Patent Grant
11490651
Example embodiments generally relate to a tongue and a tongue assembly, with an injection port, for a rod forming apparatus, a rod forming apparatus with the tongue assembly, and a method of installing the tongue assembly on the rod forming apparatus.
During the manufacture of cigars, tobacco can have a relatively high cost. Therefore, an efficient use of tobacco is important. High-quality cigars should be uniformly and consistently filled.
At least one example embodiment is directed toward a tongue for rod forming.
In one embodiment, the tongue includes a shaft, the shaft being hollow, the shaft including a first end and a second end, the first end defining a first opening with a first radius of curvature, the second end defining a second opening with a second radius of curvature, the first radius of curvature being larger than the second radius of curvature, the shaft defining at least one injection port that traverses through an inner surface of the shaft; and a first plate connected to the shaft, the first plate including an engaging structure configured to mount the tongue onto a lower plate and align the shaft with a groove defined by the lower plate.
In one embodiment, the first opening has a first cross-sectional flow area that is larger than a second cross-sectional flow area of the second opening.
In one embodiment, the inner surface is arcuate-shaped and has a continually reducing radius of curvature from the first end to the second end of the shaft.
In one embodiment, the at least one injection port is configured to inject at least one substance onto the inner surface, the at least one substance being at least one of water, at least one flavorant, at least one additive, or combinations thereof.
In one embodiment, the at least one injection port traverses a centerline of the inner surface, the centerline running along a longitudinal length of the inner surface.
In one embodiment, the at least one injection port includes a single injection port.
In one embodiment, the at least one injection port includes two injection ports.
In one embodiment, the at least one injection port includes a first plurality of injection ports that are located at a first position along a longitudinal length of the shaft.
In one embodiment, the first plurality of injection ports includes, at least one first injection port that traverses a centerline of the inner surface, the centerline running along the longitudinal length of the shaft, at least one second injection port traversing a first side of the inner surface, and at least one third injection port traversing a second side of the inner surface, the first side and the second side being on either side of the centerline.
In one embodiment, the at least one injection port includes a second plurality of injection ports that are located at a second position along a longitudinal length of the shaft.
In one embodiment, the first position is near the first end of the shaft.
In one embodiment, the second position is near a mid-section of the shaft.
In one embodiment, the second position is between a mid-section of the shaft and the second end of the shaft.
In one embodiment, the engaging structure is at least one of a mounting bolt hole or a slot.
In one embodiment, the shaft further includes, a tapered entrance connected to the first end of the shaft, the tapered entrance defining an enlarged opening, the first opening having a first cross-sectional flow area that is smaller than a second cross-sectional area of the enlarged opening.
In one embodiment, the first cross-sectional flow area is larger than a third cross-sectional flow area of the second opening.
In one embodiment, the second cross-sectional area of the enlarged opening is one of rectangular-shaped or squared-shaped.
In one embodiment, the shaft runs along an edge of the first plate.
In one embodiment, the first plate is connected along at least a portion of an upper surface of the shaft.
In one embodiment, the first plate includes, a first protrusion on a first side of the first plate, and a second protrusion on the first side of the first plate, the first protrusion and the second protrusion defining a notch, and the first protrusion runs along at least part of an upper portion of a longitudinal length of the shaft.
At least one example embodiment is directed toward a tongue assembly.
In one embodiment, the tongue assembly includes the tongue, and a lower mounting plate connected to a lower portion of the tongue.
In one embodiment, a lower end of the lower mounting plate includes a third protrusion, the third protrusion running substantially underneath the second protrusion, the third protrusion being positioned to at least partially align and mount the tongue assembly onto a lower plate of a rod forming apparatus.
In one embodiment, the lower mounting plate includes a shelf, the shelf extending from an inner side of the lower mounting plate toward the shaft, the shelf including an inclined surface, the inclined surface being upwardly facing and inclined away from the shaft.
In one embodiment, the inclined surface is configured to at least partially assist in folding a lap edge of at least one covering of a rolled consumer product toward an upper surface of the shaft, as the lap edge of the at least one covering travels through a third opening defined by the tongue assembly.
In one embodiment, the third opening is at least partially defined by the inclined surface and a side of the shaft.
In one embodiment, the tongue assembly further includes an upper mounting plate, a first surface of the upper mounting plate mating with an upper surface of the first plate and a second surface of the lower mounting plate mating with a lower surface of the first plate, and the upper surface, the lower surface, the first surface, and the second surface each being substantially flat.
In one embodiment, the upper mounting plate includes a fourth protrusion and a fifth protrusion, the fourth protrusion mating with the first protrusion and the fifth protrusion mating with the second protrusion.
In one embodiment, the fourth protrusion defines at least two bolt holes, the at least two bolt holes being on either side of the first protrusion, the at least two bolt holes being configured to align the first plate with the upper mounting plate.
In one embodiment, the first plate defines a first notch, and the upper mounting plate defines a second notch, the first notch and the second notch being substantially aligned with each other.
In one embodiment, the first notch and the second notch are both substantially V-shaped.
At least one example embodiment is directed toward a rod forming apparatus.
In one embodiment, the rod forming apparatus includes an in-feed section configured to convey a column of tobacco in a downward direction; a finishing section configured to receive the column of tobacco, the finishing section being configured to roll the column of tobacco into a wrapped tobacco rod, the finishing section including a tongue, the tongue including, a shaft, the shaft being hollow, the shaft including a first end and a second end, the first end defining a first opening with a first radius of curvature, the second end defining a second opening with a second radius of curvature, the first radius of curvature being larger than the second radius of curvature, the shaft defining at least one injection port that traverses through an inner surface of the shaft; and a first plate connected to the shaft, the first plate including an engaging structure configured to mount the tongue onto a lower plate and align the shaft with a groove defined by the lower plate.
