Patent Description:
An operating machine for processing smoking articles comprises numerous components assembled together.

Some of these components are pneumatic, or they have, on their outer surface, holes through which (more frequently) suction is generated to hold an element being processed in contact with the outer surface of the component or through which (more rarely) a puff of compressed air is generated to pneumatically push on an element being processed.

A pneumatic component generally comprises a series of holes made through the outer surface of the pneumatic component and a system of internal channels arranged at least partially inside a pneumatic component to distribute the sucking or the compressed air to the holes. Normally, and for simplicity of production, the channels (often formed from the solid using chip removal processing) have a straight progression with elbow curves (i.e., forming a <NUM>° angle); in any case, these regular channel shapes, imposed by the necessity of manufacturing without excessive complications, is decisively challenging in terms of fluid dynamics, i.e. it entails the loss of significant charges leading to decidedly unfavourable energy efficiency (i.e. to produce relatively limited suction or blowing, a lot of power is needed and, thus, it is necessary to consume a significant amount of energy).

The patent application <CIT> describes a method for manufacturing a piece formed for a cigarette packaging machine; the formed piece comprises a base body on which printed parts with surfaces in contact with the materials being processed are made using a laser ray.

The patent application <CIT>discloses a solenoid valve body of hardened stainless steel made by additive manufacturing.

The purpose of this invention is to overcome the above-mentioned drawbacks, i.e., to provide an operating machine for processing smoking articles that is free of the drawbacks described above.

This purpose is achieved with an operating machine for processing smoking articles in accordance with the attached claims.

The claims describe preferred embodiments of this invention forming an integral part of this description.

The attached drawings illustrate some non-limiting embodiments of the holding head according to the invention and further some illustrative embodiments, in which:.

With reference to <FIG>, the reference number <NUM> indicates, as a whole, a filter application machine for applying filters to cigarettes (i.e., an operating machine for processing smoking articles).

The filter application machine <NUM> comprises multiple rotating conveyors, each of which is assembled so that it can rotate, with continuous motion, around a central rotation axis and supports, on the side, a series of sucking seats each of which is designed to hold at least one corresponding cigarette and/or at least one corresponding filter.

In particular, the filter application machine <NUM> comprises a transfer drum <NUM>, (called a "spider", in the jargon) which is assembled so that it can rotate, with continuous motion, around a rotation axis <NUM> and supports multiple tools, each of which is mounted so that it rotates around the transfer drum <NUM> to rotate around a respective rotation axis parallel to the rotation axis <NUM> of the transfer drum <NUM> so as to always remain horizontal and parallel to itself. Each assembly supports a sucking holding head <NUM> (better illustrated in <FIG>, <FIG>, and <FIG>) equipped with two sucking seats <NUM> that are parallel and simultaneously take two cigarette segments from a double forming beam of a cigarette packaging machine; according to a different embodiment not illustrated, each holding head <NUM> comprises a single sucking seat <NUM> taking just one cigarette segment at a time from a single forming beam of a cigarette packaging machine.

In addition, the filter application machine <NUM> comprises a separation drum <NUM>, which is assembled so that it can rotate, with continuous motion, around a rotation axis <NUM> and supports multiple holding heads <NUM> (illustrated in <FIG>, <FIG>, and <FIG>), each of which is equipped with a single sucking seat <NUM> designed to hold a corresponding filter.

Finally, the filter application machine <NUM> comprises a staggering drum <NUM> or scaler (better illustrated in <FIG>), which is assembled so that it rotates, with continuous motion, around a rotation axis <NUM>. The staggering drum <NUM> staggers two (or more) segments of cigarette filters initially placed side-by-side and with their heads circumferentially (tangentially) in contact with each other (via a circumferential movement of at least one filter segment) to arrange them at a certain circumferential distance from each other. Thus, the filter segments entering the staggering drum <NUM> are circumferentially aligned between them, while the filter segments exiting the staggering drum <NUM> are separated (staggered) circumferentially between them. In particular, the staggering drum <NUM> takes the filter segments from an entry station arranged at the cutting drum and feeds the circumferentially staggered filter segments to an outlet station arranged near a subsequent combining drum.

According to what is illustrated in <FIG>, <FIG>, and <FIG>, the staggering drum <NUM> comprises a central body <NUM> (only partially illustrated in <FIG>), which is assembled so that it can rotate around the rotation axis <NUM> (i.e., it is connected so that it can rotate around a frame of the filter application machine <NUM>), and multiple operating rings <NUM>, which are fitted, one after the other, around the central body <NUM> to form a shell that surrounds the central body <NUM> (i.e., the operating rings <NUM> form a shell covering the central body <NUM>). The operating rings <NUM> define sucking seats <NUM> that are designed to hold the cigarettes and are provided with respective suction holes <NUM> flowing out through the outer surface of the operating rings <NUM>. The operating rings <NUM> are fitted (mounted) in a removable manner on the central body <NUM> and, thus, can be replaced (i.e., mounted and remounted) relatively quickly.

