Patent Publication Number: US-7588524-B2

Title: Fiber filter production

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   The present application claims priority under 35 U.S.C. §119 of German Patent Application No. DE 10 2006 018 102.6, filed on Apr. 18, 2006, the disclosure of which is expressly incorporated by reference herein in its entirety. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The invention relates to a method for producing and a device for producing filter rods of the tobacco-processing industry. 
   2. Discussion of Background Information 
   A method for producing a web for the production of filters or filter rods of the tobacco-processing industry is known from commonly owned European Patent Application No. EP 1 464 241 A1. Moreover, a filter rod-making machine of the tobacco-processing industry is disclosed. The filter rod-making device comprises at least one filter material feed device from which the filter material can be transferred in metered quantities and a rod assembly device in which the filter material is poured to form a rod. The filter rod-making device known from EP 1 464 241 A1 further includes the feature that the filter material can be conveyed in a fluidized bed from the filter material feed device to the rod assembly device. The method disclosed in this document is characterized by the following process steps:
         Feeding separated filter materials to a fluidized bed,   Transporting the filter material in the fluidized bed essentially by means of a transport air flow in the direction of a rod assembly device, and   Pouring the filter material on the rod assembly device.       

   A method and a device for producing a web for the production of filter rods is known from commonly owned European Patent Application No. EP 1 464 240 A1. the method is characterized by the following process steps:
         Separating fibers of at least one type of filter material in a separating device,   Feeding the separated fibers to a conveyor that moves in a conveying direction,   Pouring the separated fibers on the conveyor, whereby a web is formed, the separating device comprising at least one separating element that rotates about a rotational axis, the rotational axis being aligned essentially parallel to the conveying direction of the conveyor.       

   The device described in the preceding paragraph is characterized in that separating devices are provided which are embodied separately from one another. 
   The devices in the two referenced European patent applications process finite fibers so that webs, filter rods and filters are produced from finite fibers and optionally other filter constituents such as granulates. 
   SUMMARY OF THE INVENTION 
   The present invention provides an efficient variant of a filter rod-making method and a device for producing filter rods. 
   Accordingly, the invention provides a method for producing filter rods of the tobacco-processing industry, such that fibers of finite length, composed of two different fiber types, are combined and mixed directly before a separating step. 
   The method according to the invention makes it possible for a segregation of fiber materials to be avoided before the separation step. Within the scope of the invention, directly before a separating step means that mixing and combining occur without any further intermediate step to the separating step or is free from a processing step or a separating step directly follows the combining and mixing. Within the scope of the invention, in particular finite fibers from two or at least two different fiber types are processed. Preferably, the mixing occurs with the combining or begins with the combining. In particular, this also means that the mixing begins with the combining and is continued on a predetermined conveyor path. 
   If a step for pouring to form a fiber web takes place after the separating step, a very homogenous filter rod can be produced. The separating step preferably comprises an acceleration of the fibers, in which a very homogenous separation as well as a very homogenous filter rod can be achieved. In a particularly simple process management, the acceleration takes place in or by a teasel. Within the scope of the invention, teasel also means a carding device or a part of a carding device or a card. In particular, a teasel is also understood to mean one or more rollers that are embodied on the circumferential surface in a similar manner to a natural teasel. These can also be embodied with sawtooth or trapezoid-tooth assemblies. Correspondingly, fine carded rollers can also be present. 
   Preferably, the fibers of two different fiber types are brought together unmixed before the step of combining and mixing. Within the scope of the invention the term unmixed means in particular homogenous. If the fibers are accumulated unmixed before being combined, a particularly good metering of the fibers is possible. They can then subsequently first be preseparated or separated, are then combined and mixed and subsequently separated again in order to be able to produce homogenous filter rods. An accumulation of the fiber mixture can also be provided before the final separating step. 
   A particularly preferred embodiment is given if the combined fibers are conveyed to a separating device by a transport air flow. The conveyance by a transport air flow preferably occurs in the area of the intermixing of the fibers. However, this can also already take place shortly before the combination of the different fiber types or directly before it. 
   A particularly efficient embodiment of the separating device is given if it comprises several rolls arranged one behind the other, the rotational speeds of which increase in the fiber conveying direction. A separation can thus be carried out very efficiently which prevents a segregation of the fibers. 