In one embodiment, the in-feed section includes, an upper belt and an in-feed belt, the upper belt and the in-feed belt defining a descending channel, the descending channel being configured to convey the column of tobacco in the downward direction, a pair of squeeze bars that are configured to receive the column of tobacco from the descending channel, the pair of squeeze bars being configured to compress the column of tobacco, a lower belt configured to move the column of tobacco through the pair of squeeze bars and into the finishing section, and the lower belt being further configured to move at least one covering, positioned below the column of tobacco, into the finishing section.
In one embodiment, the finishing section further includes, a compression box, the compression box including a lower plate defining a groove, wherein the shaft of the tongue is configured to longitudinally align with the groove, the compression box being configured to further compression the column of tobacco into a tobacco rod, an adhesive applicator, the adhesive applicator being configured to apply an adhesive to a portion of the at least one covering, one or more folders downstream of the compression box, the one or more folders being configured to fold the at least one covering, with the adhesive, around the tobacco rod, and a cutter, the cutter being configured to cut the tobacco rod into rolled consumer products.
At least one example embodiment is directed toward a method of installing a tongue assembly on a rod forming apparatus.
In one embodiment, the method includes aligning a shaft of a tongue with a groove, the groove being defined by a lower plate of a compression box, the tongue including, a shaft, the shaft being hollow, the shaft including a first end and a second end, the first end defining a first opening with a first radius of curvature, the second end defining a second opening with a second radius of curvature, the first radius of curvature being larger than the second radius of curvature, the shaft defining at least one injection port that traverses through an inner surface of the shaft; and a first plate connected to the shaft, the first plate including an engaging structure configured to mount the tongue onto the lower plate and align the shaft with a groove defined by the lower plate.
In one embodiment, the method further includes bolting the first plate onto the lower plate to stabilize the aligned shaft with the groove.
In one embodiment, the bolting of the first plate onto the lower plate includes, connecting a lower mounting plate to the first plate by mating a first upper surface of the lower mounting plate to a first lower surface of the first plate, the first upper surface and the first lower surface being substantially flat, the lower mounting plate and the first plate being configured to be bolted together onto the lower plate, the lower mounting plate including, a shelf, the shelf extending from an inner side of the lower mounting plate toward the shaft once the lower mounting plate is connected to the first plate, the shelf including an upwardly facing inclined surface that inclines away from the shaft.
In one embodiment, the bolting of the first plate onto the lower plate further includes, connecting an upper mounting plate to the first plate by mating a second upper surface of the first plate to a second lower surface of the upper mounting plate, the second upper surface and the second lower surface being substantially flat, the lower mounting plate, the upper mounting plate and the first plate being configured to be bolted together onto the lower plate, the upper mounting plate including, a first protrusion and a second protrusion, the first protrusion mating with a third protrusion of the first plate and the second protrusion mating with a fourth protrusion of the first plate, the third protrusion and the fourth protrusion extending from one side of the first plate.
In one embodiment, the first plate defines a first notch, and the upper mounting plate defines a second notch, the first notch and the second notch being substantially aligned with each other once the upper mounting plate is connected to the first plate.
In one embodiment, the method further includes holding the first plate on the lower plate to stabilize the aligned shaft with the groove by connecting the first plate to an arm support device using an engaging structure.
The various features and advantages of the non-limiting embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may have been exaggerated.
Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.
Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives thereof. Like numbers refer to like elements throughout the description of the figures.
It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations or sub-combinations of one or more of the associated listed items.
It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, regions, layers and/or sections, these elements, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.
Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or groups thereof.
When the words “about” and “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value, unless otherwise explicitly defined.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of example embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.
In an example embodiment, the rod forming apparatus 10 includes a feed section 2, an in-feed section 4, a web section 6 and a finishing section 11. In an example embodiment, the feed section 2 includes at least one conveyer 3 for receiving tobacco 1 from a tobacco source (not shown). In an example embodiment, the tobacco 1 is shredded tobacco, as described in more detail herein. In an example embodiment, the feed section 2 includes a storage container 5 that may be at least one of a reservoir, a vat, a shipping container, etc. In an example embodiment, the rod forming apparatus 10 does not include a conveyor 3, as the tobacco 1 may be manually placed into the storage container 5, or the storage container 5 may be used until depleted and then replaced with another storage container 5.
In an example embodiment, the feed section 2 includes a feeder 8. The feeder 8 may be physically located below the storage container 5, and may receive tobacco 1 from the storage container 5. In an example embodiment, the feed section 2 does not include a storage container 5, and instead includes the feeder 8 and/or the conveyor 3. In an example embodiment, the storage container 5 and the feeder 8 are one integral element. Other configurations of the feed section 2 are contemplated.
In an example embodiment, the feeder 8 includes one or more outlets 9 at a lower portion of the feeder 8. In an example embodiment, the one or more outlets 9 are distributed in an outlet array 9a. In an example embodiment, the feeder 8 is a vibratory waterfall type feeder. In an example embodiment, the storage container 5, or the feeder 8, or both the storage container 5 and the feeder 8 include at least one electromagnetic (motorized) vibrator 7a/7b for causing the tobacco 1 to vibrate and uniformly settle, as the tobacco 1 leaves the storage container 5 and/or the feeder 8.
In an example embodiment, the feeder 8 and/or the outlets 9 are capable of distributing the tobacco 1 onto an upper (conveyor) belt 12, as shown in better detail in
In an example embodiment, the feed section 2 and upper belt 12 provide the tobacco column 1a to the in-feed section 4 of the roll forming apparatus 10. In an example embodiment, the tobacco column 1a is transferred into the in-feed section 4 by a second belt section 12b of the upper belt 12 and an in-feed (compression) belt 20 that are downstream of the feeder 8. Specifically, in an example embodiment, the tobacco column 1a rides on the second belt section 12b (shown in better detail
In an example embodiment, the second belt section 12b and/or the descending belt section 20a feed the tobacco column 1a into the finishing section 11 of the rod forming apparatus 10. In an example embodiment, the second belt section 12b and/or the descending belt section 20a feed the tobacco column 1a to a lower belt 22. In an example embodiment, the lower belt 22 is a garniture belt, or a garniture tube belt. In an example embodiment, the lower belt 22 travels along a set of rollers 23.
