Machine and method for producing substantially cylindrical articles of the tobacco processing industry

A method of producing filter tips for cigarettes, each of which comprises two portions of filter material arranged on opposite ends of a portion of granular material; the first portion of filter material is wrapped in a sheet so as to obtain an intermediate element having a substantially tubular shape and an open end; the granular material and the second portion of filter material are then inserted through the open end, while the intermediate element is kept vertical with the open end facing upwards; in this way it is possible to obtain high quality filter tips at high speed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the U.S. National Stage application of International Patent Application No. PCT/IB2015/059299, filed Dec. 2, 2015, which claims the benefit of Italian Patent Application No. BO2014000680, filed Dec. 2, 2014.

TECHNICAL FIELD

The present invention relates to a machine and a method for producing substantially cylindrical articles of the tobacco processing industry.

BACKGROUND ART

In the tobacco processing industry, it is known to produce multi-segment filter tips provided with different materials.

The patent application bearing publication number US2014/2061470 describes the production of a cylindrical article comprising a filter segment, a segment of granular material and a segment of tobacco. To obtain this cylindrical article, a band of flexible material is wrapped around the filter segment so as to obtain a cup-like form, which is filled with the granular material. At this point, the segment of tobacco is placed on top and is only subsequently connected to the remaining parts of the article by rolling a sheet of paper material around the segment of tobacco and the segment of filtering material. The above-described operations are performed while keeping everything vertical.

That proposed by patent application US2014/2061470 has several drawbacks, from which we cite the fact that production is relatively slow and of low quality.

DISCLOSURE OF INVENTION

It is an object of the present invention to provide a machine and a method that enable at least partially overcoming the drawbacks of the known art and, at the same time, are of easy and inexpensive implementation.

According to the present invention, a method is provided for producing substantially cylindrical articles of the tobacco processing industry according to that set forth in the independent claim below and, preferably, in any of the dependent claims directly or indirectly dependent on the above-mentioned independent claim.

According to a further aspect of the present invention, a machine is provided for producing substantially cylindrical articles of the tobacco processing industry, as described below. In particular, the machine is designed to implement the above-mentioned method.

BEST MODE FOR CARRYING OUT THE INVENTION

In accordance with a first aspect of the present invention, inFIG. 1, reference numeral1indicates, as a whole, a machine for producing substantially cylindrical articles2of the tobacco processing industry (FIG. 15). Each substantially cylindrical article2comprises a respective portion3having (in particular, consisting of) a first material (for example, tobacco and/or a filtering material such as cellulose acetate) of the tobacco processing industry, at least one respective portion4having (in particular, consisting of) a second material (for example, tobacco and/or a filtering material such as cellulose acetate) of the tobacco processing industry, at least one respective portion5having (in particular, consisting of) a loose third material different from the first and second materials, and a respective cover6having at least one associated sheet7wrapped (in particular, in a substantially tubular manner) around portions3,4and5.

In particular, the sheet7comprises (more precisely, consists of) paper. However, more generally, the sheet7could be made of a pliable material and therefore in addition to paper, could be made of a metal foil or plastic. Thus, the material with which sheet7is made is not limited to the described embodiments. Instead, as used here, the term pliable material generally refers to a ribbon-like material that has a certain resistance to bending or that has a certain level of plastic deformation, for example, a metal foil or a paper-laminated metal foil.

In addition to the above examples, other embodiments could include, without limitation, thin sheets of plastic, polymers, composites, rubber or other materials known in the art.

According to some embodiments, the cover6has other elements in addition to sheet7, such as one or more other sheets and/or bands (for example, of paper and/or tin foil), these also wrapped in a tubular manner around portions3,4and5.

According to mutually alternative embodiments, the first and the second materials are the same or are different.

Advantageously, it may be noted that the cover is usefully in contact with portions3and4.

The substantially cylindrical article2usually has a substantially circular cross-section.

According to some embodiments, the loose material is a powdered or granulated (in particular, granulated) material. For example, the loose material could comprise (more precisely, consist of) activated carbon (particles).

According to specific embodiments, the article2is a filter tip and portions3and4are made of a filtering material.

