Patent Application
20110011412
Cigarettes and other smoking articles commonly include filter portions (universally known as filter segments) intended to remove some impurities and toxins from the cigarette smoke as it is inhaled. These filters may also add flavorings to the cigarette smoke as it is inhaled. Cigarette manufacturers may wish to include several different filter segments within a single cigarette filter in order to impart desired filtering and flavor characteristics to the cigarette. The several filter segments within a cigarette filter must usually be placed in a particular order and must lack gaps therebetween in order to function properly.
An apparatus for assembly of multi-segment rod-like articles, particularly cigarette filters, including a filter segment intercalating unit, a filter rod assembly unit and a filter segment transfer unit coupled to the intercalating unit and the assembly unit, the intercalating unit further including at least one filter segment delivery unit and a filter rod transporting device. The multi-segment delivery unit including a hopper, a rotating drum having a plurality of transverse flutes and a plurality of circumferential slits defined in the surface thereof, and a cutting device disposed adjacent to said rotating drum, said cutting device having a plurality of blades received within said slits of the rotating drum in order to cut the filter rods into segments.
The transfer unit further includes a pulley assembly, a first wheel operatively engaged with said pulley assembly, a second wheel operatively engaged with said first wheel, and a third wheel operatively engaged with said second wheel, each of said first, second and third wheels having a plurality of fingers defined in the circumference thereof; and the assembly unit including a garniture, a filter rod gap sensor and a filter rod cutting device.
a is a view of an exemplary embodiment of a filter segment delivery mechanism of a filter rod supply unit.
b is a view of another exemplary embodiment of a filter segment delivery mechanism of a filter rod supply unit.
c is a diagram of a pushrod assembly for an exemplary embodiment of a filter rod supply unit.
a is a view of a portion of an exemplary embodiment of a filter segment delivery mechanism and a conveyor belt.
b is a cross section of a portion of an exemplary embodiment of a filter segment delivery mechanism and a conveyor belt along line A-A.
a is a view of an exemplary embodiment of a filter segment transport mechanism.
b is a view of a set of filter segment catchers.
c is a detailed view of an exemplary embodiment of a filter segment catcher.
d is a view of an exemplary embodiment of a filter segment catcher.
e is a view of an exemplary embodiment of a segment catcher.
Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows.
As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiment are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.
Turning to
Each rod supply unit 200 may be coupled to intercalating unit 110 in a modular, or “plug-and-play” manner to facilitate coupling and decoupling of each rod supply unit 200 from intercalating unit 110 without extensive configuration. Such a manner of coupling may enable the user to quickly and simply adapt intercalating unit 110 based on the desired characteristics of the output composite cigarette filter. For example, hopper 202 of each rod supply unit 200 may contain base filter rods 204 of equal or varying size, structure, or other characteristics to those contained in any other rod supply unit 200, depending on the desired characteristics of the output composite filter. Each rod supply unit 200 may then deliver different or equal filter rod segments 114 to conveyor 112 such that each segment is placed on conveyor 112 in a desired order and with desired spacing in relation to other segments 114.
As a result, filter rod segments 114 may be grouped on conveyor 112 such that each group 116 contains the desired components of a composite cigarette filter arranged in the desired order. If a composite filter with a greater or fewer number of components is desired, one or more rod supply units 200 may be coupled or decoupled to intercalating unit 110 and provided with base filter rods 204 having the desired characteristics. Conveyor 112 may be driven by a servomotor or any other motive device known by one of ordinary skill in the art. The speed of conveyor 112 may be synchronized with the speed of rod delivery mechanism 208 of each rod supply unit 200.
Conveyor 112 may then carry filter segments 114 or groups of filter segments 116 to transfer unit 130. Transfer unit 130 may be configured to facilitate transfer of filter rod segments 114 or segment groups 116 to a garniture 122 of assembly unit 120. In one embodiment, conveyor 112 of intercalating unit 110 may be vertically offset relative to garniture 122 of assembly unit 120. Transfer unit 130 may be configured to facilitate transfer of filter rod segments 114 or segment groups 116 from conveyor 112 to a garniture 122 when conveyor 112 is vertically offset relative to garniture 122.
Turning now to
In one embodiment, the distance between two slits 217 may be substantially equal to the length of a filter rod segment 114. As a result, each flute 216 may be subdivided by slits 217 into a plurality of portions, wherein each portion may be substantially equal to the length of a filter rod segment 214. In one embodiment, aperture 218 may be provided in each portion of flute 216. Apertures 218 may be supplied with vacuum such that base filter rods 204 and filter rod segments 114 are maintained in contact with flutes 216 of rotary drum 210.