In an example embodiment, the tobacco column 1a enters the finishing section 11 through a channel 21. In an example embodiment, the channel has a continually and linearly decreasing cross-sectional area, as described in detail in association with
In an example embodiment, the rod forming apparatus 10 includes the web section 6, where the web section 6 provides at least one covering 31 that may be applied longitudinally around the consumer product 300. In an example embodiment, the at least one covering 31 includes at least two web layers. In an example embodiment, the at least one covering 31 includes a binder web 30 and a wrapper web 34. In an example embodiment, the binder web 30 is used to bind the tobacco 1, and in doing so, the binder web 30 may come into intimate direct contact with the tobacco 1. In an example embodiment, the wrapper web 34 is used to cover the binder web 30. In an example embodiment, a bulk portion of the binder web 30 and the wrapper web 34 are respectively housed on a binder reel 32 and a wrapper reel 36. A series of rollers 38 may be used to guide the binder web 30 and the wrapper web 34 into the finishing section 11. In an example embodiment, the binder web 30 and the wrapper web 34 are formed from tobacco, tobacco pulp, compressed tobacco, or a derivative or extract of tobacco, where the binder web 30 and the wrapper web 34 are in the form of flatten sheets or ribbons.
In an example embodiment, once the tobacco column 1a and the at least one covering 31 proceed into the finishing (rod forming) section 11, via the force of the lower belt 22, the tobacco column 1a is guided through the compression box 100a to form a tobacco rod 1b (see at least
In an example embodiment, the lower belt 22 causes the at least one covering 31 and the tobacco column 1a to travel in unison through the compression box 100a to a short folder 42, as discussed in more detail herein (see
In an example embodiment, the lower belt 22 causes the finished rod 41 to pass through a cutter 48. In an example embodiment, the cutter 48 cuts the finished rod 41 into segments, where these segments form the consumer product 300 (
In an example embodiment, a decline angle 27 of the descending section 21a of the channel 21 (defined by the second belt section 12b and the descending belt section 20a), assists in driving the tobacco column 1a through the channel 21 with enough velocity that the tobacco column 1a has a necessary momentum to flow through the horizontal section 21b of the channel 21 and the compression box 100a, where the tobacco column 1a is further compressed along the way. To that end, an exceedingly steep decline angle 27 can cause the tobacco column 1a to flow at too great of a velocity, causing a potential over-compression of the tobacco column 1a (and, subsequent potential “accordion effect,” caused by the over-compression), due to any minor disruption or impedance of the flow of the tobacco column 1a through the rod forming apparatus 10. An exceedingly mild decline angle 27 can leave the tobacco column 1a without enough velocity and momentum to carry the tobacco column 1a through the channel 21 and the compression box 100a. Therefore, in an example embodiment, the angle of decline 27 is about 10-45 degrees (relative to a horizontal plane, where the horizontal plane is perpendicular to gravity). It should be understood that the decline angle 27 varies, depending for instance on a speed of the second belt section 12b and the descending belt section 20a, and a composition of the tobacco column 1a.
In an example embodiment, the channel 21 is also at least partially defined by the horizontal section 21b, where the horizontal section 21b feeds the tobacco column 1a into the compression box 100a. In an example embodiment, the horizontal section 21b also has a continually narrowing cross-sectional flow area that causes the tobacco column 1a to be further compressed prior to flowing into the compression box 100a. In an example embodiment, the horizontal section 21b of the channel 21 is defined at least in part by the lower belt 22, the horizontal belt section 20b, and horizontal portions 84 of the first squeeze bar 60 and the second squeeze bar 62 (see
In an example embodiment, the in-feed section 4 includes a transition piece 56 that further defines the channel 21. Specifically, in an example embodiment, the transition piece 56 fills a gap (bridges a transition) between the second belt section 12b and the lower belt 22, allowing the tobacco column 1a to more smoothly flow over the transition piece 56 as the tobacco column 1a leaves the second belt section 12b and flows onto the lower belt 22. In an example embodiment, the transition piece 56 may serve to reduce a level of turbulence that might otherwise be imparted to the tobacco column 1a traversing between the second belt section 12b and the lower belt 22. Specifically, in an example embodiment, the transition piece 56 occupies a space at the transition between the upper belt 12 and the lower belt 22, where this space would otherwise allow the tobacco column 1a to potentially accumulate and intermittently release, which may impact a consistency of the final consumer product 300.
In an example embodiment, a speed of travel of the upper belt 12 matches a speed of travel of the in-feed belt 20. In an example embodiment, a speed of travel of the lower belt 22 matches the speed of travel of the upper belt 12 and the in-feed belt 20.
In an example embodiment, the at least one covering 31 comes into intimate direct contact with the tobacco column 1a, as the at least one covering 31 moves under and past the transition piece 56 and the tobacco column 1a moves over and past the transition piece 56. In an example embodiment, the lower belt 22 is directly below the at least one covering 31 (obscured from view in
In an example embodiment, the hook 82 can be a different shape than what is shown in
In an example embodiment, a depth 91a of the horizontal portion 84, at a proximal end 84a of the horizontal portion 84, is larger than a depth 91b of a distal end 84b of the horizontal portion 84. In an example embodiment, the depth of the horizontal portion 84 continues to decrease along a longitudinal length of the horizontal portion 84, from the proximal end 84a to the distal end 84b. In an example embodiment, a length of an upper surface 84c of the horizontal portion 84 is shorter than a length of a lower surface 84d of the horizontal portion 84. In an example embodiment, a step 81 divides the lower surface 84d of the horizontal portion 84 from the lower surface 83b of the main shaft 80. In an example embodiment, the lower surface 84d is substantially flat.
