The aerosol-forming article 5 is rod-shaped and comprises six segments that are arranged in an end-to-end position. The aerosol-forming article 5 has a mouth end comprising a filter segment 40 at its most proximal end or most downstream end. An aerosol-cooling segment 30 is arranged adjacent to and upstream of the filter segment 40. An empty cavity 20 is arranged between the aerosol-cooling element 30 and the aerosol-forming rod segment 10. At the distal end of the aerosol-generating article 5 two hollow acetate tube segments (HAT) 50, 51 are arranged. The hollow acetate tube 51 arranged at the most distal end of the article 5 is a thin hollow acetate tube 51 and has a wall thickness smaller than the wall thickness of the hollow acetate tube 50 arranged adjacent the aerosol-generating rod segment 10. The hollow acetate tube 50 has a wall thickness of about 2 mm. The thin hollow acetate tube 51 has a wall thickness of about 0.8 mm.

[0198] The plurality of segments is wrapped in a wrapper 55, for example a paper or plastics wrapper. The individual segments may be individually wrapped before being assembled and wrapped with the wrapper 55 to form the rod-shaped aerosol-generating article 5.

[0199] The wrapper 55 comprises a row of perforations 555 for an airflow to pass and enter the wrapper 55 through the perforations 55. The perforations are arranged at an upstream end of the aerosol-generating rod segment 10. The airflow having entered the wrapper 55 passes outside and along the susceptor casing into the direction of the proximal end of the article 5. The airflow picks up vaporized substances from the heated aerosol-forming gel and forms an aerosol in the cavity 20, is cooled down in the aerosol-cooling element 30 and filtered in the filter element 40.

[0200] Exemplary values for the length of the individual segments of the article of FIG. 7 are: length for the thin HAT segment 51: 6 mm, length of the HAT 50: 5 mm, length of the aerosol-generating rod segment 10: 15 mm, length of the cavity 20: 8 mm, length of the aerosol-cooling element 30: 7 mm, length of the mouthpiece filter element 40: 4 mm. Total length of the article 5: 45 mm.

[0201] In FIG. 8 an embodiment of an aerosol-generating article 5 is schematically shown. The article comprises a plurality of segments wrapped in a wrapper 55. The aerosol-generating rod segment 10 is arranged between a most distally arranged front segment 60 and an airflow directing element 70.

[0202] The aerosol-generating rod segment 10 comprises a cup-shaped susceptor casing 1. The cup-shaped susceptor casing 1 has a constant circular cross section and comprises an inwardly directing flange 127, diminishing the size of the opening 13 of the casing 1. The material of the casing 1 is, for example, aluminium or stainless steel, for example Sxx or S4xx, such as SS430.

[0203] The aerosol-forming gel 2 is arranged inside the casing 1 as well as outside the casing 1. In the embodiment shown in FIG. 8 the aerosol-generating rod segment 10 is a gel plug comprising the susceptor casing, which gel plug defines the size of the aerosol-generating rod segment 10.

[0204] The front segment 60 comprises a ferrite bead 61. The ferrite bead 61 may, for example, be ferrite K1 and may have a size of about 2.4 mm and a weight between 10 mg to 20 mg.

[0205] The ferrite bead 61 is arranged at a proximal end of the front segment 60. By this, the ferrite bead 61 is arranged adjacent the aerosol-generating rod segment 10 and close to the bottom 11 of the casing 1 in the aerosol-generating rod segment 10. By this, a heating of the casing 1 may be enhanced in a bottom region of the casing 1 opposite the opening 13 of the casing.

[0206] The airflow-directing element 70 comprises a truncated hollow cone 71. The truncated end of the hollow cone 71 is directing versus the aerosol-generating rod segment 10. Vaporized gel enters the cone through the truncated end and expands in the cone 71 to be distributed over the entire cross section of the article.

