GB1581599A - Method and apparatus for decorating cigar wrapper material and decorated cigar wrappers - Google Patents

Description

(54) METHOD AND APPARATUS FOR DECORATING CIGAR WRAPPER MATERIAL, AND DECORATED CIGAR WRAPPERS (71) We, GULF & WESTERN COR PORATION, a corporation organised under the laws of the State of New York, United States of America, of 1 Gulf & Western Plaza, New York, New York 10023, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates generally to a method and apparatus for decorating sheet material, and, in particular, a sheet of manufactured cigar wrapper material.

More particularly, the invention relates to a method and apparatus for embossing a predetermined vein-like pattern, on such sheet material.

The present invention is particularly useful in embossing a vein pattern similar to the vein pattern of a naturally appearing tobacco leaf on a manufactured cigar wrapper. Cigars generally are wrapped with either a natural tobacco leaf or a manufactured wrapper which includes a mixture of natural tobacco, adhesives and cellulosic fibers.

The advantage of using a manufactured cigar wrapper rather than a natural tobacco leaf resides in its considerably lower cost and the increased ability to manipulate both taste and aroma by the addition of appropriate additives. The natural tobacco leaf has, historically, been the symbol of a quality cigar and, accordingly, it has been a goal of cigar manufacturers to simulate the appearance of a natural tobacco leaf wrappers on manufactured wrappers.

To this end, cigar wrapper manufacturers have, on numerous occasions, attempted to print or draw a natural vein pattern on a sheet of manufactured cigar wrapper. For example, British Patent No.

14,494, which issued to William Watson on November 3, 1884, teaches the embossing, stamping or printing of natural tobacco leaf designs on manufactured tobacco paper. Similarly, U.S. Patent No. 2,316, 785, which issued to Frederick C. Gladeck on April 20, 1943, discloses the embossing of a sheet of manufactured tobacco wrapper with a pattern which simulates leaf tobacco. See also, in this regard, U.S.

Patent No. 3,145,717 which issued to F. H.

Osborne, et al. on August 25, 1964 and which discloses the calendering or embossing of a sheet of manufactured cigar wrap per with a leaf design having stems and veins.

A particular problem experienced by cigar wrapper manufacturers in embossing or engraving such a veined pattern on the manufactured cigar wrapper is that during subsequent manufacturing operations and during use, as the sheet is stretched, the raised vein pattern is stretched flat and is thus removed. This is particularly true when the humidity of the wrapper rises.

Prior art attempts at embossing or printing vein patterns on manufactured cigar wrappers have also not, heretoforce, been successful because the generally uniform colour of the manufactured wrappers did not appear natural when compared to the randomly coloured natural tobacco leaf.

It is an object of the present invention to provide methods of and apparatus for embossing a vein-like pattern on a sheet of manufactured cigar wrapper material, which will resist being removed during subsequent processing operations and during use.

To this end, from one aspect the invention consists in a method of decorating a sheet of manufactured cigar wrapper material, comprising feeding said sheet towards and around a guide mandrel, embossing a decorative vein-like pattern on said sheet as said sheet passes around the guide mandrel to form a raised vein-like pattern on one surface of said sheet and a complementary depressed vein-like pat tern on the opposite surface of the sheet, reinforcing only said vein-like pattern, and drawing the decorated sheet from said guide mandrel.

From another aspect the invention consists in apparatus for decorating a sheet of manufactured cigar wrapper material, comprising a rotatable sheet guide mandrel, feeding means for feeding said sheet to and around said mandrel, drawing means for drawing said sheet from said mandrel, a decorating means for embossing a decorative raised vein-like pattern on one surface of said sheet as the sheet passes between said decorating means and said mandrel and providing a complementary depressed pattern on its opposite surface, and means for applying a reinforcing material only to said vein-like pattern.

Preferably, the method includes the steps of, and the apparatus includes the means for, imparting a base colour and a shade colour pattern on the embossed sheet of manufactured cigar wrapper material.

From a further aspect, the invention consists in a cigar wrapper comprising a sheet of manufactured cigar wrapper material having opposed surfaces and a predetermined cross-sectional thickness, said sheet having a vein-like pattern embossed through said cross-sectional thickness to form a raised pattern on one of said og posed surfaces and a complementary depressed pattern on the opposite surface, and means applied to said sheet to resist said vein-like pattern being stretched flat when the wrapper is stretched during subsequent manufacturing steps or use.

From yet another aspect, the invention consists in a cigar wrapper comprising a sheet of manufactured cigar wrapper material having opposed surfaces and a predetermined cross-sectional thickness, said sheet having a vein-like pattern embossed through said cross-sectional thickness to form a raised pattern on one of said om posed surfaces and a complementary depressed pattern on the opposite surface, and means provided in the depressions of said vein-like pattern for reinforcing the vein-like pattern.

From yet a further aspect, the invention consists in a cigar wrapper comprising a sheet of manufactured cigar wrapper material having opposed surfaces and a predetermined cross-sectional thickness, said sheet having a vein-like pattern embossed through said cross-sectional thickness to form a raised pattern on one of said opposed surfaces and a complementary depressed pattern on the opposite surface, and a second sheet of material which is cohesively laminated in juxtaposition to said opposite surface.

Preferably, the depressed pattern on said opposite surface of the sheet is filled with a filler material in order to reinforce the vein-like pattern.

In order that the invention may be more readily understood, reference will now be made, by way of example, to the accompanying drawings, in which: FIG. 1 illustrates in schematic form one embodiment of decorating apparatus of the present invention; FIG. 2 illustrates in schematic form an alternate embodiment of decorating ap paratus of FIG. 1 wherein two sheets are laminated together after decoration; FIG. 3 is an enlarged, side elevational view of the embossing station of the ap paratus of FIGS. 1 and 2; FIG. 3A illustrates in schematic form alternative forms which the embossing roller forming part of the embossing station of FIG. 3 may assume; FIG. 3B is an enlarged, partial sectional view of the embossing roller; FIG. 3C is a partial front elevational view illustrating the cooperating relationship between the embossing roller and the center cylinder; FIG. 3D is a positive print illustrating the vein pattern which is embossed on the sheet material; FIG. 4 is an enlarged, general side elevational view of the base colour station of the apparatus of FIGS. 1 and 2; FIG. 4A is an enlarged, general front elevational view of the base colour station of the apparatus of FIGS. 1 and 2; FIG. 4B is a front elevational view of the colour gravure roller of the base colour station; FIG. 4C is a front elevational view of the colour transfer roller of the base colour station; FIG. 4D is illustrative of the sheet material after the vein pattern and base colour have been applied; FIG. 5 is an enlarged, general side elevational view of the shading station of the apparatus of FIGS. 1 and 2; FIG. 5A is a front elevational view of the shade gravure roller of the shading station FIG. 5B is illustrative of the sheet material after the vein pattern, the base colour and the shade pattern have been applied; FIG. 6 is an enlarged perspective view of the reinforcing station of FIGS. 1 and 2; FIG. 6A is a side view of the reinforcing station of FIG 6; FIG. 6B is a partial bottom view of the distribution plate used in the reinforcing station of FIG. 6; FIG. 7 is an enlarged, general side eleva tional view of the laminating station of FIGS. 1 and 2; FIG. 7A is a front elevational view of the laminating roller; FIG. 8 is a print of a photograph of a sheet of cigar wrapper material decorated using the apparatus of FIGS. 1 and 2; FIG. 8A is a partial cross-sectional view of a cigar wrapper decorated using the apparatus of FIGS. 1 and 2; FIG. 8B is a partial cross-sectional view of a decorated and laminated cigar wrapper using the apparatus of FIG. 2; FIG. 9 illustrates a cigar having a decorated laminated wrapper produced using the apparatus of FIG. 2; and FIG. 10 is an enlarged cross-sectional view of the cigar of FIG. 9 taken along line 10-10 with exaggerated wrapper thickness.

