U.S. patent application number 12/652522 was filed with the patent office on 2011-07-07 for apparatus and method for insertion of capsules into filter tows.
This patent application is currently assigned to AIGER GROUP AG. Invention is credited to Bogdan Nikolov, Dimitar Yanchev.
Application Number | 20110162662 12/652522 |
Document ID | / |
Family ID | 44223984 |
Filed Date | 2011-07-07 |
United States Patent
Application |
20110162662 |
Kind Code |
A1 |
Nikolov; Bogdan ; et
al. |
July 7, 2011 |
APPARATUS AND METHOD FOR INSERTION OF CAPSULES INTO FILTER TOWS
Abstract
An apparatus for insertion of capsules into cigarette filter
tows is disclosed. The apparatus may include a tow processing unit,
a capsule insertion unit and a filter rod making unit. The capsule
insertion unit may include a hopper, a capsule presorter, a belt,
an inlet pipe, a capsule insertion wheel, and a tow gathering
funnel.
Inventors: |
Nikolov; Bogdan; (Plovdiv,
BG) ; Yanchev; Dimitar; (Plovdiv, BG) |
Assignee: |
AIGER GROUP AG
Zug
CH
|
Family ID: |
44223984 |
Appl. No.: |
12/652522 |
Filed: |
January 5, 2010 |
Current U.S.
Class: |
131/94 |
Current CPC
Class: |
A24D 3/0216 20130101;
A24D 3/061 20130101 |
Class at
Publication: |
131/94 |
International
Class: |
A24C 5/47 20060101
A24C005/47 |
Claims
1. An apparatus for insertion of capsules into cigarette filter
tows, comprising: a tow processing unit coupled to a capsule
insertion unit and a filter rod making unit coupled to the capsule
insertion unit, the tow processing unit further comprising a tow
bale, a plurality of rollers, a plurality of banding jets and a
plasticizer chamber; the capsule insertion unit further comprising
a hopper, a presorting unit, an endless belt disposed between said
presorting unit and an inlet pipe, an insertion wheel rotating
about an axis of rotation, said insertion wheel further comprising
a circular cavity in communication with said inlet pipe and a
distribution disk disposed within said cavity, and a tow gathering
funnel configured to receive an edge of said insertion wheel; and
the rod making unit further comprising a garniture bed, a sensor, a
knife carrier and an ejector.
2. The apparatus of claim 1, wherein the insertion wheel further
comprises: at least one capsule quality sensor; a plurality of
radial channels in communication with said circular cavity, each of
said radial grooves configured to receive a plurality of capsules;
a plurality of insertion channels, each of said insertion channels
being in communication with a corresponding radial channel and
terminating at the outer edge of the insertion wheel; and a
plurality of separation mechanisms, each of said plurality of
separation mechanisms disposed between a corresponding radial
channel and a corresponding insertion channel.
3. The apparatus of claim 1, wherein each of said plurality of
separation mechanisms further comprises: a vertical channel in
communication with a corresponding radial channel and a
corresponding insertion channel; a sliding member slidably disposed
within said vertical channel, the sliding member comprising a
cavity configured to receive a single capsule; and a bearing
assembly coupled to said sliding member and received within a
groove of a cam.
4. The apparatus of claim 1, wherein said presorting unit further
comprises: a vibrating mechanism; a plurality of transport threads;
a rotating brush having an axis of rotation perpendicular to the
direction of said transport threads; at least two aspiration
devices configured to provide negative air pressure and coupled to
extraction pipes; and a control unit for varying the amount of
negative air pressure supplied to at least one of said at least two
aspiration devices.
5. The apparatus of claim 2, wherein said radial channels have a
linear shape.
6. The apparatus of claim 2, wherein said radial channels have an
arcuate shape.
7. The apparatus of claim 2, wherein the at least one capsule
quality sensor further comprises a microwave sensor.
8. The apparatus of claim 2, wherein the at least one capsule
quality sensor further comprises an optical sensor.
9. The apparatus of claim 2, wherein the at least one capsule
quality sensor further comprises a laser sensor.
10. The apparatus of claim 2, wherein the at least one capsule
quality sensor further comprises an inductive sensor.
11. The apparatus of claim 2, wherein the at least one capsule
quality sensor further comprises a capacitive sensor.
12. The apparatus of claim 2, wherein the at least one capsule
quality sensor further comprises a video camera.
13. The apparatus of claim 1, wherein said tow gathering funnel
further comprises: at least one guide member; and at least one
tongue member.
