Patent Grant
11252989
Example embodiments generally relate to a tongue for a rod forming apparatus, a rod forming apparatus with the tongue, and a method of installing the tongue 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 major body, the major body having a first longitudinal length that runs from a first end to a second end of the major body, the major body including, a first channel defined along a first edge of the major body, a second channel defined along a second edge of the major body, the first channel and the second channel being hollow and running substantially along the first longitudinal length from the first end to the second end of the major body, the first channel and the second channel opposing each other and facing away from each other.
In one embodiment, the major body further includes: a first portion, the first portion defining the first channel, and a second portion, the second portion being connected to the first portion, the second portion defining the second channel, wherein the first portion and the second portion are identical to each other.
In one embodiment, the first channel includes a first inner surface, the second channel includes a second inner surface, and the first inner surface and the second inner surface both have a substantially arcuate-shaped cross-sectional profile.
In one embodiment, the first inner surface has a first radius of curvature, the second inner surface has a second radius of curvature, and the first radius of curvature and the second radius of curvature each continually reduce in size from the first end to the second end of the major body.
In one embodiment, the first channel has a first width, the second channel has a second width, and the first width and the second width each continually reduce in size from the first end of the major body to the second end of the major body.
In one embodiment, the major body includes: a first sidewall and a second sidewall that oppose each other, the first sidewall and the second sidewall converging towards each other from the first end to the second end of the major body to cause the major body to have a tapered profile.
In one embodiment, the first channel has a first width, the second channel has a second width, and the first width and the second width each substantially span from the first sidewall to the second sidewall to cause each of the first channel and the second channel to have a tapered profile.
In one embodiment, the first channel includes a first opening, the second channel includes a second opening, and the first opening and the second opening each have a cross-sectional profile that is one of rectangular-shaped or square-shaped.
In one embodiment, the first channel includes a first tapered entrance between the first opening and a first end of the first inner surface, and the second channel includes a second tapered entrance between the second opening and a first end of the second inner surface.
In one embodiment, the first tapered entrance includes a first inclined surface between the first opening and a first end of the first inner surface, and the second tapered entrance includes a second inclined surface between the second opening and a first end of the second inner surface.
In one embodiment, the first tapered entrance includes a first pair of sloped sidewalls on adjacent sides of the first inclined surface, and the second tapered entrance includes a second pair of sloped sidewalls on adjacent sides of the second inclined surface.
In one embodiment, the major body includes: a first sidewall defining a first groove running substantially along the first longitudinal length, the first groove being adjacent to the first channel, and a second sidewall defining a second groove running substantially along the first longitudinal length, the second groove being adjacent to the second channel.
In one embodiment, the first groove includes a first tapered end and a first enlarged end, and the second groove includes a second tapered end and a second enlarged end, the first tapered end and the second tapered end being at least partially defined by the first end of the major body, and the first enlarged end and the second enlarged end are at least partially defined by the second end of the major body.
In one embodiment, the first enlarged end of the first groove includes a first irregularly shaped convex edge that includes a first sharply angled portion and a first substantially horizontal portion, and the second enlarged end of the second groove includes a second irregularly shaped convex edge that includes a second sharply angled portion and a second substantially horizontal portion.
In one embodiment, the first substantially horizontal portion and the second substantially horizontal portion are respectively angled to be about perpendicular to the first sidewall and the second sidewall of the major body.
In one embodiment, the major body includes a first endwall and a second endwall on the first end and the second end of the major body, respectively, and the first sharply angled portion and the second sharply angled portion each traverse across a first centerline, the first centerline running through a center of a second longitudinal length of the second endwall of the major body.
In one embodiment, the first sidewall defines a third groove, and the second sidewall defines a fourth groove, the third groove and the fourth groove being substantially at a same elevation of the major body.
In one embodiment, the third groove and the fourth groove exist along a first plane, the first plane dividing the tongue into a first portion and a second portion, the first portion defining the first channel and the second portion defining the second channel, the first portion and the second portion being identical to each other.