   The invention is directed to a method for producing filter rods of the tobacco-processing industry comprising fibers of finite length of at least one fiber type that preferably comprises the foregoing process steps at least in part. In this regard, a step of separating the fibers in a separating device is provided, such that the separated fibers that exit from the separating device have a component motion in the direction of a conveyor, in particular a suction rod conveyor, in particular against gravity. It is hereby possible for the amount of air flow that is required in the prior art, e.g., according to EP 1 464 241 A1, to be considerably reduced and also for less air to have to be removed from the method process which makes it possible to simplify process management. 
   The separated fibers are preferably flung into a suction duct directly from the separating device. Preferably, the suction rod conveyor is connected to the suction duct, and namely in particular directly, so that the fibers need to cover a very short distance after the separating device in order to be poured in the suction rod conveyor, e.g., on one or more suction belts. 
   In a preferred embodiment in the conveying direction downstream of the separating device the fibers are mixed with another filter material, such as, e.g., a granulate from activated charcoal and/or binder that has a component motion in the direction of a suction rod conveyor, in particular against gravity. This produces in particular a good intermixing of the fibers with the other filter material as well as the possibility of transport with as little suction air or transport air as possible 
   If two suction ducts arranged next to one another or a division of one suction duct into two partial suction ducts arranged next to one another are provided, two filter rods can be produced simultaneously so that the throughput or the production quantity of filter rods can be increased. The suction ducts are hereby preferably essentially parallel and have an angle to one another between 0° and 15°. 
   Further, the invention provides a device for producing filter rods of the tobacco-processing industry with at least two fiber feed ducts that open into a duct. A separating device is connected to the one duct, and a conveyor, in particular, a suction rod conveyor, is provided onto which the separated fibers of finite length can be poured. In particular, hereby the one duct and the separating device lie directly one behind the other in the conveying direction of the fibers or adjacent to one another. The device according to the invention renders possible a particularly simple intermixing of different fiber types, such that a segregation in the further process or in the further processing of the fiber mixture is avoided. Furthermore, a very compact device is rendered possible. 
   Preferably, a device is provided for generating an air flow in the one duct, which device is suitable in particular for conveying the fiber mixture. Furthermore, the provision of a device for generating an air flow in the one duct, which can preferably be a ventilator that drives through the one duct, renders possible a very efficient mixing of the material. To this end, for example, the ventilator can have one or more ventilator impeller wheels through which the fibers pass, whereby a rotation component is fed to the fiber mixture, which renders possible a very good intermixing. 
   If a retaining duct is respectively connected upstream of the at least two fiber feed ducts or is contained in the at least two fiber feed ducts, a very homogenous fiber mixture as well as a very good preliminary metering is possible. 
   Preferably, the one duct is embodied as a retaining duct. The variant in which a ventilator drives through the one duct means in particular that the ventilator is integrated into the duct. 
   The separating device preferably comprises several rolls arranged one behind the other, the rotational speeds of which increase in the fiber conveying direction. Preferably, at least one roll is embodied in a teasel-like manner. To this end the roll preferably has on the circumferential surface a structure like a natural teasel, i.e., in particular prongs or pins lying close together. The roll can also be embodied on the circumferential surface in the form of sawteeth or trapezoid teeth. The assemblies of the rolls lying one behind the other can be embodied to be progressively finer in the fiber conveying direction, so that fibers that are transported by rolls lying one behind the other are subjected to a longitudinal alignment, parallelization and separation. 
   Preferably, a suction duct is directly connected to the separating device, which suction duct is aligned vertically and terminates with a suction rod conveyor. A device with a very compact design is thus possible. Preferably, the suction rod conveyor is arranged at the upper end of the suction duct, which results in a very uniform fiber web formation in the suction rod conveyor so that very homogenous filter rods can be produced. Preferably, two suction rod conveyors or two suction belts are provided in a suction rod conveyor in order to render possible a very high throughput and a high production quantity of filter rods. 
   If two suction ducts are provided, or one suction duct is divided into two ducts in the fiber conveying direction shortly before the suction rod conveyors or the suction rod conveyor with two suction belts, a uniform distribution of the fibers is possible. 
   A uniform distribution of the quantities of fibers that are taken up by the suction belts or the suction rod conveyors can take place, e.g., by adjusting the air flow or the suction air flow through the respective suction belts or suction rod conveyors. 
   The present invention is directed to a method for producing filter rods of the tobacco-processing industry. The method includes combining and mixing fibers of finite length of two different fiber types, and separating the combined and mixed fibers. The combining and mixing occurs directly before the separating. 
   According to a feature of the invention, the mixing can occur with the combining. 
