Abstract:
A traditional do-it-yourself cigarette making machine operates at a relatively slow throughput There is provided a method and apparatus for rolling your own cigarettes wherein pre-cut tobacco of a desired humidity is molded in a mold ( 74, 80 ) to form a tobacco plug ( 79 ), subsequently the plug is advanced into a cylindrical shell ( 98 ), the empty cigarette tube ( 94 ) is then placed about the shell ( 98 ) and the cigarette tube is expelled leaving a complete cigarette The apparatus is ideally placed in a retail outlet where a person may go in and purchase the tobacco and cigarette tubes and insert them in an apparatus to roll the cigarettes.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a method and apparatus, and more particularly relates to a method of fabricating cigarettes and to an apparatus for producing cigarettes. 
       BACKGROUND OF THE INVENTION 
       [0002]    The manufacture of cigarettes is well known in the art and naturally, specialized equipment is utilized by large cigarette manufacturers. However, there also exists a niche of “roll your own” which is popular with some smokers as the separate purchase of the tobacco and cigarette tube is substantially cheaper than the purchase of pre-manufactured cigarettes. 
         [0003]    Smaller machines for filling prepared cigarette papers also known. With this type of machine, it is necessary to form a strand or plug which is inserted into the preformed paper cigarette paper shell or tube. The bulk tobacco has to be separated and then reformed into a continuous thin strand or skein in order to prevent the burning tobacco from crumbling when the cigarette is smoked. 
         [0004]    An example of a manual cigarette filling device is shown in U.S. Pat. No. 3,509,887 in which the tobacco supply is first collected by hand and then the amount needed for one cigarette inserted in an elongated forming device. Subsequently, a contact pressure dish is pressed onto the preformed tobacco strand and the tobacco pressed together to form a rounded tobacco strand. By means of a manual lever device, the preformed tobacco strand is then pressed into a cigarette paper tube which is positioned on a mounting device and held by a contact pressure device. Other types of manual cigarette filling devices have also been known in the art and are generally directed to filling a single tobacco tube when required. 
         [0005]    There is also a market for cigarette smokers who do not wish to use a small do it yourself machine to roll their own cigarettes, but would rather have a machine which could roll cigarettes at a relatively fast throughput. Also, some cigarette smokers prefer to utilize a specific type of tobacco and tube while at the same time not wanting to revert to the traditional roll your own cigarettes. 
       SUMMARY OF THE INVENTION 
       [0006]    It is an object of the present invention to provide a method for smokers to have a roll your own cigarette which is of a commercial quality. 
         [0007]    It is a further object of the present invention to provided an apparatus which can throughput a high number of cigarettes and which may be utilized by a number of users. 
         [0008]    According to one aspect of the present invention there is provided an apparatus for manufacturing cigarettes, the apparatus comprising a hopper for receiving pre-cut tobacco, a compactor for compacting the pre-cut tobacco into a cylindrical tobacco plug, a first transfer mechanism for transferring the pre-cut tobacco from the hopper to the compactor; a transition section having at least one hollow cylindrical transition tube designed to receive an empty tobacco tube thereabout, a second transfer mechanism to transfer the tobacco plug to the hollow cylindrical transition tube, and a pushing mechanism to push the tobacco plug into the cigarette tube and thereby discharge the cigarette tube from the transition tube. 
         [0009]    According to a further aspect of the present invention there is provided a method of filling a tobacco tube with pre-cut tobacco to form a cigarette comprising the steps of compacting the tobacco to form a cylindrical plug, placing the cylindrical plug in a transition tube; placing a cigarette tube over the transition tube, and pushing on the cylindrical plug of tobacco while in the transition tube to thereby fill the cigarette tube with tobacco as the cigarette tube is discharged from the transition tube. 
         [0010]    According to a further aspect of the present invention there is provided a method of filling a cigarette tube with pre-cut tobacco, the method comprising the steps of providing a transition tube having a cylindrical configuration with an external diameter slightly less than the internal diameter of a cigarette tube, inserting a guide tube within the transition tube to extend through the free end of the transition tube, placing an open end of the cigarette tube over the guide and over the transition tube, withdrawing the guide member while continuing to place the cigarette tube on the transition tube, and pushing a pre formed plug of tobacco into the transition tube and continuing to push until the cigarette tube is discharged from the transition tube with the pre cut tobacco therein. 