If there is a format change, i.e. when the filter application machine <NUM> needs to process cigarettes of different sizes (in particular, with different diameters), it is necessary to modify the shape of the sucking seats <NUM> (which must reproduce, in negative, the shape of the cigarettes); this operation requires the replacement of just the operating rings <NUM> (in which the sucking seats <NUM> are formed) and does not require the replacement of the central body <NUM> and, thus, it is clearly faster and easier (it is significantly easier to disassemble/assemble just the operating rings <NUM> rather than the whole staggering drum <NUM>). In addition, a set of spare parts for a new cigarette format is clearly more economical and compact (the operating rings <NUM> alone require much less material than the whole staggering drum <NUM>). In other words, in each staggering drum <NUM>, the corresponding central body <NUM> becomes a part of a standard machine totally disconnected from the smoking articles format (i.e., it is never replaced or adjusted during a format change), while the operating rings <NUM> alone are part of a format machine that must vary as a function of the smoking article format (i.e., they must be replaced during a format change).

The operating machines <NUM> have a series of sucking seats <NUM> (each of which is designed to hold a cylindrical smoking article) provided with corresponding suction holes <NUM>; in addition, and as illustrated in <FIG>, the operating rings <NUM> comprise a series of tubular ducts <NUM>, each originating from an input opening <NUM> arranged in the area of an inner wall of an operating ring <NUM> and ending in a respective suction hole <NUM> in the area of an outer wall of the operating ring <NUM>. In other words, each tubular duct <NUM> connects a pneumatic distributor formed in the central body <NUM> to the suction holes <NUM>. The tubular ducts <NUM> are formed inside the corresponding operating rings <NUM>.

It is important to note that the valves adjusting the suction flow are formed inside the central body <NUM> and, thus, they always remain the same (and, so, in the same position) for all the formats, since the central body <NUM> is a part of a standard machine that is not replaced during a format change; obviously, the inlet openings <NUM> of the tubular ducts <NUM> formed in the operating rings <NUM> are positioned so that they can be optimally coupled with the corresponding openings formed in the central body <NUM>.

The staggering drum <NUM> of the filter application machine <NUM> circumferentially staggers the filter segments to a relatively limited degree; i.e., the circumferential movement of some filter segments in relation to other filter segments has a relatively limited stroke. In contrast, a staggering drum of a combining machine producing combined filters circumferentially staggers the filter segments to a relatively high degree (if compared to the staggering drum <NUM> of the filter application machine <NUM>); i.e., the circumferential staggering of some filter segments compared to other filter segments has a relatively limited stroke (if compared to the staggering drum <NUM> of the filter application machine <NUM>).

In <FIG>, <FIG>, and <FIG>, a holding head <NUM> comprising a sucking seat <NUM> provided with multiple suction holes <NUM>, which are connected to a suction source, is illustrated. In particular, each holding head <NUM> comprises a support body <NUM> that is L-shaped and consists of a main element <NUM>, in which the sucking seat <NUM> is formed, and a connection element <NUM> forming a right angle with the main element <NUM> and is connected to the separation drum <NUM>. According to what is illustrated in <FIG>, inside the support body <NUM> of each holding head <NUM>, a tubular duct <NUM> is formed, which ends in the suction holes <NUM> and connects the suction holes <NUM> to a pneumatic distributor formed in the separation drum <NUM>.

In <FIG>, <FIG>, and <FIG>, a holding head <NUM> comprising two sucking seats <NUM>, each of which is provided with multiple suction holes <NUM>, which are connected to a suction source, is illustrated. In particular, each holding head <NUM> comprises a support body <NUM> that is U-shaped and comprises two, straight main elements <NUM> parallel to each other, in which the sucking seats <NUM> are formed, and a connection element <NUM> connecting the main elements <NUM> together. Each main element <NUM> has an attachment <NUM> that is fixed to the transfer drum <NUM>. According to what is illustrated in <FIG>, inside the support body <NUM> of each holding head <NUM>, a tubular duct <NUM> is formed, which ends in the suction holes <NUM> and connects the suction holes <NUM> to a pneumatic distributor formed in the transfer drum <NUM>.