In an example embodiment, the main shaft 80 has an incline angle 80c that is about 10-45 degrees, relative to the lower surface 84d of the horizontal portion 84. In an example embodiment, the incline angle 80c matches the decline angle 27 the descending section 21a of the channel 21 (defined by the second belt section 12b and the descending belt section 20a, as shown in
In an example embodiment, the tip 86 on the distal end of the horizontal portion 84 includes two protrusions 85 that form a notch 85a. In an example embodiment, only one protrusion 85 exists on the distal end of the horizontal portion 84, where the protrusion 85 extends from the inner surface 89a of the first squeeze bar 60. In an example embodiment, the tip 86 does not include protrusions 85.
In an example embodiment, the second (inner) squeeze bar 62 opposes the first (outer) squeeze bar 60 in the rod forming apparatus 10, as shown in at least
In an example embodiment, the shaft 110 is hollow, and is in the shape of a half-pipe (semi-cylindrical shape), as shown better detail in at least
In an example embodiment, a longitudinal length of the shaft 110 of the tongue 102 is relatively short. In an example embodiment, the relatively short longitudinal length of the shaft 110 reduces a potential “accordion effect” that can occur when pockets of less compressed tobacco, in the tobacco rod 1b, and become compressed together at high speeds, during use of the rod forming apparatus 10. In an example embodiment, the longitudinal length of the shaft 110, from the inlet 112 to the outlet 114, is about 10-18 cm, or about 11-15 cm, or about 12.7 cm.
In an example embodiment, the shaft 110 defines one or more injection ports 110d (where a first injection port 110d1 and a fourth injection port 110d4 are shown in
In an example embodiment, the at least one substance is water. In an example embodiment, water injection at the one or more injection ports 110d is used to clean the shaft 110, and lubricate the inner surface 119 of the shaft 110. In an example embodiment, the water injection at the one or more injection ports 110d is used to increase a moisture content of the tobacco rod 1b. In an example embodiment, the water injection is used to mitigate potential tobacco and/or flavorant build-up in the shaft 110 under conditions where the shaft 110 ‘runs dry,’ especially due, at least in part, to overly dry tobacco flowing through the shaft 110 at relatively high rates of speed. In an example embodiment, water injection is performed on a metered basis in the shaft 110, using an injection rate that is proper to for the blend, consistency and moisture content of tobacco, the machining conditions (rate or production, speed and applied pressure on the tobacco rod 1b flowing through the shaft 110, ambient temperature, etc.), the material and surface smoothness of the shaft 110 (e.g., metal material, coated metal material, food-safe plastic/polymer, smooth or rough surface), and the production duration (e.g., the amount of anticipated wear of the inner surface 119 of the shaft 110), in order to avoid buildup of tobacco and other substances in the shaft 110, as well as buildup of elements of the rod forming apparatus 10 that are downstream of the compression box 100a.
In an example embodiment, the injection rate includes an injection of water at regular intervals, in between periods of time without any water injection. In another example embodiment, the injection rate includes intermittent water injection at irregular intervals. In an example embodiment, the injection rate of the water is determined via a measurement of an overall dryness of the tobacco, where the measurements are taken before, during or after a duration of time when the rod forming apparatus 10 is in use. In an example embodiment, the injection rate of water is continuous, or continuous for one or more periods of time, followed by periods of time where water is not injected. In an example embodiment, the water injection mitigates jamming, assists in the overall performance of the rod forming apparatus 10, and reduces maintenance demands and down-time of equipment. In an example embodiment, the injection rate of water is used to extend the useful life of the tongue 102, so that the water injection is used to extend the use of the tongue 102 prior to removing the tongue from the rod forming apparatus 10 for maintenance and/or replacement.
In an example embodiment, the at least one substance is at least one flavorant that can become commingled with the tobacco rod 1b, as the tobacco rod 1b flows through the shaft 110. In an example embodiment, the at least one flavorant may be at least one of a natural flavorant, an artificial flavorant, or a combination of a natural flavorant and an artificial flavorant. For instance, the at least one flavorant may include menthol, etc. In an example embodiment, the at least one substance is a mixture of water and the at least one flavorant. In an example embodiment, the at least one injection port 110d is used to intermittently, or regularly, inject the at least one flavorant and water, at separate intervals, or periods where they are injected at a same time, followed by periods where they are injected separately.
In an example embodiment, the at least one substance is at least one additive. In an example embodiment, the at least one additive changes a property of the tobacco in the tobacco rod 1b. In an example embodiment, the additive includes a humectant. In an example embodiment, the humectant is used to adjust and/or maintain a moisture content of the tobacco rod 1b, act as a preservative for the tobacco rod 1b, or both. In an example embodiment, examples of humectants include glycerol, propylene glycol, or combinations thereof. In an example embodiment, the humectant reduces a water activity in the consumer product 300, thereby reducing an opportunity for growth of micro-organisms. In an example embodiment, the humectant provides a higher moisture feel for a potentially dry composition of the tobacco 1. In an example embodiment, the considerations related to an injection rate, and the impact the humectant has on the tobacco, the compression box 100a, and/or the other equipment in the rod forming apparatus 10, are the same as the considerations described in relation to the injection rate of water (discussed herein).
In an example embodiment, the at least one substance is water, the at least one flavorant, the at least one additive, or combinations thereof. In an example embodiment, the one or more injection ports 110d are used to inject any or all of these substances, either together, or separately, either at regular or intermittent times, or on a continuous or semi-continuous basis. In an example embodiment, the one or more injection ports 110d are used to inject at least one first flavorant, where water is subsequently injected to flush residual levels of the at least one first flavorant. Following flushing, in an example embodiment, at least one second flavorant is injected via the one or more injection ports 110d. In an example embodiment, the at least one first flavorant is different than the at least one second flavorant.