   In accordance with another feature of the instant invention, after the separating, the method can further include forming a fiber web. 
   According to still another feature, the separation can include accelerating the fibers. The accelerating of fibers may occur in or by a teasel. 
   The fibers of two different fiber types may be unmixed before the combining and mixing. The method can further include accumulating the unmixed fibers before the combining and mixing. 
   Moreover, the method can include conveying the combined fibers to a separating device by a transport air flow. The separating device may include several rolls arranged one behind the other, the rotational speeds of which increase in the fiber conveying direction. 
   In accordance with another feature of the invention, the combining and mixing can include forming a compact fiber cake at an entrance to a separating device. Further, the separating may include loosening the fibers of the compact fiber cake. 
   The invention is directed to a method for producing filter rods of the tobacco-processing industry. The method includes accumulating fibers of finite length of at least one fiber type, and separating the fibers in a separating device. The separated fibers exiting the separating device have a motion component in a direction of a conveyor. 
   In accordance with a feature of the invention, the motion component can be against gravity. 
   According to another feature of the present invention, the conveyor can be a suction rod conveyor. 
   Further, the method can include flinging the separated fibers into a suction duct directly from the separating device. The conveyor may be connected to the suction duct. 
   In accordance with a further feature of the instant invention, in a conveying direction downstream of the separating device, the method can include mixing fibers with another filter material having a motion component in the direction of a conveyor. The motion component can be against gravity. 
   Further, the suction duct can include one of two suction ducts arranged next to one another or a division forming two partial suction ducts arranged next to one another. 
   The instant invention is directed to a device for producing filter rods of the tobacco-processing industry. At least two fiber feed ducts opening into a mixing duct, a separating device connected to the mixing duct, and a conveyor structured and arranged to receive separated fibers of finite length. 
   According to feature of the invention, the conveyor may be structured and arranged to receive separated fibers to be poured from the separating device. 
   In accordance with another feature of the present invention, the device can include a device for generating an air flow in the mixing duct. 
   The device may further include retaining ducts arranged upstream of the at least two fiber feed ducts. 
   According to still another feature of the instant invention, the at least two fiber feed ducts form retaining ducts. 
   In accordance with a further feature of the present invention, the mixing duct can be embodied as a retaining duct. 
   According to another feature, the device can include a ventilator drive through the mixing duct. 
   Further, the separating device may include several rolls arranged one behind the other, the rotational speeds of which increase in the fiber conveying direction. At least one of the several rolls may be embodied in a teasel-like manner. 
   In accordance with still yet another feature of the present invention, the conveyor may be a suction rod conveyor. The device can also include a suction duct connected directly to the separating device, in which the suction duct is aligned essentially vertically and terminates with the conveyor. The suction rod conveyor can be arranged at an upper end of the suction duct. Further, the suction rod conveyor may include one of: two suction rod conveyors or two suction belts. The device can also include two suction ducts. Moreover, the device may include a suction duct divided into two ducts in a fiber conveying direction upstream of the one of the two suction rod conveyors or the two suction belts. 
   Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein: 
       FIG. 1  is a diagrammatic sectional representation of a device according to the invention; 
       FIG. 2  is a diagrammatic sectional representation of a device according to the invention in another embodiment; 
       FIG. 3  illustrates a section from a device according to the invention in another embodiment in diagrammatic representation; and 
       FIG. 4  illustrates a section from a device according to the invention in yet another embodiment in diagrammatic representation. 
   

   DETAILED DESCRIPTION OF THE PRESENT INVENTION 
   The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. 
     FIG. 1  shows a sectional representation through a device according to a first exemplary embodiment of the invention. In a fiber processing device  10 , fibers  12  of a first fiber type and fibers  13  of a second fiber type are respectfully fed through a first feed pipe  14  and a second feed pipe  15  into a first retaining duct  11  and a second retaining duct  11 ′, respectively, by, e.g., transport air. First fiber type  12  can be, e.g., a multiple-component fiber, in particular bi-component fiber, and second fiber type  13  can be fibers of cellulose acetate, cellulose or carbon fibers. Diverse fiber materials that have a finite length can be provided. With regard to the different fiber materials reference is made to the commonly owned German Patent Application No. DE 102 17 410.5, the disclosure of which is expressly incorporated by reference herein in its entirety. The length of the fibers can preferably be smaller than the length of the filter rod to be produced. Accordingly, this can be between 0.1 mm and 60 mm and, in particular, preferably between 0.2 mm and 10 mm. With fibers produced synthetically, the fiber thickness should be 1 to 20 dtex, preferably 2 to 6 dtex. The average fiber diameter can be in the range of preferably 10 to 40 μm, in particular, 20 to 38 μm and, in particular, preferably between 30 and 35 μm. The fibers are preferably curled, in particular, zigzag shaped, and have 10 arches per 10 mm. 