In one embodiment, the major body defines at least one first injection port and at least one second injection port, the at least one first injection port traversing through a first inner surface of the first channel and the at least one second injection port traversing through a second inner surface of the second channel.
In one embodiment, the first channel includes a first opening, and the second channel includes a second opening, and the first opening and the second opening each have an interior width that is about 7-12 mm wide and an interior depth that is about 7-12 mm.
In one embodiment, a first length of the first tapered entrance and a second length of the second tapered entrance are each about 5-20% of the first longitudinal length of the major body.
In one embodiment, a first length of the first tapered entrance and a second length of the second tapered entrance are each about 5-10% of the first longitudinal length of the major body.
In one embodiment, the first longitudinal length of the major body is about 115-160 mm.
In one embodiment, the first tapered end and the second tapered end each are about 2.0-3.0 mm wide, and the first enlarged end and the second enlarged end each are about 6.0-8.0 mm wide.
At least another example embodiment is directed toward a tongue support assembly with a tongue.
In one embodiment, the tongue support assembly includes a tongue; and a tongue holder configured to selectively hold the tongue in one of a first position and a second position, the tongue including a major body, the major body having a first longitudinal length that runs from a first end to a second end of the major body, the major body including, a first channel defined along a first edge of the major body, a second channel defined along a second edge of the major body, the first channel and the second channel being hollow and running substantially along the first longitudinal length from the first end to the second end of the major body, the first channel and the second channel opposing each other and facing away from each other, and wherein the first position causes the first channel of the tongue to extend from the tongue holder and the second position causes the second channel to extend from the tongue holder.
In one embodiment, the tongue holder includes: a hollow body, the hollow body including engaging structure that mates with opposing grooves defined by a first sidewall and a second sidewall of the tongue to selectively hold the tongue in one of the first position and the second position.
In one embodiment, the engaging structure includes ribs that oppose each other, the ribs converging towards each other from a first end to a second end of the hollow body, and a first sidewall and a second sidewall of the tongue both converge towards each other along the first longitudinal length of the major body so that the tongue can be wedged between the ribs as the tongue is inserted into the hollow body in a direction that is toward the second end of the hollow body.
In one embodiment, the tongue support assembly further comprise: a base, the base being configured to connect the tongue support assembly to a rod forming apparatus; and an arm configured to hold the tongue holder, the arm being slideably positioned on the base to assist the tongue support assembly in positioning the tongue on a lower plate of the rod forming apparatus to form a compression box, the tongue holder being configured to align the first channel with a groove defined by the lower plate if the tongue is in the first position, and the tongue holder being configured to align the second channel with the groove if the tongue is in the second position.
At least another example embodiment is directed toward a rod forming apparatus for forming consumer product into a rod.
In one embodiment, the rod forming apparatus includes an in-feed section configured to convey a column of tobacco in a downward direction, the in-feed section having a discharge end; and a finishing section configured to receive the column of tobacco from the discharge end, the finishing section being configured to compress and roll the column of tobacco into a tobacco rod that is wrapped, the finishing section including a compression box, the compression box including, a tongue, the tongue including, a major body, the major body having a first longitudinal length that runs from a first end to a second end of the major body, the major body including, a first channel defined along a first edge of the major body, a second channel defined along a second edge of the major body, the first channel and the second channel being hollow and running substantially along the first longitudinal length from the first end to the second end of the major body, the first channel and the second channel opposing each other and facing away from each other, and a lower plate defining a first groove, the tongue configured to be oriented in one of a first position and a second position, the first position causing the first channel to be aligned with the first groove to interface with the discharge end, and the second position causing the second channel to be aligned with the first groove to interface with the discharge end.
In one embodiment, the major body of the tongue further includes: a first portion, the first portion defining the first channel, and a second portion, the second portion connected to the first portion, the second portion defining the second channel, wherein the first portion and the second portion are identical to each other.