14. An apparatus for inserting capsules into filter tows,
comprising: a hopper; a presorting unit, said presorting unit
further comprising a vibrating mechanism, a plurality of transport
threads, a rotating brush having an axis of rotation perpendicular
to the direction of said transport threads, at least two aspiration
devices configured to provide negative air pressure and coupled to
extraction pipes and a control unit for varying the amount of
negative air pressure supplied to at least one of said at least two
aspiration devices; an endless belt disposed between said
presorting unit and an inlet pipe; a insertion wheel rotating about
an axis of rotation, said insertion wheel further comprising a
circular cavity in communication with said inlet pipe, a
distribution disk disposed within said circular cavity, a plurality
of radial channels in communication with said circular cavity, each
of said radial channels configured to receive a plurality of
capsules, and a plurality of insertion channels, each of said
insertion channels being in communication with a corresponding
radial channel and terminating at the outer edge of the insertion
wheel; a plurality of separation mechanisms, each of said plurality
of separation mechanisms disposed between a corresponding radial
channel and a corresponding insertion channel; and a tow gathering
funnel, said tow gathering funnel comprising at least one guide
member and at least one tongue member, and configured to receive an
edge of said insertion wheel.
15. The apparatus of claim 8, wherein each of said plurality of
separation mechanisms further comprises: a vertical channel in
communication with a corresponding radial channel and a
corresponding insertion channel; a sliding member slidably disposed
within said vertical channel, the sliding member comprising a
cavity configured to receive a single capsule; and a bearing
assembly coupled to said sliding member and received within a
groove of a cam.
16. The apparatus of claim 1, wherein said capsules have a diameter
between approximately 0.5 mm and approximately 8 mm.
17. A method for insertion of capsules into filter tows,
comprising: placing a plurality of capsules in a hopper of a
capsule insertion unit; withdrawing said capsules from said hopper;
determining the quality of said capsules; discarding capsules that
do not meet desired quality standards; distributing said capsules
into a plurality of radial channels of an insertion wheel;
individually separating said capsules; and positioning said
capsules at a desired position within a filter tow.
Description
BACKGROUND
[0001] Cigarettes and other smoking articles commonly include
filter portions (universally known as filter segments) intended to
remove some impurities and toxins from the cigarette smoke as it is
inhaled. In certain cases, cigarette manufacturers may wish to
impart flavor to the cigarette smoke as it is inhaled by the
smoker.
[0002] One method of imparting flavor to a cigarette may be to
include a flavor capsule within the filter portion of a cigarette.
When the capsule is ruptured, it releases flavorings or aromatic
material into the air stream passing through the filter. These
capsules may also alter other chemical or physical characteristics
of the inhaled smoke, such as, for example, cooling or moistening
the smoke such that the smoker is provided with an enhanced smoking
experience.
SUMMARY
[0003] An apparatus for insertion of capsules into cigarette filter
tows, including a tow processing unit coupled to a capsule
insertion unit and a filter rod making unit coupled to the capsule
insertion unit, the tow processing unit including a tow bale, a
plurality of rollers, a plurality of banding jets and a plasticizer
chamber, and the rod making unit including a garniture bed, a
sensor and a knife carrier. The capsule insertion unit including a
hopper, an in-line presorting device, an endless belt disposed
between the hopper and an inlet pipe, an insertion wheel rotating
about an axis of rotation, the insertion wheel including a circular
cavity in communication with said inlet pipe, an in-line sensor
continuously controlling the quality of the capsules and a tow
gathering funnel configured to receive an edge of the insertion
wheel.
[0004] The insertion wheel includes a plurality of radial channels
in communication with the circular cavity of the wheel, each radial
channel configured to receive a plurality of capsules; a plurality
of insertion channels, each insertion channel in communication with
a corresponding radial channel and terminating at the outer edge of
the insertion wheel; and a plurality of separation mechanisms, each
separation mechanism disposed between a corresponding radial
channel and a corresponding insertion channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is an exemplary diagram of an apparatus for insertion
of capsules into filter tows.
[0006] FIG. 2a is a view of an exemplary embodiment of a capsule
insertion unit.
[0007] FIG. 2b is a view of an exemplary embodiment of a capsule
presorting device.
[0008] FIG. 3a is a cross-section of an exemplary embodiment of a
capsule insertion unit.
[0009] FIG. 3b is a diagram of an exemplary embodiment of an
insertion wheel and a distribution disk of a capsule insertion
unit.
[0010] FIG. 4a is a cross-section detail of an exemplary embodiment
of a separation mechanism in an upper position.
[0011] FIG. 4b is a cross-section detail of an exemplary embodiment
of a separation mechanism in a lower position.