Referring now to FIG. 1, there is shown schematically an apparatus according to the present invention and its method of use to decorate and colour a sheet of manufactured cigar wrapper material. In this embodiment, only one layer of sheet material, having a predetermined thickness with opposed surfaces A and B, is preferably coated on at least one side A with a hydro phobic coating prior to processing through the apparatus of the present invention.

This sheet material, which includes a mixture of ground tobacco and refined pulp and measures about 0003 inches in thickness, is processed according to the following methods and using the following apparatus.

As shown in FIG. 1, identical sheet material is stored on either a lower roll 12 or an upper roll 13 in an unwind station 10 with the coated side A facing outwardly.

The free end of the undecorated sheet material is first fed through a spicing unit 14 and toward a rotatable sheet guide mandrel constituted by a center cylinder 24 in such a manner that the uncoated side B is upwardly facing. Splicing unit 14 permits continuous running of the apparatus since, as the sheet material on the lower roll 12 is depleted, similar sheet material from the upper roll 13 may then be spliced by splicing unit 14 into the material from the lower roll 12. Embossing, colouring and shading stations, 20, 40 and 60 respectively, are positioned about the center cylinder 24.

The sheet material passes through and about idler take-up rollers 22A, 22B, 22C and 22D and around center cylinder 24, first passing through the nip between the center cylinder 24 and an embossing roller 26 where a predetermined vein-like pattern is embossed through the thickness of the sheet, forming a raised pattern on the coated side A of the sheet. The embossed sheet then continues around the center cylinder 24, where the uncoated side B of the sheet is treated with colourants to simulate a natural tobacco leaf at a base colour station 40 and at a shade pattern station 60. Station 80 at which the veinlike pattern is reinforced will be described hereinafter.

The sheet material, after having passed through the shade pattern station 60, has a raised, embossed pattern on the coated surface A thereof, with the uncoated surface B being coloured and shaded. The decorated sheet material is removed from the center embossing cylinder 24 at a removal station 100. The decorated sheet material may, if desired, be coated at a coating station 120 and stained at a staining station 140. It is desirable to pass the decorated sheet through a humidifier 160 which increases the moisture level of the sheet and thus prevents it from tearing or cracking. The decorated sheet material is then rewound at a rewind station 180.

FIG. 2 illustrates schematically the method and apparatus used in decorating one sheet of manufactured cigar wrapper material and then laminating the decorated sheet to a second, undecorated sheet.

It will be appreciated that this method utilizes essentially the same apparatus as discussed in FIG. 1 with certain minor differences. In the apparatus of the embodiment of FIG. 2, the sheet material to be decorated is stored on lower rolls 12 and 12A and the sheet material to be laminated to the decorated sheet is stored on the upper rolls 13 and 13A at the unwind station 10 with both sheets being processed simultaneously. The sheet from the lower rolls 12 and 12A is processed in an identical manner as the sheet of FIG. 1, and, after this decoration, colouring and shading, it is then laminated to the second undecorated sheet from upper rolls 13 and 13A at laminating station 100' of FIG. 2. Two lower rolls 12 and 12A and two upper rolls 13 and 13A are provided to permit splicing at splicing units 14 and 16 as a roll is depleted, thus assuring continuous operation of the apparatus.

The detailed description of the various portions of the apparatus which follows will apply to the apparatus used for the manufacture of both laminated and nonlaminated sheet material, as shown schematically in FIGS. 1 and 2, any differences being specifically noted.

The sheet material to be decorated which, in the embodiment of FIG. 1 is stored on both the upper and lower rolls 13 and 12 respectively, and, in the embodiment of FIG. 2 is stored on lower rolls 12 and 1 2A is first fed from the unwind station 10 toward the embossing 20, colouring 40 and shading stations 60, which are positioned about the center cylinder 24.

In the embodiment of FIG. 2, where two sheets are laminated together, sheet material from upper rolls 13 or 13A is fed simultaneously over the top of the center cylinder 24 and is cohesively laminated in juxtaposition to the decorated sheet at laminating station 100'.

When forming decorated and laminated sheets with the apparatus of FIG. 2, each sheet should have a thickness of preferably about 00015 inches and each is preferably coated on at least one side A or A' with a hydrophobic coating material such as, for example, a derivitized cellulosic material.

The hydrophobic coating applied to the coated side A' of the sheet material from the upper rolls 13 and 13A preferably includes a gryceride in an amount sufficient to lower the melting point of the coating to below about 400"F. The sheet of manufactured cigar wrapper material from the lower rolls 12 and 12A is also preferably coated on side A with a hydrophobic coating, similar to the hydrophobic coating applied to sheet material from the upper rolls 13 and 13A, but not including glyceride.

In the embodiment of FIG. 1, where sheet material from upper and lower rolls 13 and 12, respectively are used, the sheet material preferably is about 0 003 inches thick and is coated on side A with a hydrophobic coating.

The sheet of manufactured cigar wrapper material to be decorated preferably includes ground tobacco, refined pulp, filler materials, adhesives, has a preferable sheet weight of from about l 0 g!ft to about 6'0 g/ft2 and has a moisture level of at least about 19%.

As shown in FIGS. 1 and 2, the coated sheet material to be decorated is directed through the two rollers 14A and 14B which comprise splicing unit 14 of unwind station 10 and toward the embossing, colouring, shading and reinforcing stations 20, 40, 60 and 80, respectively positioned about center cylinder 24. Splicing unit 14 permits splicing of the sheet material to be decorated from one roll to another as the one roll is depleted to ensure a continuous feed of material. A second splicing unit 16 is provided for use in the embodiment of FIG. 2 and comprises rollers 16A and 16B which permit splicing of the sheet material from one of the upper rolls to the outer roll 13A.

Take-up rollers 22A, 22B, 22C and 22D serve to ensure that the sheet material remains taut throughout processing. The take-up roller 22D, positoined beneath the embossing station 20 may be a bowed roller such as, for example, a Mount Hope roller, since such a roller maintains the sheet material flat and taut during processing.

The coated sheet material to be decorated is first introduced into embossing station 20 where it passes through the nip between the center cylinder 24 and the embossing roller 26. Embossing roller 26 is shown in greater detail in FIGS. 3, 3A, 3B and 3C, FIGS. 3 and 3C illustrating the cooperation between the center cylinder 24 and the embossing roller 26.

As shown in FIG. 3C, center cylinder 24, which is preferably steel with either a chrome-plated or paper filled outer surface portion, is rotatably mounted on a frame 18 by means of hub portions 24A which extend from opposite ends of the center cylinder 24 and are rotatably journaled in apertures on opposite sides of the frame 18.