         [0011]    The present invention is directed to a market wherein a smoker may go into a store and purchase a supply of precut tobacco and preformed cigarette papers or tubes. The user would then be able to insert the tobacco and tubes into a machine which would produce a predefined number of cigarettes. 
         [0012]    The apparatus according to the present invention will preferably include means for supplying cigarette tubes to the apparatus. While a number of different storage devices may be utilized, a preferred embodiment will utilize canisters of a desired capacity which may then be inserted into the machine. Naturally, different numbers and types of tubes may be utilized depending upon the requirements of the user. 
         [0013]    The apparatus will also include an input hopper into which cut tobacco strands may be placed. The precut tobacco is hermetically stored in a suitable container. As such, the tobacco hopper will have an input and an output with the tobacco preferably being transferred by a conveyor between the input and output. During the transfer, a combing or dethatching device is provided for helping in the separation of the tobacco strands. A suitable device may comprise a rotating shaft having teeth extending outwardly therefrom. 
         [0014]    The tobacco is then compacted and formed into a tobacco plug. Although there are many known ways of doing so, a preferred arrangement utilizes two conveyors which may include a converging section. The conveyors advance in the same direction to move the tobacco between half molds wherein it is formed into a plug. Alternatively, the conveyors may each converge to a final discharge point. Preferably, the conveyors are vertically aligned. 
         [0015]    From the conveyors, the tobacco is preferably placed between two half molds, at least one of which is moveable and which are arranged to form a plug of tobacco in a cylindrical configuration. 
         [0016]    Meanwhile, the arrangement for the tobacco tubes will involve singulating them and advancing them to a desired position. According to the preferred aspect of the present invention, a tobacco tube is placed over a transition tube which is sized to have an exterior diameter which is substantially equal or slightly less than the inner diameter of the cigarette tube. 
         [0017]    In one arrangement, a moveable guide is utilized and which moveable guide has a conical end which is substantially smaller than the diameter of the cigarette tube. The guide member may extend through the transition tube such that when a cigarette tube is to be placed on the transition tube, the guide will function to properly guide the cigarette tube and allows for out of round cigarette tubes to be utilized. Once the cigarette tube has started to be placed on the transition tube, the guide member is withdrawn until the cigarette is firmly abutted against the transition tube. 
         [0018]    As an alternative to the above, the transition cylinder may have a tapered end to provide some guiding to the cigarette tube when it is placed thereon. 
         [0019]    In one embodiment, the cigarette tubes are singulated from the canister and placed on a rotating turret which has a plurality of recesses on the exterior surface thereof. Each recess is sized to receive a single cigarette tube and the turret is advanced sequentially through a number of stations as will be described in greater detail hereinbelow. Alternatively, the turret can be eliminated as will be shown in the drawings. 