With reference to <FIG>, reference number <NUM> indicates, as a whole, a wrapping machine that is designed to produce a rigid cigarette pack with a hinged lid and functions with intermittent motion (i.e., motion that involves a cyclical alternation of motion and rest phases).

The wrapping machine <NUM> comprises a forming unit A, in which groups of cigarettes are formed in succession; a wrapping unit B, in which, around each group of cigarettes, a corresponding wrapping sheet is wrapped to create an inner wrapping; and a wrapping unit C, in which, around each inner wrapping, a collar is wrapped and a blank for creating an outer container provided with a lid.

The forming unit A of the cigarette groups comprises a hopper <NUM> provided with three outlet mouths for simultaneously feeding three cigarette groups to three corresponding pockets of a forming conveyor that supports multiple pockets.

The wrapping unit B comprises a wrapping conveyor <NUM> designed to feed each cigarette group along a straight, horizontal wrapping path. In particular, the wrapping path extends through a feeding station S1, wherein each cigarette group is coupled to a corresponding wrapping sheet that is folded in a U around the cigarette group.

The wrapping machine <NUM> comprises a feeding device <NUM> that cyclically feeds the wrapping sheets into the feeding station S1, i.e., it arranges each wrapping sheet in the feeding station S1 so that the wrapping sheet is intercepted by a corresponding cigarette group that advances along the wrapping path.

The wrapping machine <NUM> comprises a wrapping drum <NUM>, which supports multiple pockets <NUM> (one of which is illustrated in <FIG>), each of which is designed to contain an inner wrapping and a collar, and is assembled so that it rotates (with intermittent motion, i.e., "in steps") around a horizontal, parallel rotation axis. Each pocket <NUM> of the wrapping drum <NUM> receives a collar at a feeding station S2, thus receiving an inner wrapping at a transfer station S3, subsequently it receives a blank at a feeding station S4, and transfers the inner wrapping, the collar, and the blank together at a transfer station S5.

The wrapping machine <NUM> comprises a feeding device <NUM> that cyclically feeds the collars in the feeding station S2, i.e., arranges each collar opposite a pocket <NUM>. In the embodiment illustrated in <FIG>, the feeding device <NUM> separates the collars from a continuous band via a transverse cut; alternatively, the feeding device <NUM> could feed the collars from the hopper.

The wrapping machine <NUM> comprises a feeding drum <NUM> that supports multiple sucking holding heads (not illustrated), each of which is designed to hold a corresponding blank, and is assembled so that it rotates (with intermittent motion, i.e., "in steps") around a horizontal rotation axis to feed each sucking holding head along a circular feeding path.

Finally, the wrapping machine <NUM> comprises a wrapping drum <NUM> that is arranged downstream of the other wrapping drum <NUM>, it supports multiple pockets, each of which is designed to contain an inner wrapper, a collar, and a blank (received from the wrapping drum <NUM> in the transfer station S5), and it is assembled so that it rotates (with intermittent motion, i.e., "in steps") around a horizontal rotation axis.

The feeding device <NUM> comprises a movable support (not illustrated) that supports an individual sucking holding head <NUM> (illustrated in <FIG>) designed to hold a corresponding collar; in particular, the movable support cyclically moves the holding head <NUM> forward and backwards between a collar removal station and a collar delivery station. According to what is illustrated in <FIG>, each sucking holding head <NUM> comprises a cylindrical connection body <NUM>, which is connected to the feeding drum (not illustrated), and a tubular duct <NUM> projecting from a side surface of the connection body <NUM>, it is perpendicular to a longitudinal axis of the connection body <NUM>, and ends in two holding portions <NUM>, each of which is provided with (at least) one suction hole <NUM>. In other words, in the final part, each tubular duct <NUM> branches out in two sections, each of which ends in a corresponding holding portion <NUM>. The two holding portions <NUM> of the same tubular duct <NUM> are arranged at a certain distance from each other, to engage corresponding portions of a collar so as to grasp the collar safely and stably (i.e., without the collar being free to be deformed in an uncontrolled manner during the manipulation thereof). According to a different embodiment not illustrated, each tubular duct <NUM> only ends in an individual holding portion <NUM> or it ends in three-four holding portions <NUM> separated from each other.

Each sucking holding head <NUM> comprises a flat reinforcement element <NUM>, which is arranged alongside the tubular duct <NUM>, is radially oriented (perpendicularly) in relation to the tubular duct <NUM>, is connected to the tubular duct <NUM> at a middle line of the tubular duct <NUM>, and projects from a side surface of the connection body <NUM>. According to what is illustrated in the attached figures, in each holding head <NUM>, the reinforcement element <NUM> is initially arranged (i.e., in a part near the connection body <NUM>) on both sides of the tubular duct <NUM> and is subsequently arranged (i.e., in a part that is distal to the connection body <NUM>) on one side of the tubular duct <NUM> only. In each holding head <NUM>, the reinforcement element <NUM> preferably has an outer edge <NUM> (visible in <FIG>), which is oriented perpendicularly to the reinforcement element <NUM> and confers greater stiffness against buckling.