Cutting device 220 may be positioned adjacent to rotary drum 210 and may have side wall 222. Side wall 222 may have a substantially arcuate shape defining a cavity 224 such that a portion of the circumference of rotary drum 210 is received within cavity 224. Cutting device 220 may include a plurality of cutting blades (not shown). In one embodiment, the quantity of cutting blades (not shown) may be equal to the quantity of circumferential slits 217. The cutting blades (not shown) may protrude substantially into cavity 224 and may be received by slits 217 such that the edge of a cutting blade (not shown) may extend into rotary drum 210 beyond the surface of a flute 216, thereby facilitating the cutting of base filter rods 204 into half-segments 205 and intermediate segments 206, which may then be cut into filter rod segments 114.
Cutting blades (not shown) may be arranged within cutting device 220 depending on the desired size of filter segments 114. In one embodiment, the cutting blades may be arranged such that filter rods 204 are subdivided into half-segments 205 and intermediate segments 206 in successive cutting steps, as shown in
In one embodiment, as shown in
In another embodiment, as shown in
Turning now to
Delivery wheel 240 may also be disposed to facilitate the transfer of filter segments 114 from transfer wheel 230 to delivery wheel 240. Delivery wheel 240 may include equally spaced fingers 244 positioned around the circumference of delivery wheel 240 and a guide plate 246 positioned adjacent to delivery wheel 240. Guide plate 246 may be positioned such that a channel 248 is defined between delivery wheel 240 and guide plate 246, with the width of guide channel 248 being substantially similar to the radius of filter segments 114. Fingers 244 can facilitate transfer of filter segments 114 from transfer wheel 230 to conveyor 112. Fingers 244 can also be positioned around the circumference of delivery wheel 240 to facilitate maintaining substantially equal spacing between any two successive filter segments 114 on conveyor 112. Conveyor 112 may have a groove 113 defined therein. Groove 113 may be substantially U-shaped and may have a radius substantially similar to the radius of filter segments 114 to facilitate transporting filter segments 114 on conveyor 112 such that spacing between segments 114 is not altered during transport.
In operation, base filter rods 204 may be placed in hopper 202 of a rod supply unit 200. Base filter rods 204 may then be delivered through the hopper to rotary drum 210, and picked up by rotary drum 210 such that each base filter rod 204 is carried within a single flute 216 of rotary drum 210. Vacuum supplied through apertures 218 provided within flute 216 may aid in maintaining contact between base filter rod 204 and the surface of flute 216. As drum 210 rotates, it can carry base filter rods 204 towards cutting device 220, where base filter rods 204 may be cut by a plurality of cutting blades (not shown) that are received within slits 217 of rotary drum 210. In one embodiment, base filter rods 204 may be cut into successively smaller portions by the cutting blades (not shown) of cutting device 220, such that each base filter rod 204 is cut into a plurality of segments 114.
For example, as shown in
At the end of guide channel 248, filter rod segments 114 may be deposited on conveyor 112, whereupon they may be conveyed towards a subsequent rod supply unit 200. Each subsequent rod supply unit 200 may deposit filter rod segments 114 on conveyor 112 such that each subsequent filter rod segment 114 is grouped with previous filter rod segments 114. In this manner, filter rod segment groups 116 are generated, wherein each filter rod segment group contains a set of filter rod segments 114 arranged in a desired order. Filter rod segment groups 116 are then conveyed by conveyor 112 towards transfer unit 130.
In another embodiment, intercalating unit 110 may include at least one rod supply unit 300 and at least one flexible belt 312, as shown in
Each segment catching device 320 may include a pair of arms 322a and 322b. Each of arms 322a and 322b may have a first end 323, a second end 324 and a cross-member 325 positioned between first end 323 and second end 324. First end 323 and second end 324 of each arm may be positioned such that first end 323 of arm 322a is substantially coaxial with second end 324 of arm 322b and first end 323 of arm 322b is substantially coaxial with second end 324 of arm 322a. Cross-members 325 of each of arms 322a and 322b may be positioned transversely to each other, facilitating pivotally coupling arm 322a to arm 322b by pin 326. First end 323 of each of arms 322a and 322b may have a bottom portion 327 having a substantially cylindrical shape capable of engaging a cam 334 and may be springedly coupled by spring 328. Plate 330 may be coupled to pin 326 and may have aperture 329 defined therein. Aperture 329 may have a diameter substantially similar to the diameter of flexible belt 312 such that flexible belt 312 may be received within aperture 329 and be fixedly coupled to plate 330. Screw 328 may be threadably coupled to bottom end 323 of arm 322b.