In an example embodiment, use of the one or more injection ports 110d to introduce the at least one substance into the tobacco 1 at the compression box 100a is performed in lieu of introducing the at least one substance at a location within the rod forming apparatus 10 that is upstream of the compression box 100a. For example, introducing the at least one substance into the tobacco 1 at the compression box 100a, is performed instead of introducing the at least one substance into the tobacco 1 at the storage container 5, the feeder 8, the trough 14, or introducing the at least one substance into the tobacco 1 prior to the tobacco 1 being introduced into the rod forming apparatus 10. In another example embodiment, introduction of the at least one substance into the tobacco 1 at the compression box 100a is performed in addition to introducing a same or different substance into the tobacco 1 at a location that is upstream of the compression box 100a.
In an example embodiment, the at least one substance is introduced into the tobacco 1 at the compression box 100a, so that the elements of the rod forming apparatus 10 that are upstream of the compression box 100a do not need to be subsequently cleaned to remove undesired, residual levels of the at least one substance. For example, in an example embodiment, the at least one substance is introduced at the compression box 100a, so that residual levels of the at least one substance are not later discovered in the storage container 5, the feeder 8, the trough 14, the upper belt 12, the in-feed belt 20, the lower belt 22, etc. Injections of water at the compression box 100a, following introduction of the at least one substance, cause residual levels of the at least one substance to be flushed from the compression box 100a and/or equipment downstream of the compression box 100a. In an example embodiment, introduction of the at least one flavorant at the compression box 100a, which may be followed by injections of water at the compression box 100a to flush residual levels of the at least one flavorant (as needed, or if needed), allow for the subsequent introduction of different flavorants into the tobacco 1 without needing to shut down the rod forming apparatus 10 and/or clean major equipment within the rod forming apparatus 10.
In an example embodiment, the at least one substance is injected onto the inner surface 119 of the shaft 110, as opposed to being injected into a central location within the cross-sectional flow area of the shaft 110, to ensure that the at least one substance contacts, and in some regards streams along, the inner surface 119. In another example embodiment, the at least one substance is injected within a central location of the cross-sectional flow area of the shaft 110, via the use of an injection tube (not shown), or other structure, that extends away from the inner surface 119 of the shaft 110, in order to inject the at least one substance within the shaft 110 at a location that is somewhere other than directly on the inner surface 119 of the shaft 110.
In an example embodiment, the at least one substance is injected into the one or more injection ports 110d, via a pump, a test syringe pump, a micro-pump, a squeeze bulb (manually actuated) pump, a syringe, a fluid metering device, any well-known pump device, or combinations thereof. In an example embodiment, the at least one substance is injected individually into each of the one or more injection ports 110d, either at the same time or at different times. In an example embodiment, the at least one substance is injected into a manifold (tubular connecting structure), where the manifold is connected to at least one, or all, of the one or more injection ports 110d. In at least some example embodiments, use of the manifold allows for injection into some or all of the one or more injection ports 110d simultaneously. In an example embodiment, the manifold includes isolation valves to isolate or cease a flow of the at least one substance to some or all of the one or more injection ports 110d.
In an example embodiment, the upper plate 108 includes one or more bolt holes 101 that are used to mount the tongue 102. In an example embodiment, the one or more bolt holes 101 includes two bolt holes 101, where at least one of the bolt holes 101 traverses through the second protrusion 108b. In this example embodiment, the bolt holes 101 are engaging structure that is used to mount the tongue 102 on at least a portion of the rod forming apparatus 10 to stabilize the tongue 102. In an example embodiment, the one or more bolt holes 101 is located on a side (half) of the upper plate 108 that is opposite the location of the shaft 110. In an example embodiment, the inner surface of the one or more bolt holes 101 define threads capable of mating with mounting bolts. In another example embodiment, the inner surface of the one or more bolt holes 101 is a smooth surface devoid of threads.
In an example embodiment, the tapered entrance 116 and the inner surface 119 of the shaft 110 are made from a food-safe plastic or polymer material. In an example embodiment, the tapered entrance 116 and the inner surface 119 of the shaft 110 are made from a polyether ether ketone (PEEK). In an example embodiment, the tongue 102 is made from a food-safe plastic or polymer material, or a polyether ether ketone (PEEK).
In another example embodiment, the shaft 110, or the inner surface 119 of the shaft 110 and the tapered entrance 116, or the overall tongue 102, or the portions of the tongue 102 that contact the tobacco rod 1b and/or the at least one covering 31, are made from a metal, such as stainless steel or carbon steel. In this example embodiment, the inner surface 119 of the shaft 110 and the tapered entrance 116, or the overall tongue 102, or the portions of the tongue 102 that contact the tobacco rod 1b and/or the at least one covering 31, are made from metal that may be coated with a food-safe coating. In an example embodiment, the food-safe coating is made from a food-safe plastic or polymer material, or a polyether ether ketone (PEEK).
In an example embodiment, a majority of a lower surface 108c of the upper plate 108 is substantially flat.
In an example embodiment, the shaft 110 defines the one or more injection ports 110d at different locations along the longitudinal length of the shaft 110. For example in an example embodiment, a first set (plurality) 110e1 of the one or more injection ports 110d is located near the inlet 112 of the shaft 110, and a second set (plurality) 110e2 of the one or more injection ports 110d is positioned near a mid-section of the shaft 110. In an example embodiment, the mid-section of the shaft 110 is a middle of the shaft 110, relative to the longitudinal length of the shaft 110. In an example embodiment, the first set 110e1 of the one or more injection ports 110d includes at least three injection ports (e.g., the first injection port 110d1, the second injection port 110d2 and a third injection port 110d3). In an example embodiment, the second set 110e2 of the one or more injection ports 110d is between a mid-section of the shaft 110, and the outlet 114 of the shaft 110.