It is important to underline how the tubular duct <NUM> does not only have the function of "suction conveyor" passively supported by the reinforcement element <NUM>, but also performs an important structural function being a genuine reinforcement rib of the base element <NUM>. In other words, the reinforcement element <NUM> alone would not be able to withstand the mechanical stresses to which it is subject in use, since only the reinforcement element <NUM> together with the tubular duct <NUM> (which substantially reinforces the reinforcement element <NUM>) is able to withstand the mechanical stresses to which it is subject in use. In other words, in the mechanical sizing of a holding head <NUM>, the tubular duct <NUM> performs an important function and, thus, in use the tubular duct <NUM> supports a significant part of the mechanical stresses to which the holding head <NUM> is subject. As a result, the tubular duct <NUM> is (partially) able to support itself, i.e., it also has an important structural function and is not, therefore, only used as a "suction conveyor".

According to what is illustrated in <FIG>, each pocket <NUM> of the wrapping drum <NUM> comprises a rectangular peripheral frame <NUM> that is entirely solid and delimits a cavity arranged at the centre. In other words, the peripheral frame <NUM> is rectangular and extends in a ring around the cavity arranged at the centre. Each pocket <NUM> is a suction pocket and comprises multiple sucking holes <NUM>, flowing out through an outer surface of the peripheral frame <NUM> and, in use, they have the function of holding a corresponding collar and blank inside the pocket <NUM>. In addition, each pocket <NUM> comprises a series of tubular ducts <NUM> (illustrated in <FIG> and <FIG>) ending in the sucking holes <NUM> and extending inside the peripheral frame <NUM>, i.e., they are formed inside the hollow peripheral frame <NUM>, avoiding depositing the material at the tubular ducts <NUM>.

In <FIG>, reference number <NUM> indicates, as a whole, a packaging machine for the production of smoking articles (such as cigarettes containing tobacco) or of parts of smoking articles (for example, filters for conventional cigarettes and for new-generation cigarettes). The packaging machine <NUM> comprises a preparation unit <NUM>, in which a continuous cylinder <NUM> (worm) of filtering material (or tobacco) is produced in a known way, and a forming beam <NUM>, in which a paper band <NUM> (or another container material) is wound around the continuous cylinder <NUM> in a tube fed by a feeding unit <NUM>. In other words, the continuous cylinder <NUM> is fed at the inlet of the forming beam <NUM> above the paper band <NUM>, which is successively folded along the forming beam <NUM> into a tube around the cylinder <NUM>.

The packaging machine <NUM> comprises a gumming device <NUM>, which is arranged at a gumming station arranged at the start of the forming beam <NUM> in an area wherein the paper band <NUM> has not yet been folded in a tube around the cylinder <NUM>. Before completely folding the paper band <NUM> in a tube, the gumming device <NUM> applies a continuous strip of glue to one edge of the paper band <NUM>.

In <FIG> and <FIG>, an initial part <NUM> of the forming beam <NUM> is illustrated (identified in the jargon with the name "tongue"), which has, inside, a cylindrical passage channel <NUM> inside of which the continuous cylinder <NUM> slides, partially wound by the paper band <NUM>. Along one surface of the passage channel <NUM> a series of blowing holes <NUM> opens (three on the left side and three on the right side) and another series of blowing holes <NUM> (nine on the left side and nine on the right side). Inside the initial part <NUM> of the forming beam <NUM>, tubular ducts are formed, which flow into the blowing holes <NUM> and other tubular ducts, which flow into the other blowing holes <NUM>.

The holding heads <NUM>, the holding heads <NUM>, and the operating rings <NUM> of the filter application machine <NUM>, the holding heads <NUM> and the pockets <NUM> of the wrapping machine <NUM>, and the initial part <NUM> of the forming beam <NUM> of the packaging machine <NUM> are examples of pneumatic components of an operating machine for processing smoking articles that are advantageously produced using additive manufacturing. In other words, each pneumatic component (holding head <NUM>, holding head <NUM>, operating ring <NUM>, holding head <NUM>, pocket <NUM>, and initial part <NUM>) is a single monolithic piece, it is composed of a single, indivisible body made all together and entirely seamlessly, and is manufactured using additive manufacturing.