   Fibers  12  or  13  are removed from the accumulation area of the fibers of the retaining ducts  11  and  11 ′ by intake rolls  16  and  16 ′ and beaten out with a beater roll  17  or  17 ′ and transferred into first fiber feed duct  19  or second fiber feed duct  19 ′. The different fiber types  12  or  13  are combined to form a fiber mixture  32  in a combining region  20 . Fiber mixture  32  reaches a conveyor duct  21  and can accumulate shortly before intake roll  22  of a carding device or a part of a carding device. 
   The metering of fiber types  12  and  13  takes place through, e.g., the control of the removal speeds of the fibers by intake rolls  16 ,  16 ′ and/or beater roll  17 ,  17 ′. Intake rolls  16 ,  16 ′ can be embodied to run slowly, such that they convey the fibers against a spring-mounted groove (not shown). The fibers are hereby drawn in and compressed into a thin compact fiber cake (not shown). 
   The fiber cake conveyed downwards between intake rolls  16 ,  16 ′ and groove is subsequently trimmed off or beaten out at the lower end of the groove by respectively one rapidly running beater roll  17 ,  17 ′. The fibers are thereby loosened, separated and carried into ducts  19 ,  19 ′. A supporting air flow can be used hereby, which is not shown in  FIG. 1 . At the end of the conveyor duct  21 , the fiber mixture is gathered by intake roll  22  and conveyed against groove  23  and subsequently a leaf-spring battery  24 . Groove  23  is spring-mounted. A thin, compact fiber cake is produced (not shown) and conveyed between intake roll  22 , groove  23  and leaf-spring battery  24  and compacted. 
   If the fiber cake leaves the effective range of leaf-spring battery  24 , it is gathered and taken on by rapidly running roll  25 . Rolls  25 ,  26  and  27  are embodied as or with a teasel or equipped with sawtooth assemblies or trapezoid-tooth assemblies. The roll speeds increase from roll  25  to roll  27 . 
   After the fibers of fiber mixture  32  have been held in the assembly of roll  25  for a rotation of approx. 180°, fibers  32  are transferred tangentially to counter-rotating roll  26 . Since roll  26  rotates more quickly than roll  25  and in particular has a finer teasel structure or a finer sawtooth assembly or trapezoid-tooth assembly, a longitudinal alignment, parallelization and separation of the fibers takes place during the transfer. 
   After fibers  32  have been held on the circumference in the assembly of roll  26  for approx. 180°, fibers  32  are transferred tangentially in turn to counter-rotating roll  27 . Since roll  27  rotates more quickly than roll  26  and has, in particular, a finer teasel-like structure or a finer sawtooth assembly or trapezoid-tooth assembly, a longitudinal alignment, parallelization and separation of the fibers again takes place during the transfer. After fibers  32  have been held in the assembly of roll  27  for 180°, fibers  32  are transferred tangentially upwards into an air flow  44  of the channel or suction duct  28 . Subsequently, fiber mixture  32  reaches a suction belt  29  of a suction rod conveyor  30 . Air flow  44  can additionally be separated from the fiber mixture or fiber/granulate mixture via a lateral suctioning  45  (or 45′ in  FIG. 4 ) before suction rod conveyor  30 . 
   A conventional rod-forming device, such as, e.g., according to FIG. 10 of European Patent Application No. EP 1 464 241 A1, is connected to the suction rod conveyor, which is not shown in the figure. In this regard, the disclosure of EP 1 464 241 A1 is incorporated by reference herein in its entirety. After a fiber cake has been produced on suction belt  29  of suction rod conveyor  30 , the fiber cake is usually trimmed, fed to a forming device in order to produce a fiber rod with the desired cross-sectional geometry from the fibers forming from which the fiber cake or fiber web is formed and optionally to wrap the fiber rod with a wrapping material in order subsequently to be cut to length in filter rods. 
   Instead of a direct injection of fibers  32  into suction duct  28 , fibers  32  can be dropped first onto an endless apron and subsequently suctioned into a suction duct according to EP 1 584 248 A1, such that, preferably, one roll more or one roll less is then used in the carding device. 