In this example embodiment, the first set 110e1 of the one or more injection ports 110d can be substantially evenly distributed along a circumference of the inner surface 119 of the shaft 110, as shown in
In an example embodiment, more than two sets of injection ports (e.g. more than 110e1 and 110e2) are defined by the shaft 110.
In an example embodiment, the shaft 110 defines only a single injection port. In an example embodiment, the single injection port is the third injection port 110d3 or the sixth injection port 110d6. In an example embodiment, the single injection port is defined in the shaft 110 to be positioned at a center location of the circumference of the inner surface 119 of the shaft 110 (e.g., a highest elevation along the inner surface 119 of the shaft 110).
In an example embodiment, the shaft 110 defines only two injection ports. In an example embodiment, the two injection ports are the third injection port 110d3 and the sixth injection port 110d6. In an example embodiment, the one or more injection ports 110d are located between the inlet 112 and the mid-section of the shaft 110, along the longitudinal length of the shaft 110. In an example embodiment, the tapered entrance 116 defines at least some, or all, of the one or more injection ports 110d.
In an example embodiment, the one or more injection ports 110d are defined at any location along the longitudinal length of the shaft 110, and may include any number of injection ports.
In an example embodiment, some or all of the one or more injection ports 110d are defined so that they have an oval-shaped opening along the inner surface 119 of the shaft 110, as shown in
In an example embodiment, at least some of the one or more injection ports 110d traverse a centerline 110f of the inner surface 119 of the shaft 110. In an example embodiment, at least one of the injection ports from each set of the injection ports (e.g., 110e1 and 110e2), traverses the centerline 110f of the inner surface 119. In an example embodiment, the centerline 110f is an imaginary line running along the center of the inner surface 119, along the longitudinal length of the inner surface 119. In an example embodiment, the centerline 110f substantially divides the inner surface 199 into equal halves (e.g., equal sides). In this example embodiment, other injection ports, of each set of injection ports (e.g., 110e1 and 110e2), are located on either side of the centerline 110f. In an example embodiment, the centerline 110f is at a center location of the circumference of the inner surface 119 of the shaft 110 (e.g., a highest elevation along the inner surface 119 of the shaft 110).
In an example embodiment, during use of the rod forming apparatus 10, the lap edge 33 of the at least one covering 31 (see at least
In an example embodiment, the upper mounting plate 104 includes a first protrusion 118a and a second protrusion 118b that define a notch 113. In an example embodiment, the notch 113 substantially matches a shape of the notch 103 (
In an example embodiment, the first protrusion 118a includes an enlarged end portion 118a1. In an example embodiment, the first protrusion 118a includes one or more bolt holes 111a. In an example embodiment, the one or more bolt holes 111a straddle sides of the first protrusion 108a of the tongue 102, so that bolts 111b (
In an example embodiment, the second protrusion 118b includes a beveled (smoothed) front surface 118b1. In an example embodiment, the second protrusion 118b includes an angled surface 118c that substantially aligns with the angled surface 108d of the tongue 102.
In an example embodiment, the lower mounting plate 106 includes a shelf 122 that extends from an inner side of the lower mounting plate 106 toward the shaft 110 of the tongue 102. In an example embodiment, the shelf 122 includes an inclined surface 124 that is upwardly facing, and extends toward an end surface 106a of the lower mounting plate 106 (shown in better detail in
In an example embodiment, a protrusion 126 extends from a lower end of the lower mounting plate 106. In an example embodiment, the protrusion 126 runs along a longitudinal length of the lower mounting plate 106, and assists in allowing the lower mounting plate 106 and the tongue assembly 100 to be correctly aligned and mounted onto the lower plate 150 of the compression box 100a (see
In an example embodiment, the overall height of the tongue assembly 100 is substantially uniform, such that the tongue assembly 100 is substantially flat when installed on the rod forming apparatus 10. Said another way, when the tongue assembly 100 is installed on the rod forming apparatus 10, the top surface of the upper mounting plate 104 is substantially flat, and the general height of the tongue assembly 100 (from the lower surface 132 of the lower mounting plate 106 to the upper surface of the upper mounting plate 104) is substantially uniform, along a length of the tongue assembly 100.
In an example embodiment, the upper mounting plate 104 is used to support and protect the tongue 102 from deformation and/or warping during use in the rod forming apparatus 10, especially if the shaft 110, or the overall tongue 102, is made from a material other than metal.
In an example embodiment, the tongue assembly 100 does not include the upper mounting plate 104 (see the example embodiment of
In an example embodiment, the upper mounting plate 104 and/or the lower mounting plate 106 are integrally and/or monolithically formed with the tongue 102, such that the upper mounting plate 104 and/or the lower mounting plate 106 are not separate elements from the tongue 102.
In an example embodiment, and as shown in at least
In an example embodiment, one or more of the following corners are beveled (rounded), in the event the lap edge 33 of the at least one covering 31 may contact them, so that the at least one covering 31 is not inadvertently torn or damaged: the front corner 122a of the shelf 122, the front corner 128a of the angled surface 128, the front corner 108b1 of the angled surface 108d, and the beveled corners 118a1a of the enlarged end portion 118a1 of the upper mounting plate 104.
In an example embodiment, a side surface 133 of the lower mounting plate 106 is substantially flat.
In an example embodiment, an elevation (height) of the upper surface 110c of the shaft 110 is about even with an elevation of the adhesive applicator 40 (
In an example embodiment, an extension 118a2 of the upper plate 108 connects to the upper surface 110c of the shaft 110.
