Abstract:
Described herein is a method and apparatus for transferring rods, or tubes, comprising feeding a plurality of rods into a hopper, feeding the rods through a hopper using agitation and gravity to align the rods in a single-file stacked configuration, and transferring the rods with pushers on a continuous cable so that that the rods may be transferred for insertion in the tobacco column. This method and apparatus may utilize one or more drums for transferring rods from the hopper to the pushers on the continuous cable.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims the benefit of provisional application Ser. No. 60/847,167, filed Sep. 26, 2006, for all useful purposes, and the specification and drawings thereof are included herein by reference. 
     
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a device and method of transferring components, such as rods or tubes, for use in smoking article manufacturing. 
       BACKGROUND OF THE INVENTION 
       [0003]    Drum transfer systems are known in the tobacco industry on cigarette tipping and packaging machinery. However, many drum supply methods are speed limited to such an extent that they cannot feed components fast enough to meet the minimum speed for forming a consistent tobacco rod. Thus, a need exists for a faster rod transfer device and method to permit the formation of a consistent tobacco rod. 
       SUMMARY OF THE INVENTION 
       [0004]    Described herein is a method for transferring rods, or tubes, comprising feeding a plurality of rods into a hopper, feeding the rods through a hopper using agitation and gravity to align the rods in a single-file stacked configuration, and transferring the rods with pushers on a continuous cable so that that the rods may be transferred for insertion in the tobacco column. This method may utilize one or more drums for transferring rods from the hopper to the pushers on the continuous cable. 
         [0005]    Also described is an apparatus for transferring rods comprising a hopper for feeding a plurality of rods to a transfer point, said hopper capable of feeding the rods through hopper using agitation and gravity to align the rods in a stacked single-file configuration, and a cable/chain with intermittently spaced pushers for engaging the rods so that that the rods may be transferred for insertion in the tobacco column. This device may comprise one or more drums for transferring rods from the hopper to the pushers on the continuous cable. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Novel features and advantages of the present invention in addition to those noted above will be become apparent to persons of ordinary skill in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which: 
           [0007]      FIG. 1  is a side elevational view showing a first embodiment for insertion of a rod into a tobacco feed mechanism using synchronized drums; 
           [0008]      FIG. 2  is a right side elevational view of the wheel  16  shown in  FIG. 1  having the pick-up mechanism  22 A being under wheel  16 ; 
           [0009]      FIG. 3  is a side elevational view in cross-section taken along line  3 - 3  in  FIG. 1 ; 
           [0010]      FIG. 4  is a top plan view of a second embodiment for insertion of a rod into a tobacco feed mechanism using a single drum to transfer rods from a hopper to cable-driven pushers; 
           [0011]      FIG. 5  is an enlarged side elevational view of  FIG. 4  looking in the direction of line  5 - 5  shown in  FIG. 4 ; 
           [0012]      FIG. 6  is a cross-sectional view in elevation showing a tube or rod being engaged by a pusher attached to a drive chain or cable; 
           [0013]      FIG. 7  is a schematic side elevational view partially in cross-section of a third embodiment for insertion of tubes or rods into a tobacco feed mechanism using two coordinated pushers on parallel horizontal cables; and 
           [0014]      FIG. 8  is a cross-sectional view in elevation taken along line  8 - 8  of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0015]    Embodiments of the present invention will now be described with reference to the drawings. Generally speaking, rods or tubes for smoking articles are provided to a hopper. The terms “rod” and “tube” are used herein interchangeably. Both terms refer to generally to hollow and solid structures for use in smoking article manufacture. The rods may be double length rods such as the type used in the so called 2-up configuration for smoking article manufacture. The rods are fed continuously so that they may be engaged with a pusher for moving the rods in a serially aligned direction. 
         [0016]    According to a first embodiment, shown in  FIG. 1 , rods  10  are aligned using apparatus  12 , which includes a hopper  14 , first wheel  16 , second wheel  18 , third wheel  20 , and pick-up mechanism  22 . Initially, rods  10  are provided to hopper  14  that may comprise an agitation mechanism  15 . The rods  10  are aligned in an alignment chamber  24  in a single row stacked configuration using agitation and gravity to ensure continuous flow. 