In one embodiment, the first channel includes a first inner surface, the second channel includes a second inner surface, and the first inner surface and the second inner surface both have a substantially arcuate-shaped cross-sectional profile that has a continually reducing radius of curvature from the first end to the second end of the major body.
In one embodiment, the major body of the tongue includes, a first sidewall and a second sidewall that oppose each other, the first sidewall and the second sidewall converging towards each other from the first end to the second end of the major body to cause the major body to have a tapered profile.
In one embodiment, the first channel includes a first opening, the second channel includes a second opening, and the first opening and the second opening each have a cross-sectional profile that is one of rectangular-shaped or square-shaped.
In one embodiment, the first channel includes a first tapered entrance between the first opening and a first end of the first inner surface, and the second channel includes a second tapered entrance between the second opening and a first end of the second inner surface.
In one embodiment, the major body of the tongue includes: a first sidewall defining a second groove running substantially along the first longitudinal length, the second groove being adjacent to the first channel, and a second sidewall defining a third groove running substantially along the first longitudinal length, the third groove being adjacent to the second channel.
In one embodiment, the first groove includes a first tapered end and a first enlarged end, and the second groove includes a second tapered end and a second enlarged end, the first tapered end and the second tapered end being on the first end of the major body and the first enlarged end and the second enlarged end being on the second end of the major body.
In one embodiment, the first sidewall defines a fourth groove, and the second sidewall defines a fifth groove, the fourth groove and the fifth groove being substantially at a same elevation of the major body.
In one embodiment, the rod forming apparatus further includes a tongue support assembly, including, a tongue holder configured to hold the tongue, a base, and an arm configured to hold the tongue holder, the arm being slideably positioned on the base to assist the tongue support assembly in positioning the tongue on the lower plate, the tongue holder being configured to selectively orient the tongue in the first position or the second position.
In one embodiment, the tongue holder including a hollow body with ribs that oppose each other, the ribs converging towards each other from a first end to a second end of the hollow body, and a first sidewall and a second sidewall of the tongue both converge towards each other along the first longitudinal length of the major body so that the tongue can be wedged between the ribs as the tongue is inserted into the hollow body in a direction that is toward the second end of the hollow body.
In one embodiment, the first channel includes a first opening, the second channel includes a second opening, and the first opening and the second opening each have an interior width that is about 5-15% larger than a width of discharge end.
In one embodiment, the first channel includes a first opening, the second channel includes a second opening, and the first opening and the second opening each have an interior width that is about 0.25-1.5 mm larger than a width of the discharge end.
In one embodiment, the first channel includes a first opening, the second channel includes a second opening, and the first opening and the second opening each have an interior width that is about 7-12 mm wide and an interior depth that is about 7-12 mm.
In one embodiment, a width and a depth of the discharge end each are about 5-10 mm.
In one embodiment, a first length of the first tapered entrance and a second length of the second tapered entrance are each about 5-10% of the first longitudinal length of the major body.
In one embodiment, the first longitudinal length of the major body is about 115-160 mm.
In one embodiment, the finishing section further includes: an adhesive applicator, the adhesive applicator being configured to apply an adhesive to a portion of at least one covering, after the at least one covering passes through the compression box, 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 a tobacco rod formed by the compression box, and a cutter, the cutter being configured to cut the tobacco rod into rolled consumer products.
In one embodiment, the in-feed section further 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 a column of tobacco in the downward direction, a pair of squeeze bars configured to receive the column of tobacco from the descending channel, the pair of squeeze bars being configured to compress the column of tobacco, the pair of squeeze bars at least partially defining the discharge end of the in-feed section, 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 the at least one covering, below the column of tobacco, into the finishing section.
At least one example embodiment is directed toward a method.
In one embodiment, the method includes one of a first channel or a second channel of a tongue with a first groove, the first groove being defined by a lower plate of a compression box of the rod forming apparatus, the tongue including, a major body, the major body having a first longitudinal length that runs from a first end to a second end of the major body, the major body including, the first channel defined along a first edge of the major body, the second channel defined along a second edge of the major body, the first channel and the second channel being hollow and running substantially along the first longitudinal length from the first end to the second end of the major body, the first channel and the second channel opposing each other and facing away from each other.