In an example embodiment, a top surface 120 of the lower mounting plate 106 is substantially flat, and mates with the lower surface 108c of the upper plate 108 of the tongue 102.
In an example embodiment, discussion of the one or more injection ports 110d described in relation to the example embodiments of
In some example embodiments where the shaft 110, and/or the upper plate 108, or the tongue 102a as a whole are made from a hard material, the tongue assembly 100b does not include an upper mounting plate (such as the upper mounting plate 104 of
In an example embodiment, the upper plate 108 of the tongue 102a includes one or more bolt holes 101 that are counter-sunk holes (as shown in better detail in
In an example embodiment, the lower mounting plate 106 of the tongue assembly 100b is formed as a separate element from the tongue 102a. In an example embodiment, the lower mounting plate 106 is connectable to the upper plate 108 via the use of the bolts. In other example embodiments, the lower mounting plate 106 is formed integrally, or monolithically, with the upper plate 108 of the tongue 102a, such that the lower mounting plate 106 is a permanent or integral portion of the tongue 102a.
In an example embodiment, the protrusion 126 of the lower mounting plate 106 can align with a side surface 150a of the lower plate 150, to stabilize the tongue assembly 100 on the lower plate 150 and ensure that the tongue assembly 100 is properly aligned on the lower plate 150. In an example embodiment, the mounting bolt holes 111 of the upper mounting plate 104 align with the bolt holes 101 of the tongue 102 (
In an example embodiment, the tongue assembly 100 can be properly aligned on the lower plate 150, via the bolts 163 that penetrate through the tongue assembly 100 and mate with the one or more mounting bolt holes 164 in the lower plate 150, where the protrusion 126 provides another point of contact to align the tongue assembly 100. In an example embodiment, the one or more mounting bolt holes 164 include two mounting bolt holes in the lower plate 150, where two of the bolts 163 fasten the tongue assembly 100 to the lower plate 150, and where the protrusion 126 provides a third point of contact to align the tongue assembly 100 on the lower plate 150. In an example embodiment, when the tongue assembly 100 is properly aligned on the lower plate 150, the shaft 110 is centrally aligned with a groove 152 that runs along a longitudinal length of the lower plate 150 (shown in better detail in
In an example embodiment, a free-side 150e of the lower plate 150 (a side of the lower plate 150 that is not being used to bolt the tongue assembly 100 to the lower plate 150), includes an inclined portion 150f. In an example embodiment, the inclined portion 150f provides a gradually increasing depth to the free-side 150e of the lower plate 150, in an example embodiment, the inclined portion 150f may include an upper surface that includes a flat portion 150c, between a front edge 150g of the lower plate and a valley 150d2 of the lower plate 150. In an example embodiment, the inclined portion 150f further includes an inclined surface 150b, between the valley 150d2 and a ridge 150d1. In an example embodiment, a remaining upper surface of the free-side 150e of the lower plate 150 may have a common, elevated height. The inclined portion 150f, with the flat portion 150c and the inclined surface 150b, can be seen in better detail in
In an example embodiment, the lower plate 150 includes one or more mounting bolt holes 162 that can be used to mount the lower plate 150 on the rod forming apparatus 10.
In an example embodiment, and as shown in
In an example embodiment, and as shown in
In an example embodiment, and as shown in
In an example embodiment, the lower belt 22 travels between the lower plate 150 and the tongue assembly 100 (obstructed from view in
In an example embodiment, and as shown in
In an example embodiment, and as shown in
In an example embodiment, a shaft 510 runs along a bottom end (an edge) of the major body (plate) 508. In an example embodiment, the shaft 510 includes an inlet 512 and an outlet 514. In an example embodiment, the shaft 510 includes an inner surface 519 that is arcuate-shaped. Other shapes for the inner surface 519 are contemplated. In an example embodiment, a radius of curvature 519a of the inlet 512 is larger than a radius of curvature 519b of the outlet 514, and therefore the inlet 512 has a larger cross-sectional flow area as compared to a cross-sectional flow area of the outlet 514. In an example embodiment, a radius of curvature of the inner surface 519 is reduced, between the inlet 512 and the outlet 514, where this reduction in the radius of curvature may be continually and linearly reduced along a longitudinal length of the shaft 510.
In an example embodiment, discussion of the one or more injection ports 110d, described in relation to the example embodiments of
In an example embodiment, the shaft 510 and/or the major body 508 defines one or more injection ports 510d. In an example embodiment, the one or more injection ports 510d include the following (where some of these ports are shown in
In an example embodiment, the second extension 508d includes a sloped incline 508d2 and/or a flattened portion 508d1. In an example embodiment, the second extension defines an opening (slot) 508d3. In an example embodiment, the shaft 510 includes an upper surface 510a that extends along an upper portion of much of the shaft 510. In an example embodiment, the upper surface 510a helps at least partially define the opening 508d3. In an example embodiment, the upper surface 510a helps at least partially define some or all of the one or more injection ports (e.g., the first injection port 510d1, the second injection port 510d2, the fourth injection port 510d4, the fifth injection port 510d5 and the sixth injection port 510d6). In an example embodiment, the upper surface 510a forms an outer surface of the shaft 510 into a box (square, or rectangular) shaped shaft, with a square or rectangular shaped vertical cross-sectional profile (see for instance
In an example embodiment, a second side surface 510c of the shaft 510, and the first side surface 510b (
In an example embodiment, the first set 510e1 of the one or more injection ports 510d includes at least three injection ports (e.g., the first injection port 510d1, the second injection port 510d2 and a third injection port 510d3). In this example embodiment, the first set 510e1 of the one or more injection ports 510d can be substantially evenly distributed along a circumference of the inner surface 519 of the shaft 510, as shown in
In an example embodiment, more than two sets of injection ports (e.g. more than 510e1 and 510e2) are defined by the shaft 510.