A cam 334 may be received between cylindrical portions 327 of each of arms 322a and 322b and may spread apart cylindrical portions 327 such that segment catching device 320 is in an open configuration. At this point, a filter rod segment 114 may be received between the first ends 324 of each of arms 322a and 322b. As cam 334 is withdrawn, spring 328 may return 320 into a closed configuration and filter segment 114 may be frictionally coupled between first ends 324 of each of arms 322a and 322b. Screw 332 may be adjusted such that it extends toward and abuts bottom end 323 of arm 322a, thereby exerting a force to counteract spring 328. Further adjustment of screw 332 may facilitate changing the clamping force of first ends 324 on a filter rod segment 114. In one embodiment, segment catching device 320 may be adapted to receive filter rod segment 114. In another embodiment, segment catching device 320 may be adapted to receive tape 401 having filter rod segments 114 disposed therein.
In operation, a plurality of segment catching devices 320 may be positioned by flexible belt 312 under rotary drum 310 of a rod supply unit 300. Each segment catching device 320 may be positioned under rotary drum 310 such that each segment catching device 320 may receive a filter rod segment 114 from rotary drum 310. As each segment catching device 320 is positioned under rotary drum 310, cam 334 may place each segment catching device 320 into an open configuration. Filter segments 114 may then be released from rotary drum 310 and received by segment catching devices 320. In one embodiment, filter segments 114 may be deposited into a groove defined in the surface of a tape 401, and tape 401 with filter segments 114 disposed therein may be received by segment catching devices 320. Subsequently, cams 334 may be withdrawn and segment catching devices 320 returned to a closed configuration and carried by flexible belt 312 to transfer unit 130. Segments from each of a plurality of rod supply units 300 may be carried to transfer unit 130 in the above-described manner. Upon arrival at transfer unit 130, segment catching devices may be positioned such that filter segments 114 are aligned coaxially and positioned in a desired order. Segment catching devices may then be placed in an open configuration by cam 334 and filter segments 114 may then be transferred to transfer unit 130.
Turning now to
In one embodiment, first wheel 132 may be vertically offset relative to third wheel 136 to facilitate transfer of filter segments 114 or segment groups 116, when conveyor 112 and garniture 122 are vertically offset relative to each other. Consequently, first wheel 132 may be positioned at a height that facilitates the transfer of filter segments 114 or groups of filter segments 116 from conveyor 112 to first wheel 132, while third wheel 134 may be positioned at a height that facilitates transfer of filter segments 114 or groups of filter segments 116 from third wheel 136 to garniture 122. In one embodiment, second wheel 134 may be vertically aligned with third wheel 136. In another embodiment, second wheel 134 may be vertically aligned with first wheel 132. In another embodiment, second wheel 134 may be vertically offset from first wheel 132 and third wheel 136, thereby allowing transfer unit 130 to bridge varying vertical gaps between conveyor 112 and garniture 122.
In operation, filter rod segments 114 are carried by conveyor 112 to transfer unit 130. Upon entering conveyor device 140, filter rod segments may be engaged by conveyor device 140 and directed towards first wheel 132. As filter rod segments 114 approach first wheel 132, filter rod segments 114 may be engaged by fingers 133 of first wheel 132 such that a filter rod segment group 116 is disposed between any two fingers 133.
Filter rod segment groups 116 may then be transported by first wheel 132 towards second wheel 134 to a point where each group 116 may be substantially tangential to both first wheel 132 and second wheel 134. At this point, filter rod segments 114 may be engaged by fingers 135 of second wheel 134 such that a filter rod segment group 116 is disposed between any two fingers 135. Filter rod segment groups 116 may then be transported by second wheel 134 towards third wheel 136 to a point where each group 116 may be substantially tangential to both second wheel 134 and third wheel 136. At this point, filter rod segments 114 may be engaged by fingers 137 of third wheel 136 such that a filter rod segment group 116 is disposed between any two fingers 137. Filter rod segment groups 116 may then be transported by third wheel 136 to assembly unit 120.
Assembly unit 120 may include a garniture 122, a sensor 124 and a cutoff device 126. Groups of filter segments 116 may be deposited on garniture 122 via third wheel 134 of transfer unit 110. While on garniture 122, groups of filter segments 116 may be wrapped in a paper according to methods known in the art. Sensor 124 may then register gaps between filter segments 114 and groups of filter segments 116 to determine whether the gaps are within desired standards. Cutoff device 126 may then cut the continuous filter rod into individual filter rods, wherein each individual filter rod is composed of a group of filter segments 114 wrapped in a paper. Each individual rod may be cut to a specific desired length by cutoff device 126. Filter rods determined to not conform to desired standards by sensor 124 may then be ejected from the production line.
The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.