The machine1comprises a processing assembly8to wrap the sheet7around portion3(FIGS. 1, 4 and 5) so as to obtain an intermediate element9(FIGS. 11 and 12) having a substantially tubular shape with an open end10; an insertion device11(FIGS. 1, 2 and 5) to insert the third material through the open end10, into the intermediate element9(in contact with portion3) so as to obtain an intermediate element12(FIG. 13); and an insertion device to insert the second material into the intermediate element12through the open end10so that the third material is located (enclosed) between portions3and4.

The insertion devices11and13are designed to hold the open end10facing upwards.

According to some embodiments, the processing assembly8comprises a forming device14(FIG. 4), which is designed to wrap a strip15(in use, continuously fed in a substantially horizontal direction; in particular, seeFIGS. 4, 6, 7 and 8) around a succession of segments16, each comprising (in particular, consisting of) the first material and being substantially twice as long as portion3so as to obtain a rod17.

A transfer device18(in itself known, in particular a so-called spider—FIG. 8) is designed to carry the segments on the strip15(FIG. 7) so that gaps18are left between the segments16.

In some cases, the forming device14is of a known type and comprises a forming beam19(also of a known type; seeFIGS. 4 and 5).

In particular, the processing assembly8also comprises a cutting device20(FIG. 4) to cut (FIG. 8) the rod17crosswise at segments16(while the rod17is fed longitudinally and, in particular, horizontally) so as to obtain pairs21of intermediate elements9(linked together;FIG. 10).

According to specific embodiments, the processing assembly8comprises (FIG. 1) a transfer device22(in turn, comprising a spider23and a conveyor wheel24) to carry the pairs21individually and in succession to a cutting station25, where a cutting device26is located to cut (FIG. 10) each pair21at the associated gap18so as to obtain two portions3.

Advantageously, the cutting device26(FIGS. 1 and 5) comprises a conveyor wheel27and a (rotatable) blade28arranged along the circumference of the conveyor wheel27.

According to some embodiments, the machine1also comprises a rotation device29, which is located downstream of the cutting device26, to rotate the intermediate elements9of a cut pair21(by approximately 180°) so that the intermediate elements9move apart and have the open ends10oriented in mutually opposite directions (FIG. 11).

In particular, the rotation device29comprises a wheel30designed to rotate about its axis31and is, for example, structured as described in American patent U.S. Pat. No. 4,676,360.

According to some embodiments, the machine1also comprises a rotation assembly32(FIGS. 1 and 5) to rotate the intermediate element9in a way that it has the open end10facing upwards (FIG. 12; in particular, so as to give the intermediate element9a substantially vertical orientation).

In this text (unless expressly indicated otherwise), “vertical” or “substantially vertical” orientation means an orientation according to which the components having a length greater than the width (or, in any case, the diameter) are oriented such that the length has a vertical or substantially vertical orientation.

The rotation assembly32comprises a truncated cone shaped drum33(of a type in itself known; in this specific case, there are two drums33, each one for rotating respective intermediate elements9) having a rotation axis34inclined by 45° with respect to the vertical and with seats (of a type in itself known and not shown, oriented at 45° with respect to the rotation axis34).

According to the embodiment shown (FIGS. 1 and 5), two transfer wheels35are placed between the rotation device29and the rotation assembly32to carry the intermediate elements9from the rotation device29to the rotation assembly32.

In particular, with reference toFIG. 2, the insertion device11is located at an insertion station36and comprises a conveyor37(more precisely a conveyor wheel; in this specific case, two conveyor wheels, each one for conveying respective intermediate elements9) provided with a plurality of seats, each of which is designed to be engaged by an associated intermediate element9, to carry each intermediate element9along an insertion path P1through the insertion station36, from an entry station A to an exit station B. Moreover, the insertion device11typically comprises a plurality of insertion units38, each of which is designed to enable the transfer of loose material into a respective intermediate element9through the open end10. In particular, the insertion device11comprises a conveyor39(more precisely a conveyor wheel; in this specific case, two conveyor wheels) to feed each insertion unit38along the path P1in phase with the respective intermediate element9so as to have an associated insertion nozzle40(of each unit38) facing a respective open end10.