The center cylinder 24 has a recessed female decorative vein-like pattern, on the outer surface thereof. When the outer surface of the cylinder 24 is paper filled, a synchronized female or recessed decorative pattern may be formed on this surface by mounting the embossing roller 26, which includes a raised male vein-like pattern on its outer surface, adjacent the cylinder 24 and then rotating the cylinder 24 and the embossing roller 26 in opposite directions to cut a pattern synchronized to the pattern of the embossing roller 26 into its paper-filled outer surface. When the outer surface of the center cylinder 24 is chrome-plated steel, the center cylinder 24 and the embossing roller 26 should be a matched set.

The embossing roller 26, shown in FIGS.

3, 3A, 3B and 3C, is rotatably mounted on the frame 18 adjacent to the center cylinder 24 so as to permit the sheet material to pass through the nip between the embossing roller 26 and the center cylinder 24 when the cylinder 24 and the embossing roller 26 rotate in opposite directions.

The embossing roller 26, which preferably is steel with a chrome-plated outer surface 26C, includes a raised male decorative pattern on the outer surface 26C. Such pattern may be etched or engraved and is complementary to the recessed female pattern on the outer surface of the center cylinder 24. An example of the vein-like pattern is shown in FIG. 3I). As such, when a sheet of wrapper material is passed through the nip between the embossing roller 26 and the center cylinder 24, under elevated heat and pressure, the pattern on the cylinder 24 and roller 26 is embossed into and through the sheet material. An engraved pattern is preferred on the outer surface 26C of the embossing roller 26 since it produces a more pronounced raised pattern on the wrapper than an etched pattern would. Both left hand and right hand leaf patterns may be used on the outer sur face of the embossing roller 26, as shown in FIG. 3A.

Referring back to FIG. 3, embossing roller 26 is also rotatably and adjustably mounted on the frame 18 by means of stepped, hub portions 26A which extend from opposite ends of the embossing roller 26 and are rotatably journaled on adjustable mounting supports 28 which are affixed to the frame 18 at opposite sides thereof. Supports 28, which permit adjustment of the embossing roller 26 relative to the center cylinder 24, include upper and lower plates 28A and 28B, respectively, which rotatably capture the hub portion 26A of the embossing cylinder 26 and which are secured by retaining or anchor bolts 29A and 29B. Mounting shaft 32, which interconnects both sides of frame 18, is also secured to support 28 by means of support plates 28B and 29C which are secured using anchor bolts 29D and 29E.

The pressure exerted by the embossing roller 26 against the center cylinder 24 which determines vein depth, is provided by at least one conventional, adjustable air cylinder 30 which effects movement of lower plate 28B toward the center cylinder 24 along a post 29F thus forcing embossing roller 26 against center cylinder 24. The pressure between the embossing roller 26 and the center cylinder 24 may be controlled by the use of adjusting screws 29G and 29H which control the travel of lower plate 28B toward center cylinder 24.

Adjusting screws 29G and 29H are set initially to ensure proper registration between the male pattern on the embossing roller 26 and the female pattern on the center cylinder 24. The post 29F along which support plate 28B travels, is secured to the frame 18 by means of two bolts 291 and 29J.

The embossing roller 26, shown in greater detail in FIG. 3B, has a substantially hollow center portion 26B, access to which is available through the hollow, stepped, hub portions 26A. The embossing roller 26 may be heated by the introduction of steam through the hub portions 26A and into the hollow center portion 26B of the embossing roller 26. Condensed water may be removed through, for example, a conventional rotary joint on one side of the embossing roller 26 (not shown).

Embossing of the sheet material may be accomplished at temperatures above about 250"F and preferably at temperatures between about 250"F and about 350 F. An embossing temperature of about 2800F is most preferred. An embossing pressure of at least about 50 psi between the embossing roller 26 and the center cylinder 24 generated by air cylinder 30, is normally required to effect satisfactory embossing of the sheet material and a pressure of about 90 psi is preferred.

Referring back to FIGS 1 and 2, the embossed sheet material passes around the center cylinder 24 toward the base colour station 40 where the sheet material is treated with a base colourant to simulate the colour of a natural tobacco leaf. In those instances where the sheet material is pre-coloured prior to processing, the base colour station may be eliminated and the sheet may be merely embossed or embossed and shaded. The base colour station 40, shown in greater detail in FIGS. 4, 4A, 4B and 4C includes a colour transfer roller 42, of steel with a rubber or elastomeric outer surface and a colour gravure roller 44 of steel with a chromeplated outer surface.

The colour gravure roller 44, shown schematically in FIG. 4B, preferably includes a hollow center portion 44B with stepped hub portions 44A extending from the opposite ends thereof. The chromeplated outer surface of the colour gravure roller 44 is patterned, preferably having a 180Q quadra gravure recessed pyramid shaped pattern formed thereon. The colour gravure roller 44 on the frame 18 is adjustably and rotatably mounted by means of an adjustable support 50 mounted on both sides of the frame 18. Hub portions 44A of roller 44 are journaled in recessed portions of adjustable support 50.

It is preferred that the colour gravure roller 44 be cooled and this may be accomplished by passing cool water through the hollow center portion 44B of the roller 44.

The colour transfer roller 42, shown schematically in FIG. 4C, includes a rubber or elastomeric outer surface 42C, a hollow center portion 42B and stepped hub portions 42A which extend from opposite ends of the colour transfer roller 42. The elastomeric outer surface 42C of the transfer roller preferably has a hardness of between about 40 and about 70 Durometer Shore A. It is preferred that the transfer roller 42 be cooled to retard drying of the colouring agent which it transfers to the sheet material and cooling may be accomplished, for example, by the pumping of cool water into the hollow center portion 42B through one of the stepped hub portions 42A.

Since in actual operation, the colouring agent is applied to recessed portions of the colour gravure roller 44 and then transferred to the colour transfer roller 42 as the two rollers contact and rotate in opposite direction, it will be appreciated that the alignment of and the pressure between the rollers is important. The colour transfer roller 42 transfers the colouring agent in the pattern of the colour gravure roller 44 to the sheet material as the sheet material passes through the nip between the counter rotating center cylinder 24 and the colour transfer roller 42. Colouring agents may include inks and dyes and preferred colouring agents include carotenoids and annattos; food, drug and cosmetic dyes including their lake and oil solubilized forms; and other commercial food grade inks.

As shown in FIG. 4A, the colouring agent is applied directly to the colour gravure roller 44 by the use of an open ink pan 46 positioned adjacent to the colour gravure roller 44 and spaced such that, as the colour gravure roller 44 rotates, the outer surface of the gravure roller 44 passes through the colouring agent contained within the ink pen 46, thereby "inking" the roller. A doctor blade 48, mounted tangentially relative to the colour gravure roller 44 is used to remove any heavy deposits of the coating agent on the rotating colour gravure roller 44. The colouring agent is introduced into the open ink pan 46 by conventional means, i.e. by its introduction under pressure from an external supply. The colouring agent should be fed into the ink pan 46 at a suffi cient rate to maintain a substantially filled level and an overflow return system (not shown) may be provided to assure continuous circulation of the colouring agent.

The doctor blade 48, which may be steel or a plastic material, includes a bracket 49 which is preferably adjustably mounted on frame 18 in order to control its position relative to the colour gravure roller 44. The doctor blade 48 may be spring or air loaded, such as by air cylinder 49A to generate pressure against the colour gravure roller 44. It is preferable that the doctor blade 48 be reciprocating relative to the longitudinal extent of the colour gravure roller 44 to aid removing heavy deposits of colouring agents which may accumulate on the surface of the colour gravure roll 44. Reciprocation is effected by means of air cylinder 49B, shown in FIG. 4A.