In one embodiment, the method further includes inserting the tongue into a hollow body of a tongue holder in a direction that is toward a first end of the tongue holder, until the tongue is wedged within the hollow body; attaching the tongue holder to an arm of a tongue support assembly; and using the tongue support assembly to align one of the first channel or the second channel with the first groove, and wherein the hollow body includes ribs that oppose each other, the ribs converging towards each other from a second end to the first end of the hollow body, a first sidewall and a second sidewall of the tongue both converging towards each other along the first longitudinal length of the major body so that the first sidewall and the second sidewall are conformed to a shape of the ribs to allow the tongue to be wedged within the hollow body.
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, 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 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 conveyor 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 the 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 21 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 600. 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 100 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 100 to the short folder 42, as discussed in more detail herein (see at least
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 600 (
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 100, where the tobacco column 1a is further compressed along the way. To that end, if the decline angle 27 is exceedingly steep, this may 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 100. Therefore, in an example embodiment, the decline angle 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 100. 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 100. 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 600.
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 longitudinal length 315 of the tongue 300 is relatively short. In an example embodiment, the longitudinal length 315 of the tongue 300 is about 115-160 mm, or about 127-137 mm, or about 132 mm, which makes the tongue 300 relatively short, for purposes of producing the consumer product 600 (
In an example embodiment, the major body 301 includes a top half and a bottom half (e.g., first portion 305a is the top half, and second portion 305b is the bottom half, as shown in
In an example embodiment, the first inner surface 304a of the first channel 302a is substantially arcuate-shaped (also see
In an example embodiment, the first entrance 330a includes a first inclined surface (transition ramp) 306a, that inclines from the first opening 308a to the first end 310a of the first inner surface 304a. In this example embodiment, the first end 310a of the first inner surface 304a is therefore a ridge, where this ridge can be considered an inner inlet of the first channel 302a. In an example embodiment, the first entrance 330a includes sloped sidewalls 307a on an adjacent side of the first inclined surface 306a (also see
In an example embodiment, and as shown in
In an example embodiment, the first groove 350b is a convex groove. In an example embodiment, the first groove 350b is an irregularly shaped groove. In an example embodiment, the first groove 350b includes a first convex surface 340b with a first end 342b and a second end 344b. In an example embodiment, the first end 342b is tapered, with a relatively smaller width than the second end 344b. In an example embodiment, a width 342b1 of the first end 342b is about 2.0-3.0 mm, or about 2.4-2.6 mm, or about 2.5 mm, and a width 344b4 of the second end 344b is about 6.0-8.0 mm, or about 6.9-7.1 mm, or about 7 mm. In an example embodiment, the first end 342b is at least partially defined by the first endwall 324. In an example embodiment, the second end 344b is at least partially defined by the second endwall 326.
In an example embodiment, and as described in detail in relation to at least
In an example embodiment, and as shown in
In an example embodiment, the major body 301 defines a first set of injection ports 612a and a second set of injection ports 612b. In an example embodiment, the first set of injection ports 612a traverses through the first channel 302a, and the second set of injection ports 612b traverses through the second channel 302b. In an example embodiment, the first set of injection ports 612a includes one or more injection ports, and the second set of injection ports 612b includes one or more injection ports. In an example embodiment, the first set of injection ports 612a includes a first injection port 610a1, a second injection port 610a2, a third injection port 610a3, and a fourth injection port 610a4. In an example embodiment, the second set of injection ports 612b includes a first injection port 610b1, a second injection port 610b2, a third injection port 610b3, and a fourth injection port 610b4 (also see
In an example embodiment, the at least one substance is water. In an example embodiment, water injection is used to clean and/or lubricate the first inner surface 304a and/or the second inner surface 304b. In an example embodiment, the water injection 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 under conditions where the first channel 302a and/or the second channel 302b ‘run dry,’ especially due, at least in part, to overly dry tobacco flowing through the tongue 300 at relatively high rates of speed. In an example embodiment, water injection is performed on a metered basis, using an injection rate that is proper 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 tongue 300, ambient temperature, etc.), the material and surface smoothness of the first inner surface 304a and/or the second inner surface 304b (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 first inner surface 304a and/or the second inner surface 304b), in order to avoid buildup of tobacco and other substances in the tongue 300, as well as buildup of elements of the rod forming apparatus 10 that are downstream of the compression box 100.