[0207] The wrapper 55 wrapping the article 5 and keeping the individual segments in place comprises perforations 555 at a length position of the article corresponding to a distal region of the airflow-directing element 70. Air may enter the article 5 through the perforations 555 and gets into the airflow-directing element 70. The air is first led in an upstream direction as the cone entry is arranged at a position more upstream in the article 5 than the perforations 555. The air picks up vaporized gel and passes the cone in a downward direction. The aerosol comprising airflow 333 is then led further downstream to the mouth end of the article 5 (not shown).

[0208] In some embodiments the thickness of the susceptor material of the casing is 8.5 micron. In further embodiments the thickness of the susceptor material of the casing is 12 micron.

[0209] A casing 1 may, for example, have a weight of about 38 mg when empty and a weight of about 225 mg when filled with 187 mg gel.

[0210] In FIG. 9 the aerosol-generating article 5 comprises five segments. The aerosol-generating rod segment 10 is sandwiched between two hollow rod segments 50, for example two hollow acetate tubes. The one hollow tube is arranged at the most distal end of the article 5. Adjacent the more downstream arranged acetate tube 50 is an aerosol-cooling element 80 and a filter segment 40 at the most proximal end of the article 5.

[0211] The two hollow tubes 50 may be of a same construction. In FIG. 9, the hollow tube arranged at the most distal end of the article is shorter, for example by 2-5 mm shorter, than the more upstream arranged hollow tube. For example, the shorter hollow tube 50 may have a length of 4 mm. The longer hollow tube 50 may have a length of 8 mm. The hollow tubes have wall thicknesses of about 2 mm.

[0212] The article 5 shown in FIG. 10 comprises five segments: a front plug 90 followed by the aerosol-generating rod segment 10, followed by a hollow tube segment 50 and a thin hollow tube segment 51, followed by a filter segment 40 arranged at the most proximal end of the article 5.

[0213] The article has a diameter 57 of 7.23 mm and a total length 58 of 45 mm. The total length 58 is made up by the length of the individual segments: filter segment 40: 12 mm, hollow tubes each: 8 mm, aerosol-generating rod segment 10: 12 mm, front plug 90: 5 mm.

[0214] Perforations 555 in the wrapper 55 are arranged at a distance 59 of 18 mm from the most proximal end of the article 5. The perforations 555 and the airflow entering the article through the perforations 555 just upstream of the filter element 40 may cause a turbulent flow in the thin hollow tube 51. This may improve the filtering action of the aerosol containing airflow in the filter element 40.

[0215] In FIGS. 11 to 16 a manufacturing process of an aerosol-generating article 5 is shown in a simplified manner. In FIG. 11 a circular disc 101 of susceptor material has been cut-out from a susceptor sheet material, for example an aluminium foil or a stainless steel foil. The disc 101 is formed, preferably folded, into a cup-shaped susceptor 1 as shown in FIG. 12. The bottom 11 of the susceptor is circular and flat and the side walls 12 of the cup-shaped susceptor 1 are corrugated. The corrugations ar arranged along the length of the cup-shaped susceptor 1.

[0216] As may be seen in FIG. 13, the cup-shaped susceptor 1 is positioned within a hollow tube 52, for example a cardboard tube such as a spiral-wound cardboard tube. The hollow tube 52 is positioned in a vertical manner. The cup-shaped susceptor is inserted with its bottom 11 first in the hollow tube through the top end 520 of the hollow tube 52. The cup-shaped susceptor 1 is guided through the hollow tube 52 and positioned at the bottom end 521 of the hollow tube. The bottom 11 of the susceptor 1 may be flush with the bottom end 521 of the hollow tube 52.

[0217] The cup-shaped form of the susceptor 1 simplifies insertion of the cup-shaped susceptor as the bottom 11 preferably has a smaller diameter than the diameter of the side walls 12 at the opening of the cup-shaped susceptor.

[0218] Preferably, the cup-shaped susceptor 1 is slightly clamped in the hollow tube 52 by spring force of the side walls 12.