As shown in detail in FIG. 4, the colour gravure roller 44, the colour transfer roller 42, the ink pan 46 and the doctor blade 48 are adjustably mounted on and secured to the frame 18 by use of an adjustable support 50 which includes a plurality of interengaged and adjustable plates 50A, 50B, 50C, 50D and 50E and two screw threaded adjusting devices 51A and 51B which permit adjustment of the position of the plates which control the pressure between the colour gravure roller 44 and the colour transfer roller 42 and between the colour transfer roller 42 and the center cylinder 24.

A conventional adjustable air cylinder 52 is employed to generate pressure between the transfer roller 42 and the center cylinder 24 and a second conventional air cylinder 54 is used to generate pressure between the transfer roller 42 and the gravure roller 44. Adjusting screw 51A acts as a stop for air cylinder 52 permitting adjustment of the pressure between the transfer roller 42 and the center cylinder 24. Similarly, adjusting screw 51B acts as a stop for air cylinder 54 and permits adjustment of the spacing between the transfer roller 42 and the gravure roller 44.

Anchor bolts 56A and 56B secure plate 50D to plate 50A in order to rotatably capture the transfer roller 42 therebetween and anchor bolts 56C and 56D serve to secure plate 50C to plate 50B to rotatably capture the gravure roller 44 therebetween. Sup port shaft 58 is rotatably captured between plates 50E and 50A which are secured thereto by anchor bolts 56E and 56F.

The embossed sheet material, after passing through the base colour station 40 where a base colouring agent is applied in the pattern of the colour gravure roller 44 then proceeds through a shade pattern station 60 as shown in FIGS. 5 and 5A where a random or otherwise irregular colour pattern is applied.

When the sheet material is pre-coloured prior to processing, the sheet may pass directly from the embossing station 20 to the shade pattern station 60, thus bypassing the base colour station 40. A random "cloud-pattern" may be applied using contrasting colours to further simulate the irregular or random colour patterns of a naturally occurring tobacco leaf. The shade pattern station 60, shown in detail as FIGS. 5 and 5A, includes a shade transfer roller 62 of similar construction to colour transfer roller 42 and a shade gravure roller 64, of similar construction to the colour gravure roller 44, but for the pattern on the outer surface thereof.

The shade gravure roller 64, shown schematically in FIG. 5A, which is preferably made from steel, is hollow and includes on its outer, preferably chromeplated steel surface, a randomly diffused, 120Q screen pattern. An open ink pan 66 and a doctor blade 68, similar to the open ink pan 46 and the doctor blade 48 of the base colour station 40, are provided with a similar supply and circulation syst tioned on adjacent sides of the support 70 to provide pressure, respectively, between the shade transfer roller 62 and the center cylinder 24 and between the shade transfer roller 62 and the gravure roller 64.

Adjusting screws 7SA and 75B are provided to respectively control the amount of pressure between the shade transfer roller 62 and the center cylinder 24 and between the shade gravure roller 64 and the shade transfer roller 62. A plurality of anchor bolts 76A-H serve to secure the plates 71A-H together.

In the shade colour station 60, an adjustable bracket 69 is provided, including a pressure piston to adjustably mount the doctor blade 68 relative to the gravure roller 64 and an air cylinder 69A to permit reciprocation of the doctor blade 68 across the longitudinal extent of the outer surface of the shade gravure roller 64.

A shading agent is applied to the embossed and coloured sheet material by the shade transfer roller 62 which, by contacting and rotating in an opposite direction from the shade gravure roller 64 receives the shading agent in the shade pattern of the shade gravure roller 64, then transfers it to the sheet material as it passes through the nip between the center cylinder 24 and the transfer roller 62. The shade transfer roller 62, which is of a similar construction to the colour transfer roller 42, may be cooled in a similar manner as the colour transfer roller is cooled, i.e. by introducing cool water into its center.

The shading agent used may be an ink or a dye, preferably of contrasting colour to the colouring agent. Preferred shading agents include carotenoids and annattos; food, drug and cosmetic dyes including their lake and oil solubilized forms; and other commercial food grade inks. The decorated, coloured and shaded sheet material, as it emerges from the shade station 60, is shown in FIG. 5B.

The now embossed, coloured and shaded sheet material then proceeds around the center embossing cylinder 24 to the reinforcing station 80 where a filler material is deposited onto the top uncoated surface B of the sheet material as shown in FIGS. 6 and 6A. Reinforcing station 80 comprises an applicator including a hopper 82, which is mounted on frame (not shown) adjacent to the center cylinder 24 and to which may be added filler material for distribution onto the sheet material as it passes around the cylinder 24, and a wire screen 83 above a slotted distribution plate 84 through which the filler material is deposited onto the uncoated surface B of the sheet material. A rubber blade-like device 88 is adjustably mounted adjacent the bottom edge of the hopper 82 by a plurality of screws 86 and, when properly adjusted and upon rotation of the cylinder 24, serves to force the filler material into the depressed portions of the embossed pattern on uncoated surface B of the sheet and to remove any excess filler material from the non-depressed regions of the sheet material. Blade 88 may be replaced by a roller or other similar device (not shown).

A rotatably mounted doffer 87 is provided to prevent agglomeration of the filler material in the hopper 82 and a rotary blade feeder 89 is provided to aid in forcing the filler material through slotted distribution plate 84 and onto the sheet material. The rate of distribution of the feeder material is controlled by the rate of rotation of the blade feeder 89.

Filler materials may be either in powder or paste form, the powder including a mixture of ground tobacco suitable binding agents and fillers including diatomaceous earths, clays and whitening agents. Preferred diatomaceous earths include the product marketed by Grefco, Inc. of Los Angeles under the trademark Dicalite and the product marketed by Johns-Manville of Denver under the mark Celite. Preferred clays include Bentonite, marketed by NL Industries of New York, Kaolin and monmorillonite and preferred whitening agents, which serve to give the filled vein pattern a more naturally coloured look, may be selected from the group consisting of titanium dioxide, calcium carbonate and dolomite.

In certain instances, it may be desirable to use a paste type filler material rather than a powder, particularly in the embodiment where only one, non-laminated layer is used. In order to form such a paste, the powder described above may be mixed with suitable vehicles, and wetting agents.

In the embodiment of FIG. 2, where two sheets are laminated together, the sheet material from the lower rolls 12 and 12A, which has been embossed, coloured, shaded and reinforced, is then mated with and cohesively laminated in juxtaposition to the undecorated sheet material from the upper rolls 13 and 13A of the unwind station 10 which is passed over the center cylinder 24 by take-up rollers 90A and 90B. The two layers are mated in such a manner that the coated side A' of the undecorated sheet material is in juxtaposition with the uncoated side B of the embossed sheet material and are then fed into and through a laminating station 100' where they are laminated together to form a unitary embossed and laminated sheet.

The laminating station 100', as shown in FIGS. 7 and 7A, includes a laminating roller 101, preferably of chrome-plated steel and having a hollow center Dortion 101B and two hub portions 101A extending from opposite ends thereof. As shown in FIG. 7, the laminating roller 101 is journaled on an adjustable support 110 which includes plates llOA, 11 OB and llOC. Anchor bolts 112A and 112B rotatably capture and mount the hub portions lOlA of the laminating roller 101 between plates llOA and llOB. Air cylinder 114 serves to generate a constant pressure between the laminating roller 101 and the center embossing cylinder 24, the amount of pressure being controlled by adjusting screw 115 and adjusting wheel 116.