     FIG. 2  shows another embodiment according to the invention of a device for producing filter rods, such that, compared to  FIG. 1 , a ventilator  31  is provided directly following combining area  20 . Ventilator  31  generates a transport air flow  42  in conveyor duct  21 . Measures can be provided to ensure a closed circulation of the transport air flow such that, e.g., in the lower area of conveyor duct  21  transport air openings are provided, which ensure that transport air is removed from conveyor duct  21  without carrying along fibers, in order then to be fed to the ventilator again. 
   In  FIG. 2 , furthermore, a drive belt  36  is provided, which, e.g., indicates a drive of roll  25 . Rolls  25  through  27  as well as the other rolls used, however, can also be driven with a direct drive by one motor each. 
   In contrast to the exemplary embodiment according to  FIG. 1 ,  FIG. 2  depicts yet another option, namely feeding a granulate  43  to the fiber mixture. This takes place shortly before the filter material is poured onto a suction belt of a suction rod conveyor  30  in suction duct  28 . 
   To this end, granulate  43  is fed from a granulate container  33  to a drop duct with a metering roll  34 . The drop duct ends in a chamber with an accelerating roll  35  that flings the granulate tangentially in the direction of suction rod conveyor  30  into suction duct  28 . A good intermixing of the granulate with the fibers thus occurs. A fiber web  41  or a filter material web  41  then forms on a suction belt of the suction rod conveyor  30 . 
   In order to render possible a higher production speed or a higher throughput of material and to increase the number of filter rods per unit of time, it is possible to provide two suction belts  29 ,  29 ′, as indicated in  FIG. 3  and  FIG. 4 . 
   To this end, as indicated in  FIG. 3 , a suction duct  28  can be divided into two partial ducts  39  and  39 ′, which are arranged to run essentially parallel each other shortly before suction belts  29 ,  29 ′ of suction rod conveyor  30 . In  FIG. 3 , furthermore, injection area  37  for granulate is provided. 
   According to  FIG. 4 , two complete suction ducts  28 ,  28 ′ are provided that are slightly tilted with respect to one another, in this case at an angle of approx. 3°. Suction ducts  28  and  28 ′ can be embodied such that they are arranged one behind the other perpendicular to the drawing plane relative to the drawing plane of  FIG. 4  so that respectively half the depth or width of rolls  27  or  35  are provided to respectively supply conveyor ducts  28  or  28 ′ with filter material. Injection area  37  is then provided with a relatively short granulate duct  40  for front conveyor duct  28  relative to the drawing plane of  FIG. 4  and with rear conveyor duct  28 ′ relative to the drawing plane of  FIG. 4  with a somewhat longer granulate duct  40 ′. Accelerator roll  35  can be embodied as a type of brush roll. The granulate is flung into the respective suction duct by centrifugal force and mixes with the fiber stream. It is preferred if the speeds of the mass stream and the granulate fed in are different relative to one another. A good mixture is hereby produced. 
   Through the structure according to the invention the size of the rod-maker (rod-making machine) for filter production is considerably reduced, since a suction rod conveyor can be arranged directly at the separating device. Moreover, the air consumption is reduced, since the transport stream and mixing process in an otherwise conventional long channel are omitted. 
   It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. 
   LIST OF REFERENCE NUMBERS 
   
       
       
         
             10  Fiber processing device 
             11 ,  11 ′ Retaining duct 
             12  First fiber type 
             13  Second fiber type 
             14  First feed pipe 
             15  Second feed pipe 
             16 ,  16 ′ Intake roll 
             17 ,  17 ′ Beater roll 
             19  First fiber feed duct 
             19 ′ Second fiber feed duct 
             20  Combining area 
             21  Conveyor duct 
             22  Intake roll 
             23  Groove 
             24  Leaf-spring battery 
             25  Roll 
             26  Roll 
             27  Roll 
             28 ,  28 ′ Suction duct 
             29 ,  29 ′ Suction belt 
             30  Suction rod conveyor 
             31  Ventilator 
             32  Fiber mixture 
             33  Granulate container 
             34  Metering roll 
             35  Accelerator roll 
             36  Drive belt 
             37  Injection area 
             38  Forking 
             39 ,  39 ′ Partial duct 
             40 ,  40 ′ Granulate duct 
             41  Fiber web 
             42  Transport air 
             43  Granulate 
             44  Conveying direction 
             45 ,  45 ′ Suctioning