[0219] In FIG. 14, the dosing tip 201 of a dosing device 200 is inserted through the top end 520 into the hollow tube 52 for dosing a defined amount of aerosol-forming gel 2 into the cup-shaped susceptor 1. The gel 2, for example containing nicotine, may be supplied in a liquid or pasty form and may subsequently dry and harden in the cup-shaped susceptor. The liquid or pasty gel 2 flows into the corrugations of the side walls 11 and provides a close contact of the gel with the susceptor material.

[0220] In a final step as shown in FIGS. 15 and 16, an endpiece 44 is inserted into the hollow tube 52, also through the top end 520. The endpiece 44 typically comprises one or several filter segments. Preferably, the endpiece 44 is a preassembled composition of segments arranged in an end-to-end position. The endpiece 44 may comprise segments influencing aerosol-formation or having a filtering effect. For example, the endpiece 44 may comprise, a filter, a diffuser, an aerosol-cooling element or an aerosol-directing element.

[0221] The endpiece 44 is positioned at the top end 520 of the hollow tube 52. The endpiece 44 may be arranged flush with the top end of the hollow tube 52 or may be arranged in a slightly recessed manner forming an aerosol-generating article 5.

[0222] The cup-shaped susceptor 1 shown in FIGS. 12 to 16 may also be provided with positive locking means such as to retain the aerosol-forming gel in axial direction in the cup-shaped susceptor 1.

[0223] FIG. 17 and FIG. 18 show an enlarged example of an embodiment of a folded, cup-shaped susceptor casing 1 having a flat bottom 11 in the form of a polygon. The side walls 12 are corrugated in a way such that some folds 121 of the side wall 12 extend from the circumference of the bottom 11 of the cup-shaped susceptor 1 to the center of the opposite end of the cup-shaped susceptor, thus closing the opening 13 of the cup-shaped susceptor to a more or less degree depending on the extent that the side walls 12 are folded. Some other folds 120 of the side walls 12 extend from the circumference of the bottom 11 of the cup-shaped susceptor 1 basically in a straight manner to the opposite end of the cup-shaped susceptor, thus defining the outer diameter of the cup-shaped susceptor 1. Depending on the degree of folding the cup-shaped susceptor, the folds 120 of the side wall 12 direct radially outwards with respect to the bottom 11 to a more or less degree depending on the extent the side walls 12 are folded.

[0224] The folds 121 that continuously converge versus the opening of the cup-shaped susceptor 1 form positive locking means having a retaining action onto gel in the susceptor acting in the axial direction of the cup-shaped susceptor.

[0225] The side walls 12 of the cup-shaped susceptor 1 are also constructed to have a radial retaining force onto the cup-shaped susceptor itself, when the cup-shaped susceptor is used in an article as shown in FIG. 16.

[0226] FIG. 19 and FIG. 20 are further examples of folded cup-shaped susceptors 1 having a bottom 11 in the form of a polygon. In FIG. 19, the bottom 11 is folded and corrugated. The bottom 11 directs inwardly diminishing the volume of the cup-shaped susceptor and concentrating the susceptor material to a smaller area. In FIG. 20, the bottom 11 is folded and corrugated and directs outwardly enlarging the volume of the cup-shaped susceptor 1.

[0227] The folds of the side walls 12 may be folded in a similar manner as described in the example of FIGS. 17 and 18. The cup-shaped susceptors 1 may used as cup-shaped susceptor casings with positive locking means as well as cup-shaped susceptors having a retaining force on the casing itself to be fixed in its position when inserted and arranged in an aerosol-forming article as described in FIG. 16.