The two sheets are laminated together as they pass through the nip between the laminating roller 101 and the center cylinder 24 at elevated temperature and pressure. Lamination should be accomplished at a temperature sufficient to soften the hydrophobic coating on the coated surface A' of the top, undecorated sheet and thus laminate the undecorated sheet to the embossed and coloured sheet. Since it is not desirable to have the coating on the embossed sheet soften, lamination is preferably effected at a temperature of between about 250"F and about 350"F, with a temperature of about 280"F being most preferred. This temperature may be achieved by the introduction of steam into the hollow center portion 101B of the laminating roller 101 through the hollow tubular end portion 101A. The pressure exerted between the laminating roller 101 and the center cylinder 24 by air cylinder 114 should be between about 50 psi and about 150 psi, and preferably between about 75 psi and about 100 psi. A laminating pressure of about 90 psi is most preferred.

In the embodiment of FIG. 1 where the decorated sheet is not laminated to a second sheet, the laminating roller 101 is maintained at room temperature and merely serves as a removal roll for removing the embossed, coloured, shaded and reinforced sheet from the center cylinder 24.

If desired, a secondary coating may be applied to the sheet material of either FIG.

1 or FIG. 2, preferably at coating station 120 which is located adjacent laminating roller 101. Coating station 120 includes a coating transfer roller 122 and a coating gravure roller 124, shown in greater detail in FIG. 7. Coating station 120 is similar to both the base colour station 40 and the shade colour station 60 in that the coating is applied to the sheet material by the transfer roller 122 as it passes through the nip between the transfer roller 122 and the laminating roller 101. The coating transfer roller 122 and the coating gravure roller 124, which are similar in design to the colour transfer roller 42 and the colour gravure roller 44 are rotatably mounted on an adjustable support 130 which includes inter-engaged plates 1 30A-130E which are secured to one another by a plurality of anchor bolts 131A-131F. Air cylinders 132 and 133 provide pressure respectively between the coating transfer roller 122 and the coating gravure roller 124 and between the transfer roller 122 and the laminating roller 101. Pressure generated by air cylinder 132 between the gravure roller 124 and the coating transfer roller 122 is adjusted by adjusting screw 134 and the pressure generated between the transfer roller 122 and the laminating roller 101 is controlled by adjusting screw 135. The coating applied at the coating station 120 may be, for example, a hydrophobic coating and is applied to the sheet material in a similar manner as the base colour and shading were applied. The secondary coating is applied to the coating gravure roller 124 as it rotates through an open pan 126. A reciprocating doctor blade 128, adjustably mounted on support 130 and powered by air cylinder 129, is also provided. The coating is transferred to the sheet material from the coating gravure roller 124 by the oppositely rotating coating transfer roller 122 as the sheet material passes through the nip between the oppositely rotating laminating roller 101 and transfer roller 122.

An additional staining step at staining station 140 may also be incorporated into the processes of FIGS. 1 and 2, staining being effected after the decorated sheet passes from the coating station 120 over a take-up roller 138. Staining station 140 is of similar design to base colour station 40 and shading station 60 and is shown schematically in FIGS. 1 and 2. Staining is used to further delineate the pattern being embossed on the sheet material. Suitable staining agents include both saturated and unsaturated, synthetic or natural vegetable oils, such as, for example, glycerides.

Staining station 140 includes an upper, internally heated, roller 141 preferably of chrome-plated steel, which is in direct contact with an oppositely rotating transfer roller 142 which is of similar construction to colour transfer roller 42. Stain is applied to the transfer roller 142 by an oppositely rotating stain gravure roller 144 which includes an open pan 146 for applying stain to the gravure roller 144 and a doctor blade 148 for removing excess heavy deposits of stain from the gravure roller 144. Stain is introduced into pan 126 by circulation means similar to the system used for introducing and circulating the colouring and shading agents. As the decorated sheet material travels between the upper, heated roller 141 and the stain trans fer roller 142, the stain is applied to the raised, decorated side of the decorated sheet material by the stain transfer roller 144. The upper heated roller 141, like the laminating roller 101, has a hollow center portion through which steam is passed to elevate the temperature of the upper roller 141 to thus accomplish staining at elevated temperatures. Preferably, the upper heated roller 141 is maintained at a temperature of at least about 90"F with a temperature within the range of from about 100 F to about 1200F being most preferred.

The staining station 140, which includes rollers 141, 142 and 144, stain containing pan 146 and doctor blade 146, is rotatably and adjustably mounted on a frame (not shown) of similar design to frame 18 which supports the embossing, colouring, shading and laminating stations.

The decorated sheet material may, after passing through the staining station 140, be introduced into a humidifier 160 where the moisture level of the sheet material is raised to a pre-determined level. This is particularly recommended since the sheet of cigar wrapper material after processing, should have a moisture level of at least about 25% and preferably between about 28% and about 35%. A moisture level of about 30% for the final product is most preferred. Humidification is preferably accomplished by the simultaneous intro duction of steam through a plurality of jets onto both surfaces of the sheet material as it passes through the humidifier 160.

It has been found that humidification is most effective when the temperature of the sheet material is maintained at a temperature of about 1 100F and this may be accomplished by maintaining a constant circulation of air around the sheet material.

The application of a very fine spray of cool water applied to the sheet material through water jets 165 positioned immediately adjacent to the humidifier 160 results in greater moisture levels in the final, humidified product. The water on the wrapper functions as a heat sink and prevents drying of the sheet material during humidification 160.

After humidification, the sheet material is drawn into a rewind station 180, as shown in FIGS. 1 and 2, first passing over an idler roller 182 and then through a drive assembly 184 which includes upPer and lower draw rollers 184A and 184B, respectively, which serve to pull or draw the sheet material through the apparatus. It is then fed over take-up rollers 186A, 186B and 186C and rewound around either top or bottom rewind rollers 188A and 188B.

Take-up roller 186B is a moisture detection roller and monitors the moisture of the sheet material prior to re-rolling on rollers 188A and 188B, thus permitting increased or decreased humidification by humidifier 160, if necessary.

The apparatus of FIGS. 1 and 2 may be powered by conventional means (not shown) and preferably by coordinated D.C.

motors. It is preferred that three separate D.C. motors be used, with one master motor to rotatably drive the center cylinder 24 with the rollers comprising the embossing colouring, shading, reinforcing and laminating stations 100', being geared to the center cylinder 24 by conventional gearing. Secondary motors are provided at the rewind station 180 and at the staining station 140 and are subordinate to the master motor driving the center cylinder 24, with their drive speed being dependent upon the speed at which the master motor operates.

It will be appreciated that the tension of the sheet material must be maintained at a relatively constant level during processing to prevent tearing or pulling of the sheet material and irregular lamination.

This may be accomplished by the use of conventional take-up rollers or dancer rollers positioned at various points throughout the apparatus. For example, dancer rollers may be positioned between the laminating station 100' and the staining station 140 and between the staining station 140 and the humidifier 160. A potentiometer may be employed on one or more of the dancer rollers to both change the speed of the drive assembly 184 automatically and to control the speed of rewind rollers 188A and 188B in order to maintain proper tension of the sheet material.