         [0017]    As each rod  10  reaches the bottommost portion of the hopper  14 , it is engaged with a flute  26  on first rotating drum  16 . Rotating drum  16  has a raised surface  28 , shown in  FIG. 2 , to strip the rod  10  from the hopper  14  and ensure repeatable and accurate positioning within flute  26 . Pick up and retention is assisted and ensured by way of internal drum vacuum provided via vacuum plenum  32  connected via vacuum lines  30  to ports  34  that extend radially and then axially from the surface of flutes  26  as shown in phantom in an alternative embodiment shown in  FIG. 2 . The vacuum is distributed using generally conical shaped vacuum distribution mechanisms  31 , which are well known in the art. Similar ports  34  to those shown in  FIG. 2  are shown in  FIGS. 3 and 4 . Some details of the vacuum system are omitted for simplicity, but are well known to those skilled in the art of drum vacuum application. 
         [0018]    As rod  10  rotates around drum  16  it may be transferred to drum  18 , as shown in  FIG. 1 , or to a pusher mechanism  22   a , as shown in  FIG. 2 . First drum  16  may rotate in a counterclockwise direction when viewed from the right side in elevation to deliver rod  10  to drum  18  or pusher mechanism  22   a . It should be understood that drums  16  and  18  and pusher mechanism  22   a  could rotate in the direction opposite that described and shown so long as drum  16  and drum  18 , or drum  16  and pusher mechanism  22   a , travel synchronously at the time of transfer. It should also be noted that wheel  16  for the first embodiment shown in  FIG. 1  may be configured identically to the alternate first embodiment shown in  FIG. 2 . For both embodiments, stationary guides or holding fingers, not shown, may also be used if the mass of rod  10  is too great to control by vacuum alone. 
         [0019]    According to the first embodiment, shown in  FIG. 1 , second drum  18  may be synchronized with the first drum  16  by a driven bevel gear  36 , which may be driven by motor M and may have teeth, not shown, for engaging and driving bevel gears  38  and  44 . Bevel gears  38  and  44  may be attached to and rotate wheels  16  and  20 , respectively. Second drum  18  may have a guide means  40  for transferring rod  10  from drum  16  to drum  18 . As rod  10  tangentially aligns with drum  18 , the vacuum in flute  26  is reduced or disengaged. Rod  10  may then be guided into contact with drum  18  through the force of gravity and the sideward guidance of guide mechanism  40 . Alternatively or additionally, a vacuum may be engaged such that rod  10  is drawn toward flute  42  of drum  18 . Because drum  18  is synchronized with drum  16 , drum  18  rotates counterclockwise when viewed from the top of apparatus  12  and carries rod  10  to a tangentially aligned position with third drum  20 . Drum  18  may have an alignment mechanism for positioning rod  10  within flute  42  if required for given tube/rod mass and surface characteristics. This mechanism, which is not shown for the sake of simplicity, may consist of a raised surface such as the raised surface  28  on first drum  16 , shown in  FIG. 2 . 
         [0020]    Third drum  20  is synchronized with drum  18  by virtue of gear  44  being engaged with gear  36 , as discussed above. Third drum  20  may pick up rod  10  from flute  42  of drum  18  through a centrally controlled vacuum that is provided at the surface of flutes  48  via radially and axially extending ports  34 , shown in phantom in  FIG. 3 . When viewed along line  3 - 3  of  FIG. 1 , as shown in  FIG. 3 , drum  20  rotates in a clockwise direction, but may move in any direction dictated by its synchronization with drums  16  and  18 . Drum  20  may have an alignment mechanism for positioning rod  10  within flute  48  if required for given tube/rod mass and surface characteristics. This mechanism, which is not shown for the sake of simplicity, may consist of a raised surface such as the raised surface  28  on first drum  16 , shown in  FIG. 2 . 
         [0021]    After being received by third drum  20 , the rods can be removed using a pusher  50  that is attached to a cable, belt, or chain  52 , as shown in  FIG. 3 . Pusher  50  may bye round, square, or any suitable shape for pushing rod  10 . Cable  52  may be driven by a driving mechanism, which is not shown for purposes of simplicity but is well known in the art of cable, belt, and chain driving. Cable  52  is synchronized so that it moves at a matched speed with flute  48 . This allows cable  52  to guide rod  10  onto substrate  54  without damaging rod  10  during transfer. Once on substrate  54 , rod  10  may be incorporated in the further creation of a smoking article. 