In an example embodiment, the injection rate includes an injection of water at regular intervals, 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 300, so that the water injection is used to extend the use of the tongue 300 prior to removing the tongue 300 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 tongue 300. 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 injection of the at least one substance 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 600, 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 100, 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 injection of the at least one substance is 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 injection of the at least one substance is used to inject the 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. In an example embodiment, the at least one first flavorant is different than the at least one second flavorant.
In an example embodiment, injection of the at least one substance into the tobacco 1 at the compression box 100 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 100. For example, injection of 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, injection of the at least one substance into the tobacco rod 1b at the compression box 100 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 100.
In an example embodiment, the at least one substance is injected into the tobacco rod 1b at the compression box 100, so that the elements of the rod forming apparatus 10 that are upstream of the compression box 100 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 injected at the compression box 100, 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. In an example embodiment, injections of water at the compression box 100, following introduction of the at least one substance, cause residual levels of the at least one substance to be flushed from the compression box 100 and/or equipment downstream of the compression box 100. In an example embodiment, introduction of the at least one flavorant at the compression box 100, which may be followed by injections of water at the compression box 100 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 surfaces of the first inner surface 304a and/or the second inner surface 304b, to ensure that the at least one substance contacts, and in some regards streams along, the first inner surface 304a and/or the second inner surface 304b. In another example embodiment, the at least one substance is injected within a central location of the cross-sectional flow area of the first channel 302a and/or the second channel 302b, via the use of an injection tube (not shown), or other structure, that extends away from the first inner surface 304a and/or the second inner surface 304b, in order to inject the at least one substance within the first channel 302a and/or the second channel 302b at a location that is somewhere other than directly on the surface of the first inner surface 304a and/or the second inner surface 304b.
In an example embodiment, the at least one substance is injected into the first set of injection ports 612a and/or the second set of injection ports 612b, 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 first set of injection ports 612a and/or the second set of injection ports 612b, 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 first set of injection ports 612a and/or the second set of injection ports 612b. In at least some example embodiments, use of the manifold allows for injection into some or all of the first set of injection ports 612a and/or the second set of injection ports 612b 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 first set of injection ports 612a and/or the second set of injection ports 612b.
In an example embodiment, the first channel 302a, the second channel 302b, portions of the tongue 300 that contact the tobacco 1 and/or the at least one covering 31, and/or the entire tongue 300, are made from a food-safe plastic or polymer material. In an example embodiment, the first channel 302a, the second channel 302b, portions of the tongue 300 that contact the tobacco 1 and/or the at least one covering 31, and/or the entire tongue 300, are made from a polyether ether ketone (PEEK).
In another example embodiment, the first channel 302a, the second channel 302b, portions of the tongue 300 that contact the tobacco 1 and/or the at least one covering 31, and/or the entire tongue 300, are made from a metal, such as stainless steel or carbon steel. In this example embodiment, the first channel 302a, the second channel 302b, portions of the tongue 300 that contact the tobacco 1 and/or the at least one covering 31, and/or the entire tongue 300, 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, the second endwall 326 of the major body 301 define the first outlet 312a of the first channel 302a, and the second outlet 312b of the second channel 302b.
In an example embodiment, and as shown in
In an example embodiment, the first end 310a of the first inner surface 304a has a first radius of curvature that is larger than a second radius of curvature of the second end 312a of the first inner surface 304a.