         [0020]    The apparatus will include suitable sensing means at every step of the operation to ensure that this particular operation is properly carried out. Also, one may incorporate means for adjusting both the length of the cigarette and the compactness of the tobacco plug. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    Having thus generally described the invention, reference will be made to the drawings illustrating an embodiment thereof, in which: 
           [0022]      FIG. 1  is an exploded view of an apparatus according to the present invention; 
           [0023]      FIG. 2  is a perspective view of the input hopper; 
           [0024]      FIG. 3  is a perspective view of a storage device for the cigarette tubes; 
           [0025]      FIG. 4  is a view of the cigarette tube storage device in an open position; 
           [0026]      FIG. 5  is an exploded view of the transfer device for transferring tobacco from the input hopper to form a tobacco plug; 
           [0027]      FIG. 6  is a perspective view thereof; 
           [0028]      FIG. 7  is a perspective view of the turret for singulating and receiving the individual cigarette tubes; and 
           [0029]      FIG. 8  is a perspective view of the device holding the cigarette tube when the tobacco is inserted therein; and, 
           [0030]      FIGS. 9 to 14  are perspective views of a slightly modified apparatus illustrating operation of the same; 
           [0031]      FIG. 15  is a perspective view of a modified embodiment of the present invention; 
           [0032]      FIG. 16  is a perspective of a further modified embodiment of the present invention; 
           [0033]      FIG. 17  is a side view, partially in section, of a guiding mechanism which can be incorporated in the present invention; and 
           [0034]      FIGS. 18  A to  18 F illustrate the sequence for placing a cigarette tube on a transition tube and filling the same with tobacco. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0035]    Referring to the drawings in greater detail and by reference characters thereto, there is illustrated in  FIG. 1  a cigarette making apparatus which is generally designated by reference numeral  10 . Apparatus  10  includes an input hopper generally designated by reference numeral  12 , a compactor generally designated by reference numeral  14 , a cigarette tube storage container generally designated by reference numeral  16 , a tube separator generally designated by reference numeral  18 , a transfer device for inserting a cigarette plug into a cigarette tube generally designated by reference numeral  20 , and a discharge container generally designated by reference numeral  22 . 
         [0036]    Input hopper  12 , as may be best seen in  FIG. 2 , has a main body  26  with an upper inlet  28 . Mounted at the bottom of main body  26  is a conveyor  30 . Mounted proximate to the outlet of input hopper  12  is a strand separator generally designated by reference numeral  32  and which comprises a shaft  34  having a plurality of pins or combs  36  extending outwardly therefrom. Shaft  34  is rotatably driven by an electric motor  38 . 
         [0037]    Compactor  14  as seen in  FIGS. 1 ,  5  and  6 , has first and second side walls  42  and  44  which enclose a first conveyor  46  and a second conveyor  48 . As best seen in  FIG. 5 , first conveyor  46  includes an upper converging section  50  following which the conveyors  46  and  48  may be parallel or have a slight converging configuration. An electric motor acts to drive first and second conveyors  46  and  48 . Preferably, the conveyors are driven for a preset period of time. Thus, the conveyors would be designed to discharge a predetermined amount of tobacco which has been received from the input hopper. In other words, preferably the operations are incremental. 
         [0038]    Cigarette storage container  16  is illustrated in  FIG. 4  and reference will now be had thereto. Container  16  has a pair of side walls  56  and  58  and it will be noted that side wall  56  has a greater height and also has a flange  60  extending outwardly from a peripheral edge thereof. End walls  62  and  64  define the rectangular configuration while a bottom wall  66  is secured to end wall  62  by means of a hinge  68 . Associated with container  16  is a motor  70  to operate a piston  72  to move the body of the container with respect to bottom wall  66 . 
         [0039]    The tobacco compaction occurs at the output of conveyors  46  and  48  and to this end, there is provided a first half mold member  74  having a semi cylindrical recess  75  at the end thereof and which half mold  74  is driven by a motor  76  having a piston  78  associated therewith. 
         [0040]    A second mold  80  likewise has a semi cylindrical recess  81  and is moveable by means of motor  82  having piston  84  secured to half mold  80 . A cylinder  75  having a piston  79  is provided for reasons which will become apparent herein below. Preferably, one of the molds  74 ,  80  will have a cutting edge associated therewith to sever any tobacco strands extending beyond the mold recess. 
         [0041]    As may be seen in  FIG. 1 , cigarette tube storage container  16  is positioned such that the container can be lifted while maintaining hinged bottom wall  66  in position such that cigarette tubes may be loaded onto a rotatably driven turret  88  which has recesses  90  formed therein. The recesses  90  are sized to receive a single cigarette tube. A cylinder  91  is provided to transfer the cigarette tubes. Alternatively, a rotating cam could be utilized to open the container sufficiently for a cigarette tube to be discharged. 
         [0042]    As may be seen in the drawings, there is provided a tube receiving device currently designated by reference numeral  24  in which has a base  96  with a plurality of transition cylinders  98  extending therefrom. It will be noted that each transition cylinder  98  preferably has an end which is diagonally cut to ease insertion of the empty cigarette tube thereabout. 