As previously stated, when the sheet material is for a cigar wrapper, the moisture level of the sheet material must be maintained above a minimum moisture level to prevent the sheet material from tearing or cracking. It is therefore preferred that the sheet material has, prior to processing, a moisture level of at least about 19% with a moisture level of at least about 22% being most preferred. When the sheet material is at such a moisture level, prior to processing it will be more resistant to drying from the heat generated during the processing, thus making the sheet material less prone to tearing and cracking.

The resultant embossed, coloured and shaded cigar wrapper sheet is shown in FIGS. 8, 8A and 8B; FIG. 8 being a print of a photograph of the decorated surface of the wrapper; FIG. 8A being a partial crossffectional view of a non-laminated wrapper; and FIG. 8B being a partial cross-sectional view of a laminated wrapper having two layers of sheet material.

The cigar wrappers which are decorated in both the laminated and non-lamina ted embodiments of FIGS. 1 and 2 may be sheets of conventional, manufactured cigar wrapper material. In general, the sheets of manufactured cigar wrapper are a mixture of ground tobacco, refined pulp, filler materials, adhesives and other functional ingredients and preferably have a sheet weight within the range of from about 1-0 g/ft2 to about 60 g/ft2 and a moisture level of at least about 19%. The sheet of cigar wrapper material in the non-laminated embodiment of FIG. 8A preferably has a thickness of between about 002 inches and about 006 inches. While, in the laminated embodiment, of FIG. 8B, two layers of sheet material, each between about 0001 inches to about 003 inches thick, are laminated together to produce a finished laminated sheet with a thickness of between about 0002 inches and about 006 inches. In certain instances, it may be desirable to use sheets of differing thicknesses or compositions to achieve a desired result.

The cigar wrapper in FIG. 8 has a raised vein-like pattern embossed on its coated surface and is coloured and shaded on its uncoated surface to simulate the appearance of a natural tobacco leaf. As shown best in FIGS. 8A and 8B, the vein-like pattern embossed through the cross-sectional thickness of the sheet is raised from the coated outer surface 201 of the wrapper 200. While the height of the raised vein pattern may vary widely, it has been found that a height for the main vein 202 of between about 0010 and about 0'020 inches from the otherwise planar outer surface 201 most closely simulates the appearance of the main vein of a natural tobacco leaf and accordingly, such a height is preferred. A most preferred height for the main vein 202 is between about 0014 and about 0016 inches.

Similarly, it has been found that the height of the smaller vein 203 should preferably be between about 0002 and about 0009 inches and, most preferab]y between about 0004 and about 0008 inches.

As shown in FIGS. 8A and 8B, the complementary depressed portions of the veinlike pattern 202A and 203A on the uncoated side of the decorated sheet are preferably filled with a filler material in order to reinforce or aid in reinforcing the raised pattern on the outer surface 201 when the cigar wrapper is stretched taut and, particularly, when the moisture level of the wrapper increases above about 250/,.

Filler materials may either be in powder or paste form, the powder including a mixture of ground tobacco, binding agents and fillers including diatomaceous earths, clays and whitening agents. Preferred diatomaceous earths include the product marketed by Grefco, Inc. of Los Angeles, California under the trademark Dicalite and the product marketed by Johns-Manville of Denver, Colorado under the mark Celite. Preferred clays include Bentonite, marketed by NL Industries, Inc. of New York, Kaolin and monmorillonite and preferred whitening agents, which serve to give the filled vein pattern a more natural, coloured appearance, may be selected from the group consisting of titanium dioxide, calcium carbonate and dolomite. Flavouring and aromatic additives, colouring agents, preservatives, burn modifiers and ash impro- vers may also be incorporated in the filler materials.

The decorated cigar wrapper as illustrated in FIG. 8 includes a base colour which is applied to its uncoated surface, and which is clearly visible from the opposite coated surface. A random shade pattern of contrasting colour is also applied to the uncoated surface and is also visible from coated surface. The base colour applied to the uncoated surface is effected with a colouring agent, including inks and dyes and, preferably selected from the group including carotenoids and annattos; food, drug and cosmetic dyes including the lake and solubilized forms; and other commercial food grade inks. A particularly preferred colouring agent is a mixture of an alcohol soluble cellulose ester and a pigment.

The shade colour pattern is a second random colour coating selectively applied to the uncoated surface of the cigar wrap per using a shading agent. Preferred shading agents are drawn from the same class as the base colouring agents although the shading agent should be of a contrasting colour to effect the random shade or cloud pattern.

As previously stated, the cigar wrapper may have either two layers of sheet material laminated together, as shown in FIG.

8B, or be a single-layered, non-laminated wrapper as shown in FIG. 8A. The two layered, laminated wrapper is preferable, since the second, laminating sheet reinforces the embossed pattern on the decorated sheet and the laminated wrapper is thus more resistant to stretching and resultant obliteration of the embossed vein pattern.

Additionally, the use of a laminated wrapper permits the use of layers of different types and thicknesses and provides the opportunity to create, by combining layers of different properties but having a symbiotic relationship with respect to one another, cigar wrappers having flavours, aromas and other physical properties such as strength, burn characteristics and surface appearances not heretofore possible from a single layered wrapper.

In the laminated wrapper of FIG. 8B, the second or laminating layer 300 is laminated to the decorated layer 200 on the uncoated side of the decorated layer 200 which has the filled, depressed pattern.

The laminating layer 300 is, in this embodiment, a second, undecorated sheet of manufactured cigar wrapper material.

While in most cases, the laminating layer 300 may be similar in all respects, except decoration, to the decorated sheet 200 to which it is laminated, it is foreseen that layers of different thickness and/or composition may be laminated together.

I,amination, which is generally accomplished at elevated temperature and pressure, results in the physical bonding of the decorated layer 200 to the laminating layer 300.

The cigar wrapper of FIG. 8 may then be wrapped around the binder 400 and the bunch portion 500 of a cigar in a conventional manner in order to produce the cigar of FIGS. 9 and 10.

In an alternative embodiment of the present invention (not shown), the decorated layer 200 is laminated directly to the binder 400, thus eliminating the need for this additional layer and wrapping step. Such an embodiment is particularly useful in high speed rod-making machines and a preferred application is in the manufacture of tipped cigars.

The following example serves to illustrate the present invention and should not be construed as limiting its scope.

EXAMPLE In order to more clearly illustrate the properties of a decorated cigar wrapper which was decorated according to the method and using the apparatus described above a sheet of conventional manufactured cigar wrapper was decorated and then laminated to a second sheet of conventional manufactured cigar wrapper. Each of the two sheets had a thickness of about 00015 inches, a tobacco content in excess of 65% and the following physical properties: LAMINATING SHEET (Prior to process ing) dry long strength: 540 g/in dry transverse strength: 135 glin Mullen strength: 1.45 lb/in2 smoothness-top: 25 seconds/25cc/in2 smoothness- bottom: 32 seconds/25cc/in2 sheet weight: 1 55 g/ft2 sheet moisture: 2484% DECORATING SHEET (Prior to pro cessing) dry long strength: 650 g/in dry transverse strength: 410 g/in Mullen strength: 1 95 lb/in2 smoothness-top: 60 seconds/25cc/in2 smoothness- bottom: 100 seconds/25cc/in2 sheet weight: 1 40 g/ft2 sheet moisture: 25 30% The decorating sheet was coated on one surface with the following coating: Ingredients Percent By Weight cellulose-acetate-propionate 10% ethyl alcohol 63% ethyl acetate 27% The laminating sheet had originally been coated on its underside with the following coating: Ingredients Percent By Weight cellulose-acetate-propionate 5 0% acetylated monoglyceride 5 0% ethyl alcohol 63 0% ethyl acetate 270% Each sheet was coated at a level of about 80 mg/ft2 measured on a dry weight basis.