Advantageously, the conveyors37and39are substantially integral with each other (in this way, easily ensuring the movement of the units38in phase with the intermediate elements9) and thus define a single conveyor.

Advantageously, the insertion device11comprises a handling system (of a type in itself known and not shown; for example comprising a cam system and/or a system of linear motors) to move (more precisely, to lower and subsequently raise) the nozzles40inside the intermediate element9through the open end10. Thanks to the above-mentioned handling system, each nozzle40is opened when the nozzle is placed (at least partially) inside the open end.

In particular, the opening of each nozzle40is achieved by a relative separating movement between the nozzle40and a respective blocking element41(of each insertion unit38), located inside a feed channel42(of each insertion unit38) of the loose material (FIG. 16). More precisely, the handling system is designed to bring each nozzle40toward the intermediate element2(in particular, downwards) so as to move the nozzle40away from the respective blocking element and therefore open the nozzle40and allow the passage of the loose material through the nozzle40. In practice, the insertion device11is designed to keep the blocking element41vertically fixed.

As a consequence of insertion of the loose material in each intermediate element9, the respective intermediate element12is obtained.

The above-mentioned handling system is designed to move each nozzle40away from the respective intermediate element12at the exit station B. The upward movement of the nozzle40causes the blocking element41to engage again and therefore close the nozzle40.

Usually, a hopper43, designed to house the loose material and feed each feed channel42, is located above the insertion units38.

According to specific embodiments (such as that shown), a conveyor drum (two in this specific case)33′ is provided to carry the intermediate elements9from the drum33to the insertion device11.

According to an embodiment that is not shown, the machine1advantageously comprises a suction device connected to the intermediate elements9, on the opposite side to the open end10, i.e. at the end where the nozzle40is, so that, in use, the loose material is held inside the intermediate element9by suction during the filling and/or during the subsequent transport steps.

Advantageously, the machine1also has an application unit44(FIGS. 1 and 5) to apply an adhesive substance inside the open end10. In particular, the application unit44is designed to apply the adhesive substance on the inner surface of the open end10. In this way, more solid positioning of portion4inside the substantially cylindrical article2is achieved.

In accordance with that shown, the application unit44comprises a conveyor roller45to carry the intermediate element12to the insertion device11(more precisely, from the exit station B to an entry station C). According to some embodiments, the application unit44comprises a plurality of spray nozzles (not shown) designed to spray the adhesive substance once they are each arranged facing (more precisely, inside) the respective open end10. Alternatively, the application unit44comprises a plurality of spreaders (not shown).

In particular, referring toFIGS. 1, 3 and 17, the insertion device13is located at an insertion station46and comprises a conveyor47(more precisely a conveyor wheel; in this specific case, two conveyor wheels, each one for conveying respective intermediate elements12) provided with a plurality of seats, each of which can be engaged by an associated intermediate element12, to carry each intermediate element12along an insertion path P2through the insertion station46, from the entry station C to an exit station D. Usually, the insertion device11also comprises a plurality of insertion units48, each of which is designed to enable the transfer of the second material into a respective intermediate element12through the open end10. In particular, the insertion device13comprises a conveyor49(more precisely a conveyor wheel; in this specific case, two conveyor wheels) to feed each insertion unit48along path P2in phase with the respective intermediate element12so as to have an associated insertion outlet50(of each insertion unit48) facing a respective open end10.

Advantageously, the conveyors47and49are substantially integral with each other (in this way, easily ensuring the movement of the insertion units48in phase with the intermediate elements12) and thus define a single conveyor.

Advantageously, the insertion device13comprises a handling system (of a type in itself known and not shown; for example comprising a cam system and/or a system of linear motors) to produce a relative (in particular, longitudinal and, more precisely, vertical) movement between an insertion outlet50(of each insertion unit48) and the intermediate element12so as to bring the open end10inside an insertion outlet50.

More precisely, the above-mentioned handling system is designed to move the seats in which the intermediate elements12are housed vertically (longitudinally).