Each pneumatic component is made using additive manufacturing (also called 3D printing), i.e., using an industrial process that, beginning with a digital 3D model, creates the piece adding one layer over the other (some examples of technologies that can be used in additive manufacturing are stereolithography; fusion deposition modelling, also called FDM; selective laser sintering, also called SLS; or direct laser microfusion or DLM).

According to one possible embodiment, each pneumatic component (holding head <NUM>, holding head <NUM>, operating ring <NUM>, holding head <NUM>, pocket <NUM>, initial part <NUM>) is entirely made of plastic (plastic or resin), i.e., not of metal (basically to reduce the cost of production and the weight), since each pneumatic component in use is not subject to significant mechanical stresses. The plastic with which each pneumatic component is made, could, potentially, be filled (reinforced) with carbon or glass to improve the structural characteristics (for example Nylon 12CF is a thermoplastic composite for carbon-filled 3D printing with excellent structural characteristics).

According to a different embodiment, each pneumatic component (holding head <NUM>, holding head <NUM>, operating ring <NUM>, holding head <NUM>, pocket <NUM>, or initial part <NUM>) is entirely made of metal (for example, steel or aluminium), which has greater resistance to wear.

In all the pneumatic components (holding head <NUM>, holding head <NUM>, operating ring <NUM>, holding head <NUM>, pocket <NUM>, initial part <NUM>) described above, the use of additive manufacturing (which makes each component a single undivided and indivisible body) makes it possible to optimise the fluid dynamic efficiency of the corresponding tubular ducts <NUM>, <NUM>, <NUM>, <NUM>, <NUM> since the tubular ducts <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may have irregular shapes (typically with curves that form an angle very different to <NUM>° and/or with a variable cross section area) chosen to optimise the fluid dynamic efficiency (i.e., without taking into account in any way the construction and assembly issues that there would be if additive manufacturing were not used). In particular, along the same section of a tubular duct, the area of the cross-section may continuously vary (i.e., without forming "steps") in order to optimise the fluid dynamic efficiency.

In other words, the use of additive manufacturing makes it possible to transfer the shape of the tubular ducts <NUM>, <NUM>, <NUM>, <NUM>, <NUM> calculated using a fluid dynamic numerical analysis, to all the pneumatic components (holding head <NUM>, holding head <NUM>, operating rings <NUM>, holding head <NUM>, pocket <NUM>, initial part <NUM>) described above, in order to balance air flows, minimising losses, distributing the up thrust forces of the product in the most efficient manner along the whole length of the holding section.

In addition, the use of additive manufacturing (which makes each pneumatic component a single undivided and indivisible body) makes it possible to create tubular ducts <NUM>, <NUM>, <NUM>, <NUM>, <NUM> directly inside the pneumatic component without the pneumatic component being dismountable (i.e., somehow able to be opened). Thus, it is no longer necessary that a pneumatic component be composed of several pieces joined together, and the tubular ducts <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may have irregular shapes chosen only to optimise the fluid dynamic efficiency (i.e., without taking into account the construction and assembly issues that there would be if additive manufacturing were not used). The operating machine described above has numerous advantages.

In the first place, the pneumatic components (holding head <NUM>, holding head <NUM>, operating ring <NUM>, holding head <NUM>, pocket <NUM>, initial part <NUM>) of the operating machine described above have a fluid dynamics that is optimised to minimise charge losses and, thus, maximise energy efficiency (i.e., the use of moderate power is enough to produce a suction or blowing and, thus, less energy is consumed).

In addition, the optimised fluid dynamics of the pneumatic components (holding head <NUM>, holding head <NUM>, operating ring <NUM>, holding head <NUM>, pocket <NUM>, initial part <NUM>) of the operating machine described above improves (i.e., makes more stable and secure) how materials and products are held, increasing the final quality of products and reducing the number of defective products to be thrown away.

Claim 1:
An operating machine (<NUM>; <NUM>; <NUM>) to process smoking articles and comprising at least one pneumatic component having a plurality of holes (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>), which are obtained through an outer surface and can be connected to a pneumatic system, and at least one tubular duct (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>), which ends in the holes (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>; <NUM>); wherein the pneumatic component is one single monolithic piece, consists of one single indivisible body manufactured as a whole seamlessly and is manufactured by means of additive manufacturing;
wherein the tubular duct (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>) has a non-straight geometry, which optimizes fluid-dynamic efficiency; and
wherein the pneumatic component is a sucking holding head (<NUM>), which is designed to hold, through suction, a wrapping sheet, in particular a collar, or a sucking holding head (<NUM>; <NUM>), which is provided with at least one sucking seat (<NUM>; <NUM>) designed to hold a smoking article.