The laminating and decorating sheets were simultaneously processed through the apparatus of FIG. 2, the decorating sheet first having a raised, vein-like pattern embossed through its thickness at a pressure of 60 psi and at a temperature of 262"F.

Base colour was applied at a base colour station at a temperature of 80"F with an alcohol soluble ink and a shade colour pattern was applied at a temperature of 84"F at a shade colour station, also using an alcohol soluble ink of a contrasting colour to the base colour ink. The decorating sheet was then laminated to the laminating sheet at a temperature of 281"F and at a pressure of 60 psi.

The resultant decorated, laminated cigar wrapper, was humidified and rewound.

Subsequent testing indicated that the wrapper had the following physical properties: dry long strength: 700 g/in dry transverse strength: 330 g/in Mullen strength: 1 65 lb/in2 smoothness-top: 80 seconds/25cc/in2 sheet weight: 3 38 g/ft2 street moisture: 30 4% The resultant decorated cigar wrapper, although being a manufactured cigar wrapper, had the appearance of a natural tobacco leaf and the physical properties of a commercially acceptable cigar wrapper.

Although the foregoing example illustrates the formation of a decorated and laminated cigar wrapper, using the apparatus and methods of the present inventions, it will be appreciated that the presently disclosed apparatus and method may be used to manufacture sheet material for use in numerous other applications. Accordingly, the present invention should be limited only by the scope of the appended

Claims (65)

claims. WHAT WE CLAIM IS:-

1. A cigar wrapper comprising a sheet of manufactured cigar wrapper material having opposed surfaces and a predetermined cross-sectional thickness, said sheet having a vein-like pattern embossed through said cross-sectional thickness to form a raised pattern on one of said opposed surfaces and a complementary depressed pattern on the opposite surface, and means applied to said sheet to resist said vein-like pattern being stretched flat when the wrapper is stretched during subsequent manufacturing steps or use.

2. A cigar wrapper comprising a sheet of manufactured cigar wrapper material having opposed surfaces and a predetermined cross-sectional thickness, said sheet having a vein-like pattern embossed through said cross-sectional thickness to form a raised pattern on one of said opposed surfaces and a complementary depressed pattern on the opposite surface, and means provided in the depressions of said vein-line pattern for reinforcing the vein-like pattern.

3. A cigar wrapper comprising a sheet of manufactured cigar wrapper material having opposed surfaces and a predetermined cross-sectional thickness, said sheet having a vein-like pattern embossed through said cross-sectional thickness to form a raised pattern on one of said opposed surfaces and a complementary depressed pattern on the opposite surface, and a second sheet of material which is cohesively laminated in juxtaposition to said opposite surface.

4. A wrapper as claimed in claim 3.

wherein said second sheet is made of manufactured cigar wrapper material.

5. A wrapper as claimed in claim 4 wherein the two sheets of manufactured cigar wrapper material have different properties.

6. A wrapper as claimed in claim 3, 4 or 5, wherein said second sheet is a sheet of cigar binder material.

7. A wrapper as claimed in any of claims 3 to 6, wherein said sheets are different in thickness.

8. A wrapper as claimed in any of the preceding claims, wherein said depressed pattern on said opposite surface is filled with a filler material in order to reinforce said vein-like pattern.

9. A wrapper as claimed in claim 8, wherein said filler material includes ground tobacco, binder agents, and diatomaceous earths, clays and/or whitening agents.

10. A wrapper as claimed in claim 9, wherein said filler material further includes flavouring aids, aromatic additives, colouring agents, burn modifiers, ash improvers and/or preservatives.

11. A wrapper as claimed in any of the preceding claims, wherein said opposite surface is provided with a base colour coating.

12. A wrapper as claimed in claim 11, wherein said base colour coating includes a base colouring agent comprising a mixture of an alcohol-soluble cellulose ester and a pigment.

13. A wrapper as claimed in any of the preceding claims, wherein said opposite surface is provided with a random shade colour coating.

14. A wrapper as claimed in claim 13, wherein the shade colour coating comprises a shading agent comprising a mixture of an alcohol-soluble cellulose ester and a pigment, said shading agent being of a contrasting colour to the colour of the opposite surface of a wrapper.

15. A wrapper as claimed in any of the preceding claims, wherein the said one surface is coated with a hydrophobic coating.

16. A wrapper as claimed in any of the preceding claims, wherein the said one surface is stained with a vegetable oil based stain to further delineate said raised veinline pattern.

17. A cigar wrapper substantially as hereinbefore described with reference to Figures 8 and 8A, or Figures 8, 8B, 9 and 10 of the accompanying drawings.

18. A cigar having a wrapper as claimed in any of the preceding claims.

19. Apparatus for decorating a sheet of manufactured cigar wrapper material, comprising a rotatable sheet guide mandrel, feeding means for feeding said sheet to and around said mandrel, drawing means for drawing said sheet from said mandrel, a decorating means for embossing a decorative raised vein-like pattern on one surface of said sheet as the sheet passes between said decorating means and said mandrel and providing a complementary depressed pattern on its opposite surface, and means for applying a reinforcing material only to said vein-like pattern.

20. Apparatus as claimed in claim 19, wherein said means for applying a reinforcing material only to said vein-like pat tern includes an applicator for depositing a filler material along said opposite surface of said sheet and means to compress the filler material within the depressed vein-like pattern and remove excess filler material from said opposite surface.

21. Apparatus as claimed in claim 19 or 20, further comprising laminating means for laminating said sheet of manufactured cigar wrapper material to a second sheet of cigar wrapper material, and means for feeding said second sheet between said laminating means and said mandrel, said laminating means being operable to laminate said second sheet to said opposite surface of said decorated sheet as said two sheets pass between said laminating means and said mandrel.

22. Apparatus as claimed in claim 21, wherein the laminating means comprises a laminating roller positioned adjacent said guide mandrel and mounted to rotate in a direction opposite to the direction of rotation of said guide mandrel in order to draw the decorated sheet and said second sheet through the nip between the guide mandrel and said laminating roller.

23. Apparatus as claimed in claim 22, wherein said laminating roller is internally heated.

24. Apparatus as claimed in any of claims 19 to 23, further comprising colouring means for colouring said sheet of manufactured cigar wrapper material.

25. Apparatus as claimed in claim 24, wherein said colouring. means is positioned adjacent said mandrel and includes at least one colour gravure roller having a pattern on the outer surface thereof, at least one colour transfer roller in contact with said colour gravure roller and said mandrel, and means to apply a colouring agent evenly to said colour gravure roller, said colour transfer roller being mounted to rotate in a direction opposite to the direction of rotation of said colour gravure roller and said mandrel, whereby said colour transfer roller will transfer said colouring agent in the pattern of said colour gravure roller to said sheet as the latter is drawn through the nip between the oppositely rotating mandrel and the colour transfer roller.

26. Apparatus as claimed in claim 25, wherein said means to apply a colouring agent evenly comprises an open pan for receiving and holding said colouring agent and a doctor blade, said open pan being positioned relative to said colour gravure roller such that colouring agent in said pan can be applied to the outer surface of said colour gravure roller during rotation of the latter, and said doctor blade being mounted relative to and spaced sufficiently from said colour gravure roller for removing excess colouring agent from said colour gravure roller.