In an example embodiment, an interior width 328a and an interior depth 335a of the first opening 308a is relatively small. In this example embodiment, the interior width 328a of the first opening 308a of the tongue 300 is about 7-12 mm, or about 9 mm, and the interior depth 335a of the first opening 308a is about 7-12 mm, or about 8.5 mm. Meanwhile, in an example embodiment, the width 78 of the discharge end 321 of the in-feed section 4 (see
In an example embodiment, the physical characteristics of the first channel 302a apply equally to the second channel 302b.
In an example embodiment, a width of the first channel 302a (and, likewise, a width of the second channel 302b), substantially spans across a width of the tongue 300, as shown for instance in
In an example embodiment, and as discussed in relation to the example embodiment of
In an example embodiment, the first group 612a1 of the first set of injection ports 612a includes at least two injection ports (e.g., the first injection port 610a1, and the second injection port 610a2). In this example embodiment, the first injection port 610a1 and the second injection port 610a2 traverse sidewalls of the first inner surface 304a, as shown in at least
In an example embodiment, more than two groups of injection ports (e.g. more than 612a1 and 612a2) are defined by the tongue 300.
In an example embodiment, the first set of injection ports 612a includes only a single injection port. In an example embodiment, the first set of injection ports 612a includes only two injection ports. In this example embodiment, the two injection ports are either at a same location, along the longitudinal length 315 of the tongue 300, or the two injection ports are at different locations, along the longitudinal length 315 of the tongue 300. In an example embodiment, the first set of injection ports 612a are located between the first opening 308a and the mid-section of the first channel 302a, along the longitudinal length 315 of the tongue 300.
In an example embodiment, the first set of injection ports 612a are defined at any location along the longitudinal length 315 of the tongue 300, and may include any number of injection ports.
In an example embodiment, the tongue support assembly 400 includes major elements that include: a base 402, an arm 404, a mounting block 406, and engaging structure 408 (
In an example embodiment, the arm 404 is connected to mounting block 406 and the base 402. In an example embodiment, the arm 404 is slideably positioned on the base 402. In an example embodiment, a ridge 401 extends from the arm 404 and mates with a groove 412 in the base 402. In an example embodiment, the ridge 410 slides in the groove 412 to allow positioning of the arm 404 and the mounting block 406 relative to the base 402 in a first direction (Y-axis). In an example embodiment, the tongue support assembly 400 does not include the mounting block 406 and instead just includes the arm 404. In an example embodiment, the tongue support assembly 400 does not include the base 402, as the arm 404 connects to the rod forming apparatus 10 by itself, and without the use of the base 402.
In an example embodiment, a handle 414 is used to tighten the arm 404 onto the base 402, where the handle is in communication with a threaded shaft 416 that screws into a threaded hole 418 in the base 402 (see
In an example embodiment, the base 402 includes a platform (mounting plate) 420 that extends from the base 402. In an example embodiment, the platform 420 includes one or more elongated holes 422 that allow for the platform 420, and in turn the base 402, to be bolted onto the rod forming apparatus 10 at a location that is near the compression box 100. In an example embodiment, the platform 420 bolts onto a surface 435 of the rod forming apparatus 10, where the bolts 430 can slide within the one or more elongated holes 422 (
In an example embodiment, further fine positioning of the tongue 300 is accomplished via the engaging structure 408 of the mounting block 406 interfacing with and sliding between the one or more slots 502 of the tongue holder 500, in order to control the position of the tongue in a third direction (Z-axis).