In an example embodiment, at least some of the one or more injection ports 510d traverse a centerline 510f of the inner surface 519 of the shaft 510. In an example embodiment, at least one of the injection ports from each set of the injection ports (e.g., 510e1 and 510e2), traverses the centerline 510f of the inner surface 519. In an example embodiment, the centerline 510f is an imaginary line running along the center of the inner surface 519, along the longitudinal length of the inner surface 519. In an example embodiment, the centerline 510f substantially divides the inner surface 199 into equal halves (e.g., equal sides). In this example embodiment, other injection ports, of each set of injection ports (e.g., 510e1 and 510e2), are located on either side of the centerline 510f. In an example embodiment, the centerline 510f is at a center location of the circumference of the inner surface 519 of the shaft 510 (e.g., a highest elevation along the inner surface 519 of the shaft 510).
In an example embodiment, the shaft 510 defines only a single injection port. In an example embodiment, the single injection port is the third injection port 510d3 or the sixth injection port 510d6. In an example embodiment, the single injection port is defined in the shaft 110 to be positioned along the centerline 519f.
In an example embodiment, the shaft 510 defines only two injection ports. In an example embodiment, the two injection ports are the third injection port 510d3 and the sixth injection port 510d6. In an example embodiment, the one or more injection ports 510d are located between the inlet 512 and the mid-section of the shaft 510, along the longitudinal length of the shaft 510.
In an example embodiment, the one or more injection ports 510d are defined at any location along the longitudinal length of the shaft 510, and may include any number of injection ports.
In an example embodiment, the arm support device 620 includes an arm 600 that holds the tongue 500, via an engaging structure 602. In an example embodiment, the engaging structure 602 includes bolts. In an example embodiment, the engaging structure 602 interfaces, and fits between, the one or more slots 501 of the tongue 500 to grip and hold the tongue 500 in place. In another example embodiment, the engaging structure 602 includes fasteners, clasps, hooks that are capable of gripping and/or holding a portion of the tongue 500, to stabilize the tongue 500 into a locked position over the lower plate 150 of the compression box 100a.
In an example embodiment, the arm 600 is connected to a main support 604. In an example embodiment, the main support 604 sits on a base 608. In an example embodiment, in an example embodiment, a groove 616 of the main support 604 slides within a groove 610 of the base to provide fine tuning of a position of the main support 604 and the arm 600 to control a placement of the tongue 500 onto the lower plate 150 of the compression box 100a. In an example embodiment, a handle 606 is used to tighten the main support 604 onto the base 608, where the handle is in communication with a threaded shaft that screws into a threaded hole in the base 608 (not shown). In an example embodiment, other similar structure is contemplated for attaching the main support 604 to the base 608, and/or fine tuning the position of the main support 604 on the base 608.
In an example embodiment, the base 608 includes a platform 612 that extends from the base 608. In an example embodiment, the platform 612 includes one or more elongated holes 614 that allow for the platform 612, and in turn the base 608, to be bolted onto the rod forming apparatus 10 at a location that is near the compression box 100a. In an example embodiment, the bolting of the platform 612 onto the rod forming apparatus 10 allows for gross positioning of the arm support device 620, where more refined positioning is accomplished by sliding the platform 612 closer or further from the compression box 100a, as the bolts (not shown) slide within the elongated holes 614.
In an example embodiment, and as shown in
In an example embodiment, the lap (folded) edge 33 and free edge 37 of the at least one covering 31 remain extended, in the ‘flared out’ configuration relative to the tobacco rod 1b (as shown in
In an example embodiment, following the finishing folder 44, the tobacco rod 1b enters the heater 46 so that the heater 46 may apply heat to the at least one covering 31, in order to cure the adhesive 35 and fuse the at least one covering 31 around the tobacco rod 1b to form a finished rod 41. In an example embodiment, the finished rod 41 leaves the heater 46 and enters the cutter 48, to cut sections of the finished rod 41 in order to form the consumer product 300.
In an example embodiment, the tobacco 1 is shredded tobacco that is suitable for machine-made cigars. In an example embodiment, the tobacco 1 has a moisture content of about 10-20%, or about 12-18%. In an example embodiment, the tobacco 1 is blended pipe tobacco, or blended packing tobacco, that is suitable for packing a pipe. In an example embodiment, the tobacco 1 is a blend of various types of shredded, moist, tacky tobacco. In an example embodiment, the tobacco 1 is, for example, flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, reconstituted tobacco, or combinations thereof. In an example embodiment, the tobacco 1 is pasteurized. In another example embodiment, the tobacco 1 is fermented.
In an example embodiment, the tobacco 1 includes the at least one substance, as described above, where the at least one substance includes the at least one flavorant, the at least one additive, water (moisture), or combinations thereof. In an example embodiment, the at least one flavorant includes any natural or synthetic flavorant or aroma, such as menthol, etc. In an example embodiment, the at least one flavorant includes flavor compounds that include acids, alcohols, esters, aldehydes, ketones, pyrazines, or combinations thereof. In an example embodiment, the flavor compounds include, for example, phenylacetic acid, solanone, megastigmatrienone, 2-heptanone, benzylalcohol, cis-3-hexenyl acetate, valeric acid, valeric aldehyde, ester, terpene, sesquiterpene, nootkatone, maltol, damascenone, pyrazine, lactone, anethole, iso-valeric acid, ethylacetate, isoamylacetate, propylisobutyrate, isobutylbutyrate, ethylbutyrate, ethylvalerate, benzylformate, limonene, cymene, pinene, linalool, geraniol, or combinations thereof.
In at least one example embodiment, the tobacco 1 used in the manufacture of machine-made cigars, which is made by the rod forming apparatus 10, is a pipe tobacco blend having a degree of tackiness imparted thereto.
Example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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| 20210120864 A1 | Apr 2021 | US |