27. Apparatus as claimed in claim 25 or 26, wherein said colour transfer roller is internally cooled.

28. Apparatus as claimed in any of claims 19 to 27, further comprising shading means for imparting a shaded colour pattern on said decorated sheet.

29. Apparatus as claimed in claim 28, wherein said shading means is positioned adjacent to said mandrel and includes at least one shade gravure roller having a shade pattern on the outer surface thereof, at least one shade transfer roller in contact with said shade gravure roller and said mandrel, and means to apply a shading agent evenly to said shade gravure roller, said transfer roller being mounted to rotate in a direction opposite to the direction of rotation of said shade gravure roller and mandrel, whereby said shade transfer roller will transfer said shading agent in the pattern of said shade gravure roller to said sheet as the latter is drawn through the nip between the oppositely rotating mandrel and the shade transfer roller.

30. Apparatus as claimed in claim 29; wherein said means to apply a shading agent evenly comprises an open pan for receiving and holding said shading agent and a doctor blade, said open pan being positioned relative to said shading gravure roller such that shading agent in said pan can be applied to the outer surface of said shade gravure roller during rotation the latter, and said doctor blade being mounted relative to and spaced sufficiently from said shade gravure roller for removing excess shading agent from said shade gravure roller.

31. Apparatus as claimed in claim 29 or 30, wherein said shade transfer roller is internally cooled.

32. Apparatus as claimed in any of claims 19 to 31, further comprising coating means for applying a coating to the decorated sheet.

33. Apparatus as claimed in claim 32, comprising a further roller adjacent said mandrel, wherein said coating means includes at least one coating gravure roller, at least one coating transfer roller in contact with said coated gravure roller and said further roller, and means to apply a coating agent, such as hydrophobic coating agent, evenly to said coating gravure roller, said coating transfer roller being mounted to rotate in a direction opposite to the direction of rotation of said coating gravure roller and said further roller, said coating transfer roller being mounted to transfer said coating agent from said coating gravure roller to said sheet as said sheet is drawn through the nip between the oppositely rotating further roller and the coating transfer roller.

34. Apparatus as claimed in claim 33, as dependent on claim 22 or 23, or any of claims 24 to 32 as dependent on claim 22 or 23, wherein said further roller is the laminating roller.

35. Apparatus as claimed in any of claims 19 to 34, further comprising staining means for applying a stain to the decorated sheet.

36. Apparatus as claimed in claim 35, wherein said staining means includes a second rotatable sheet guide mandrel, at least one staining gravure roller, at least one staining transfer roller in contact with said gravure roller and said second sheet guide mandrel, and means to apply a stain evenly to said staining gravure roller, said staining transfer roller being mounted to rotate in a direction opposite to the direction of rotation of said staining gravure roller and said second sheet guide mandrel, whereby said staining transfer roller will transfer stain from said staining gravure roller to said sheet as the latter is drawn through the nip between the oppositely rotating second guide mandrel and the staining transfer roller.

37. Apparatus as claimed in any of claims 19 to 36, wherein the decorating means is a roller positioned adjacent to said guide mandrel, said decorating roller having a decorative vein-like pattern on its outer surface and being mounted to rotate in a direction opposite to the directoin of rotation of said guide mandrel in order to draw said sheet through the nip between said mandrel and said decorating roller to emboss the raised vein-like pattern in the sheet.

38. Apparatus as claimed in claim 37, wherein said mandrel has a depressed female vein-like pattern formed on its outer surface and the decorating roller is an embossing roller having a raised male vein-like pattern formed on its outer surface, complementary to the depressed female vein-like pattern on the surface of the mandrel.

39. Apparatus as claimed in claim 38, wherein said embossing roller is internally heated.

40. Apparatus as claimed in any of claims 19 to 39, further comprising means to humidify the decorated sheet or laminated sheets.

41. Apparatus as claimed in claim 40, wherein the humidifier means is located between the guide mandrel and the drawing means.

42. Apparatus for decorating a sheet of manufactured cigar wrapper material substantially as hereinbefore described with reference to Figures 1 and 3 to 7A, or Figures 2 to 7A of the accompanying drawings.

43. A method of decorating a sheet of manufactured cigar wrapper material, comprising feeding said sheet towards and around a guide mandrel, embossing a decorative vein-like pattern on said sheet as said sheet passes around the guide mandrel to form a raised vein-like pattern on one surface of said sheet and a complemen- tary depressed vein-like pattern on the opposite surface of the sheet, reinforcing only said vein-like pattern, and drawing the decorated sheet from said guide mandrel.

44. A method as claimed in claim 43, wherein the reinforcing of said vein-like pattern is carried out by applying a filler material along said opposite surface of said embossed sheet and selectively filling the depressed vein-like pattern with the filler material.

45. A method as claimed in claim 43 or 44, further comprising feeding a second sheet of material towards said mandrel, laminating said second sheet to the oppo site surface of said decorated sheet by passing said sheets between a laminating means and said mandrel, and drawing said laminated sheets from said mandrel.

46. A method as claimed in claim 45, wherein said second sheet is a sheet of manufactured cigar wrapper material.

47. A method as claimed in claim 45 or 46, wherein said sheets are passed between a laminating roller and said mandrel.

48. A method as claimed in claim 47, wherein the laminating roller is internally heated.

49. A method as claimed in any of claims 45 to 48, wherein the lamination is carried out at a temperature of 250"F or above.

50. A method at claimed in claim 49, wherein the lamination is carried out at a temperature of from 250C to 3500F.

51. A method as claimed in any of claims 43 to 50, comprising colouring said sheet as it passes around said mandrel.

52. A method as claimed in claim 51, comprising colouring the opposite surface of said sheet by passing the sheet between a colour transfer roller and said mandrel.

53. A method as claimed in any of claims 43 to 52, comprising imparting a shade pattern on said sheet as it passes around said mandrel.

54. A method as claimed in claim 53, in which the shade pattern is imparted to the opposite surface of said sheet by passing the sheet between a shade transfer roller and said mandrel.

55. A method as claimed in any of claims 43 to 54, comprising applying a stain to the decorated sheet.

56. A method as claimed in claim 55, wherein the stain is applied by passing the sheet between a stain transfer roller and the mandrel.

57. A method as claimed in any of claims 43 to 56, comprising applying a hydrophobic coating to said sheet.

58. A method as claimed in claim 57, comprising passing the sheet between a coating transfer roller and said mandrel.

59. A method as claimed in any of claims 43 to 58, wherein said embossing is effected by passing the sheet through the nip between an embossing roller and said mandrel.

60. A method as claimed in claim 59, wherein the embossing is carried out at a temperature of 250 F or above.

61. A method as claimed in a claim 60, wherein the embossing is carried out in the range from 250 to 350 F.

62. A method as claimed in any of claims 43 to 61, further comprising humidifying the decorated sheet or laminated sheets.

63. A method as claimed in claim 62, wherein the humidification is carried out at a temperature of about 110 F.

64. A method as claimed in any of claims 43 to 63, wherein the sheet or sheets fed to the mandrel have previously been coated with a hydrophobic coating.

65. Methods of decorating a sheet of manufactured cigar wrapper material substantially as hereinbefore described with reference to the accompanying drawings.