         [0022]    Alternatively, as shown in  FIG. 2 , pusher mechanism  22   a  may be placed below drum  16  to transfer rod  10  to the later stages of smoking article manufacture. According to this embodiment, cable  22   a  may engage rod  10  directly from first wheel  16 . 
         [0023]    According to a second embodiment, shown in  FIGS. 4 through 6 , rods  10  may be fed from hopper  14  in the manner described above, i.e. using gravity and agitation. As shown in  FIGS. 4 and 5 , rods  10  are deposited on flutes  64  of a horizontally rotating drum  60 . Flutes  64  may have a raised surface  62  to ensure repeatable and accurate positioning of rod  10 . Pick up and retention may be assisted and ensured by way of an internal vacuum provided to flutes  64  through ports  34  which may be connected to a vacuum manifold  35  and a vacuum line  30 . Additionally or alternatively, guides or holding fingers, not shown, may also be used if the mass of rod  10  is too great to control by vacuum alone. 
         [0024]    As drum  60  rotates, rod  10  is aligned with pushers  50  on a cable  52  in a manner similar to that described with reference to  FIGS. 1 through 3 . Raised surface  62  on the drum flute  64  is designed to generally mate with pushers  50  on the cable, chain, or belt  52 , as shown in  FIG. 6 . Pushers  50  engage the top portion of rods  10  to push rods  10  onto substrate  68 , as shown in  FIG. 4 , for further processing of rod  10  as a component of a smoking article. The speeds of drum  60  and cable  52  are synchronized to prevent damage to the rod  10  during transfer. Flutes  64  on drums  60  are designed for smooth tangential transfer of rods  10  and to accommodate the length and diameter of the rod  10 . 
         [0025]    A third embodiment is shown in  FIG. 7 . Rods  10  may be fed from a hopper  14 , as previously described above. However, upon reaching the bottom of hopper  14 , rods  10  are received on belt  52 A with pushers  50 A in a trough  74  that is located below hopper  14 . Belt  52 A may comprise a flat belt, a chain, or one or more cables as shown in  FIG. 8 . In fact, using two cables may assist in maintaining orientation of the pushers  50 A. As rods  10  drop in single file fashion, each rod  10  falls within the space between adjacent pushers  50 A. Belt  52 A moves in a direction to advance rods  10  through trough  74  by engaging pushers  50 A with one end of rod  10  and urging the rod  10  forward. Accurate pick up and transfer are assisted by a vacuum provided, for example, at ports  76  which are interconnected by chamber  78  within trough  74 . Chamber  78  is connected to the vacuum source through vacuum line  80 . 
         [0026]    As rods  10  advance, they are engaged from above by another belt  52 B with pushers  50 B. Belt  52 B may comprise a flat belt, a chain, or one or more cables as shown in  FIG. 8 . Using two cables may assist in maintaining orientation of the pushers  50 B. Belts  50 A and  50 B may travel at a matched speed so that pushers  52 A and  52 B remain aligned and so that rods  10  do not appreciably change position relative to one another. Pushers  50 B engage the top portion of rods  10  and push rods  10  onto substrate  68 , as shown in  FIG. 7 , for further processing of rod  10  as a component of a smoking article. A vacuum may be provided to upper trough  85  through a chamber and ports, not shown, using a configuration similar to that of chamber  78 , discussed above. 
         [0027]      FIG. 8  shows a cross-sectional view taken along line  8 - 8  in  FIG. 7 , but omits the wheel in order to highlight the fact that substrate  68  and trough  85  may be abutted to enhance the quality and efficiency of the vacuum 
         [0028]    It should be understood that the above detailed description while indicating preferred embodiments of the invention are given by way of illustration only since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from the detailed description. For example, for purposes of describing the invention, a cable is shown and described for the pusher mechanism in the various embodiments. However, it should be recognized that the cable could be replaced with a belt or chain without diverting form the invention.