According to some embodiments, each insertion unit48comprises an insertion channel51, the last section of which defines the insertion outlet50and through which portion4is fed.

Advantageously, the insertion device13also comprises a pusher unit52to push portion4inside the open end10. In particular, the pusher unit is designed to push portion4against portion5so as to compress the loose material in portion5. In this way, the position of the particles in portion5is stabilized and, in use, limits preferential gas paths around the particles.

According to some embodiments, for each insertion unit48, the pusher unit52comprises a pusher head53moveable along the insertion channel51. More precisely, the above-mentioned handling system is designed to move each pusher head53downwards when the open end10is inside the insertion outlet50.

As a consequence of insertion of the loose material in each intermediate element12, the respective substantially cylindrical article2is obtained.

The above-mentioned handling system is designed to move each insertion outlet50away from the respective substantially cylindrical article2at the exit station D.

Advantageously, each insertion unit48comprises an opening assembly54to exert a force (in particular, radial and centrifugal) on the open end10so as to keep it open. According to some embodiments, the opening assembly54comprises a plurality of suction openings55arranged (in a ring) at each insertion outlet50. In this way, the risks of damaging the sheet7are reduced.

Advantageously, each insertion unit48comprises a deformation device to reduce the size (in particular, laterally) of portion4during insertion of said portion4into the open end10. According to some embodiments, the above-mentioned deformation device comprises a section56of the insertion channel51having a width (in particular, a cross-section) less than the width (in particular, the cross-section) of portion4. In particular, the section56is tapered towards the insertion outlet50. Advantageously, the section56is arranged immediately (i.e. without the interposition of further sections) upstream of (in particular, above) the insertion outlet50.

According to the embodiment shown, the portions4are fed to the insertion device13through a conduit49′ connected to a hopper (of a type in itself known and not shown).

Usually, a conveyor system57is arranged downstream of the insertion device11for the transfer of the substantially cylindrical article2obtained to further processing units (of known type and not shown). According to the embodiment shown, the conveyor system57is designed to carry the substantially cylindrical article substantially horizontally. More precisely (for this purpose), the conveyor system57comprises a truncated cone shaped drum58.

According to alternative embodiments, the processing assembly8comprises (instead of the forming14, transfer22and rotation29devices, the spider23and the conveyor wheel24) a simple rolling device (in particular, a rolling wheel—of a type in itself known, for example, from publication WO2014/064655 and not shown here) for rolling the sheet7around (the already single) portion3so as to (directly) obtain intermediate element9. Alternatively, the sheet7, of twice the length, can be wrapped around a pair of portions3so as to form the pair21inFIG. 9. This enables obtaining excellent bonding and rolling quality of the sheet7around portion3.

In accordance with a second aspect of the present invention, a method is provided for producing substantially cylindrical articles2of the tobacco processing industry. Each cylindrical article2is defined as indicated above in accordance with the first aspect of the present invention.

According to specific and non-limitative embodiments, the method is implemented by the machine1in accordance with the first aspect of the present invention.

The method comprises a wrapping step, during which the sheet7is wrapped around a portion3so as to obtain intermediate element9having (a substantially tubular shape with) an open end10(FIGS. 6 to 8). In particular, intermediate element9has a substantially cylindrical shape and a substantially circular cross-section (FIG. 12).

Advantageously, portion3is placed at the opposite end to the open end10. In other words, the opposite end to the open end10is closed by portion3.

The method also comprises a first insertion step (FIG. 13), during which the loose third material is inserted through the open end10and into intermediate element9so as to obtain intermediate element12; and a second insertion step (FIG. 14), during which the second material is inserted into intermediate element12through the open end10so that the third material is located (enclosed) between portions9and12and the substantially cylindrical article2is obtained.

Advantageously, the first and second insertion steps are performed while the open end10is facing upwards (FIGS. 12 and 13). In particular, during the first and second insertion steps, intermediate element9and intermediate element12are oriented vertically.

Advantageously, during the wrapping step, the sheet7is arranged substantially horizontally (FIGS. 6 to 8). In addition, or alternatively, the sheet7is arranged (more precisely, is fed) substantially horizontally (and longitudinally) prior to the wrapping step.