         [0043]    In operation, turret  88  preferably has six stations or recesses for receiving the cigarette tubes. At a first station, a cigarette tube  94  is loaded thereon and it is then advanced through two more stations before the tobacco is inserted in the tube. At a fifth station, the tubes are unloaded while at a sixth station, a cleaning operation is carried out. 
         [0044]    At the tobacco station, the tube is transferred from the turret to the transition cylinder. A piston will push the tobacco plug into a transition cylinder  98  which has a cigarette tube thereabout. The cigarette tube is also filled with tobacco while a continuing push will cause the tube to retract from the transition cylinder. The filled cigarette is then discharged. 
         [0045]    A further station will verify that the tube has been fully fed; if not, it will be rejected at a subsequent station. It will be noted that after a predefined number of consecutive rejects, the machine will stop as the machine is probably missing either tobacco or tubes. 
         [0046]    In the embodiment of  FIGS. 9 to 14 , it will be noted that transition cylinders  198  have a tapered end  199 . This arrangement ensures the easy placement of an empty tube thereon. 
         [0047]    In operation, and as shown in  FIG. 9 , a cigarette tube  94  is loaded on turret  88 . The turret  88  is advanced through one station where cigarette tube  94  is aligned with cylinder  91 . As shown in  FIG. 10 , cylinder  91  is operative to move cigarette tube  94  on to transition cylinder  98 . After being placed on the transition cylinder  98  as is shown in  FIG. 11 , turret  88  is advanced. Subsequently, as may be seen  FIG. 12 , piston  77  of cylinder  75  is operative to push a tobacco plug  79  into a transition cylinder  98 . The motion is continued, as may be seen in  FIG. 13 , to exert a force on the now filled cigarette tube, as a completed cigarette. 
         [0048]    The remaining stations of the turret may be used for cleaning of the same. As previously mentioned, after the cigarette tube has been placed on the transition cylinder, an inspection may be conducted using sensors to determine that the cigarette tube is properly placed and that there is a full load of tobacco to insert therein. 
         [0049]    In the embodiment of  FIG. 15 , similar reference numerals have been utilized for similar components. The main difference between this embodiment and previous embodiments is in the use of a receiving member  22 ′ which allows the cigarette to enter therein from where it slides to a further container. 
         [0050]    Turning to the embodiment of  FIG. 16 , the prime differences are the elimination of the turret and instead, the substitution of a member  93  having a single recess  95  therein to receive an empty tobacco tube. Also, it will be noted that transition tubes  98  in this embodiment have a tapered end to allow placement of the cigarette tubes thereon. 
         [0051]    In the arrangement of  FIG. 17 , there is provided a guide wheel  100  which has a plurality of conically shaped openings  102  formed therein. Guide wheel  100  is secured to base  96  by means of members  104 . It will be noted that there is a conical shaped opening  102  for each transition tube  98 . 
         [0052]    In the embodiment of  FIG. 18 , there is provided a guide tube  104  positioned at one of the stations and being sized to fit within transition cylinder  98 . As seen in  FIG. 18A , guide member  104  is driven in the direction indicated by arrow  106  so as to enter a transition cylinder and pass therethrough as shown in  FIG. 17B . Guide member  104  has a tapered end and when extended through transition cylinder  98 , acts as a guide for cigarette tube  94  to extend thereover and then onto transition tube  98  as shown in  FIG. 17C . As the cigarette tube is placed about transition cylinder  98 , guide member  104  withdraws. 
         [0053]    At the next location, the tobacco from molds  74 ,  80  is pushed into tobacco tube  94  by cylinder  86 . Once the cigarette tube  94  has been filled with tobacco, continued movement of rod  86  will cause the cigarette to be discharged. The arrangement of  FIG. 18  can be incorporated in any of the previous embodiments with the elimination of the turret. 
         [0054]    It will be understood that the drive systems utilized in the present invention may be any suitable including pneumatic, electric, hydraulic, or combinations thereof.