In an example embodiment, the tongue 300 slides into the tongue holder 500 in a first direction 440, where the varying width (thickness) of the tongue 300 causes the tongue 300 to become lodged within the tongue holder 500 to resist further movement of the tongue 300 in the first direction 440 (as described in greater detail in relation to
In an example embodiment, and as described above, the tongue 300 is inserted into the tongue holder 500 in the first direction 440 (see
In an example embodiment, the tongue holder 500 selectively holds the tongue 300 (see at least
In an example embodiment, the tongue 300 can be removed from the shaft 506 of the tongue holder 500, and a position of the tongue 300 can be switched (turned upside down), so that the first channel 302a is faced downward and aligned on the groove 152. In an example embodiment, the ability to utilize either the first channel 302a or the second channel 302b of the tongue 300, can assist in reducing maintenance and cleaning downtime costs and effort, increasing the availability of the rod forming apparatus 10 to run for longer periods, and easing an operation of the rod forming apparatus 10 by reducing a number of times that an operator needs to retrieve a new tongue 300 to install in the rod forming apparatus 10.
In an example embodiment, a free side 150e of the lower plate 150 (a side of the lower plate 150 that does not include the tongue support assembly 400), 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 150 and a valley 150d2 of the lower plate 150. In an example embodiment, the inclined portion 150f further includes an inclined (portion) surface 150b, between the valley 150d2 and a ridge 150d1, where the ridge 150d1 is a higher elevation than the valley 150d2. In an example embodiment, a remaining upper surface of the free side 150e of the lower plate 150 may have a common, elevated height, which has a higher elevation than the flat portion 150c and the inclined surface 150b. The inclined portion 150f, with the flat portion 150c and the inclined surface 150b, can be seen in better detail in
As shown 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 at least
In an example embodiment, because a radius of curvature of an inlet 156 of the groove 152 of the lower plate 150 is larger than an outlet 158 of the groove 152 (see
In an example embodiment, and as described above, as the at least one covering 31 enters and begins to pass through the compression box 100, a lower side of the free edge 37 of the at least one covering 31 begins to contact the inclined portion 150f of the lower plate 150. In an example embodiment, a thickness of the inclined portion 150f increases, from the front edge 150g to the ridge 150d1 of the lower plate 150, which causes the free edge 37 of the at least one covering 31 to fold slightly until the free edge 37 is in a vertical, or nearly-vertical position. In an example embodiment, as the at least one covering 31 exits the compression box 100, the free edge 37 of the at least one covering is in a substantially vertical position (see
In an example embodiment, the lap edge 33 of the at least one covering 31 is folded by the compression box 100, where the lap edge 33 enters the compression box 100 in the initial ‘flared out’ configuration (see
In an example embodiment, the one or more mounting bolt holes 164 are used to connect the lower plate 150 to the rod forming apparatus 10.
In an example embodiment, the first squeeze bar 60 includes at least one protrusion 85 that fits inside the inner wall (along the sloped sidewalls 307b, as in
In an example embodiment, the horizontal section 21b of the channel 21, which is defined in part by the first squeeze bar 60 and the second squeeze bar 62, discharges the tobacco column 1a (see at least
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 600.
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.
| Number | Name | Date | Kind |
|---|---|---|---|
| 1630488 | Di Ianni | May 1927 | A |
| 4010762 | Strydom | Mar 1977 | A |
| 4619276 | Albertson et al. | Oct 1986 | A |
| 4917118 | Mangiarotti | Apr 1990 | A |
| 4979521 | Davis et al. | Dec 1990 | A |
| 5413121 | Dawson et al. | May 1995 | A |
| 5810016 | Okumoto | Sep 1998 | A |
| 7827994 | Spiers et al. | Nov 2010 | B2 |
| 9295284 | Prestia et al. | Mar 2016 | B2 |
| 20070193591 | Andersen et al. | Aug 2007 | A1 |
| 20140048083 | Williams et al. | Feb 2014 | A1 |
| 20170013872 | Williams et al. | Jan 2017 | A1 |
| Number | Date | Country |
|---|---|---|
| 579029 | Jul 1946 | GB |
| Entry |
|---|
| Notice of Allowance dated Jul. 21, 2021, issued in corresponding U.S. Appl. No. 16/663,886. |
| Number | Date | Country | |
|---|---|---|---|
| 20210120862 A1 | Apr 2021 | US |