Advantageously, after the wrapping step, intermediate element9is obtained with the open end10facing sideways (FIG. 11). In particular, intermediate element9is arranged substantially horizontally after the wrapping step.

More specifically, the method also comprises a rotation step, which follows the wrapping step and during which intermediate element9is rotated so as to have said open end facing upwards (FIGS. 11 and 12). In particular, during the first and second insertion steps, intermediate element9and, respectively, intermediate element12, are oriented substantially vertically.

According to some embodiments, a plurality of segments16comprising the first material (and, in particular of substantially twice the length of the first portions3) are arranged in succession along the longitudinal extension of a strip15, which comprises (more precisely, consists of) a plurality of said sheets7connected to each other and arranged in succession such that there is a respective gap18between two successive segments16.

In particular, during the wrapping step, the strip15is wrapped around segments16comprising (in particular, consisting of) the first material such that there is a respective gap18between two successive segments16and so as to obtain a rod17(tubular, with a substantially cylindrical shape and substantially circular cross-section) having a plurality of successive connected intermediate elements9(FIGS. 6 to 8).

According to some embodiments, the method comprises a first cutting step, during which the rod17is cut (FIG. 8) crosswise (in particular, so as to obtain pairs of connected intermediate elements9). More precisely, the rod17is cut at (in particular, substantially halfway along) segments16. In particular, the rod17is conveyed horizontally (and longitudinally) during the cutting step.

Advantageously, the method comprises a second cutting step, in which the pair21of first intermediate elements9is cut so as to obtain intermediate elements9. More precisely, the pair21of first intermediate elements9is cut at (in particular, substantially halfway along) the gap18. In particular, during the second cutting step, the pair21of first intermediate elements9is cut crosswise.

According to alternative embodiments, the method comprises a first cutting step, in which the rod17is cut crosswise at (in particular, substantially halfway along) the gaps18so as to obtain pairs of connected first intermediate elements9. In particular, the rod17is conveyed longitudinally in the cutting step. In addition, or alternatively, in the second cutting step, the pair of intermediate elements9is cut at (in particular, substantially halfway along) the first segments16so as to obtain the intermediate elements9. In particular, the pair of intermediate elements9is conveyed transversely during the second cutting step.

According to some embodiments, the intermediate element9is conveyed transversely (in particular, substantially horizontally) through an insertion station36during the first insertion step.

Advantageously, during the first insertion step, an insertion nozzle40is brought inside the intermediate element9through the open end10. In particular, the loose third material passes through the nozzle40for insertion into the first intermediate element.

Advantageously, the intermediate element12is conveyed transversely (in particular, substantially horizontally) through an insertion station46during the second insertion step.

Advantageously, the method comprises a step of applying an adhesive substance, which is before the second insertion step and after the first insertion step and during which an adhesive substance is applied inside the open end10.

Advantageously, the method comprises a positioning step, which is before the second insertion step and after the first insertion step and in which the open end10is brought inside the insertion outlet50by means of a relative (in particular, longitudinal and, more precisely, vertical) movement between an insertion outlet50and the intermediate element12. In particular, the second material passes through the insertion outlet50for insertion into the intermediate element12.

Advantageously, in the second insertion step, a force (in particular, radial and centrifugal) is exerted on the sheet7at the open end10in order to keep it open.

In particular, the force is exerted via aspirators. More precisely, the aspirators comprise suction openings55made in the insertion outlet50so that they are positioned around the open end10at the end of the positioning step.

Advantageously, the second material is at least partly elastically deformable. During the second insertion step, the second material is elastically deformed so as to reduce its lateral size and is subsequently inserted in the intermediate element12so as to expand inside the intermediate element12(and in particular, close the open end10).

Advantageously, during the second insertion step, the second material (in particular, portion4) is pushed (in particular, by means of the pusher head53) inside the intermediate element12. More precisely, the second material (in particular, portion4) is pushed so as to compress portion3.

Unless specifically indicated otherwise, the content of references (articles, texts, patent applications, etc.) cited in this text is integrally referred to herein for completeness of the description. In particular, the above-mentioned references are incorporated herein for reference.