[0228] FIG. 21 shows a bottom view, a side view and a top view of an aluminium casing 1. The aluminium casing has a circular diameter with a small bottom 11, side walls 12 having a larger diameter than the diameter of the bottom 11 and an inwardly bent rim 125 at the opposite opening 13 side of the casing. The size of the opening 13 of the casing 1 is defined by the extent of the rim 125 being bent inwardly. The rim 125 has the function to retain a gel in longitudinal axial direction in the casing 1. The rim 125 also forms a surface for sealing a closing seal to the capsule 1. Casings may be filled with aerosol-forming gel and sealed such that the so formed aerosol-generating rod segment may be stored for later incorporation into an inductively heatable aerosol-generating article 5.

[0229] The casing 1 has been formed by deep drawing an aluminium disc, widening the side walls 12 of the casing and bending the rim 125. The thickness of the aluminium used for the casing may, for example, be 10 micrometer or may be 30 micrometer for embossed aluminium. Other materials suitable for being inductively heated, deep drawn and bent may be used for forming the casing.

[0230] In FIG. 22 three sequentially arranged stations 6,7,8 in an aerosol-generating article manufacturing process are shown. In the first station 6, a forming unit, the cup-shaped casing is formed. In the second station, an insertion unit, the cup-shaped casing is inserted into a coated cardboard tube, for example as described in FIG. 13 above. In the third station 8, the filling unit, an aerosol-forming gel is filled into the susceptor casing with a dosing device 200. The so manufactured semi-finished article may be further processed, for example as described with reference to FIGS. 15 and 16.

[0231] In FIG. 23 a first step of the casing forming in the forming unit 6 is shown. A cavity 661 in the lower part of the forming tool forms a mold.

[0232] The lower part of the forming tool comprises a vertically movable lower forming tool 66, its function will be described in more detail below. The top surface of the lower forming tool 66 forms the bottom of the mold.

[0233] A blank of sheet material, such as an aluminium disc, is loaded into the forming unit 6 above the cavity 661.

[0234] A plunger 65 is lowered, while the head 650 of the plunger is inserted into the cavity 661 from above. The plunger head 650 presses the aluminium disc into the cavity 661.

[0235] The diameter of the plunger 65 is smaller than the diameter of the cavity 661.

[0236] In order to widen the side walls of the semi-finishes casing 111, the plunger head 650 is moved along the side wall of the mold. The movement of the plunger 65 and the position of the plunger head 650 during the side wall extension of the casing is shown in FIG. 24 and FIG. 25.

[0237] FIG. 24 shows the movement path of the plunger head 650 in the cavity 661 for widening the side walls of the semi-finishes casing 111. The plunger 65 moves from the center of the cavity 661 to one side of the cavity. It then rotates along the sides of the mold defining the cavity. The plunger 65 simultaneously circles and rotates in the cavity 661. The position of the plunger 65 at a side of the cavity is shown in FIG. 25. The rotation of the plunger 65 is indicated by arrow 665.

[0238] For forming the rim and bending the upper portion of the side wall of the semi-finished casing 111, the plunger 65 and the lower forming tool 66 are lifted in the direction of arrows 667 as shown in FIG. 26.

[0239] The transfer plate 68 being part of the upper forming tool comprises a mold surface 680 with an inwardly directing edge mold 681.

[0240] Upon lifting the lower forming tool 66 and plunger 65 the semi-finished capsule 111 is guided through the cavity 661 while the plunger head 650 remains in the centre of the semi-finished casing 111. Upon pressing the semi-finished casing 111 against the edge mold 681 of the transfer plate 68, the rim 125 of the casing 1 is formed.

[0241] A vacuum applied to the casing may ensure the correct placement of the casing during transfer.

[0242] In yet a further step as shown in FIG. 27, the upper forming tool is lifter further and the lower forming tool 66 is lowered as indicated by arrows 667, 668 for releasing the finished casing 1.

[0243] Through the transfer plate 68, the casing 1 is removed from the forming tool 6.

[0244] The transfer plate 68 may then transfer the cup-shaped casing 1 to the next station 7 for insertion into a cardboard tube.

[0245] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 2 % of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.