[0012] FIG. 5a is a view of an exemplary embodiment of an insertion
wheel of a capsule insertion unit operatively engaged with an
exemplary embodiment of a tow gathering funnel of a capsule
insertion unit.
[0013] FIG. 5b is a cross-sectional view of an exemplary embodiment
of a capsule positioning guide.
[0014] FIG. 6 is a view of an exemplary embodiment of a capsule
quality sensor.
DETAILED DESCRIPTION
[0015] Aspects of the invention are disclosed in the following
description and related drawings directed to specific embodiments
of the invention. Alternate embodiments may be devised without
departing from the spirit or the scope of the invention.
Additionally, well-known elements of exemplary embodiments of the
invention will not be described in detail or will be omitted so as
not to obscure the relevant details of the invention. Further, to
facilitate an understanding of the description discussion of
several terms used herein follows.
[0016] As used herein, the word "exemplary" means "serving as an
example, instance or illustration." The embodiments described
herein are not limiting, but rather are exemplary only. It should
be understood that the described embodiment are not necessarily to
be construed as preferred or advantageous over other embodiments.
Moreover, the terms "embodiments of the invention", "embodiments"
or "invention" do not require that all embodiments of the invention
include the discussed feature, advantage or mode of operation.
[0017] Turning to FIG. 1, an apparatus for inserting capsules into
filter webs 100 is provided. Apparatus 100 may include a tow
processor unit 102, a capsule insertion unit 200 and a rod making
unit 122. Tow processor unit 102 may include a bale 104, a
plurality of rollers 106, a plurality of banding jets 108 and
plasticizer chamber 110. Rod making unit 122 may include a
garniture bed 124, sensor 126, knife carrier 128 and ejector 130.
Filter tow 120 may be withdrawn from bale 104, and directed towards
rollers 106 and banding jets 108, which facilitate the expansion
and blooming of tow 120 to a desired width. After passing over
rollers 106 and banding jets 108, tow 120 may be directed to
plasticizer chamber 110, where it may be coated with plasticizer,
thereby facilitating swelling of the fibers of tow 120 and
imparting greater cohesive properties to tow 120. Upon exiting
plasticizer chamber 110, tow 120 may be directed towards capsule
insertion unit 200.
[0018] Turning now to FIG. 2a, capsule insertion unit 200 may
include a hopper 202, presorting device 230, endless belt 204,
feeding device 206, motor 208, inlet pipe 210, and insertion wheel
220. Capsule insertion unit 200 may also include tow gathering
funnel 216 and tongue members 214. Motor 208 may be a servomotor or
any other motive device known to one having ordinary skill in the
art. Hopper 202 may have an opening defined near the bottom
thereof. Presorting device 230 may be positioned between hopper 202
and endless belt 204. Endless belt 204 may be positioned in close
proximity to presorting device 230 and have an end positioned
substantially near feeding device 206 such that capsules 150 may be
collected in hopper 202 and transferred to feeding device 206
through presorting device 230 and endless belt 204. Feeding device
206 may be positioned above inlet pipe 210 and inlet pipe 210 may
be positioned above insertion wheel 220. Insertion wheel 220 may
rotate around an axis of rotation 212 and may be disposed such that
axis of rotation 212 is substantially vertical. Insertion wheel 220
may have a circular cavity 214 defined therein such that cavity 214
is concentric with insertion wheel 220. Feeding device 206 and
inlet pipe 210 may be positioned such that they are substantially
coaxial with axis of rotation 212 and such that feeding device 206
is in communication with inlet pipe 210 and inlet pipe 210 is in
communication with circular cavity 214.
[0019] Turning to FIG. 2b, an exemplary embodiment of a capsule
presorting device 230 is provided. Presorting device 230 may
include a vibrating thread transporter 231, a roller 232, a
plurality of transport threads 234, a rotating brush 236, at least
two aspiration devices 238, 240, a control device 242, at least two
extraction pipes 244, 246, and a vibrating device 248. Transport
threads 234 may be positioned such that gaps between any two of the
plurality of transport threads 234 are created. The gap between
transport threads 234 may be sized to facilitate transporting
capsules 150 that meet the desired capsule size standards through
presorting device 230 while facilitating the removal of smaller or
irregularly-shaped capsules. Vibrating device 248 may facilitate
the movement of capsules 150 through presorting device 230 while
further facilitating the removal of smaller or irregularly-sized
capsules by imparting vibrational motion to threads 234. Smaller or
irregularly-sized capsules may therefore fall through the gaps
between threads 234 into bottom aspirating device 238, and removed
via bottom extraction pipe 246. Rotating brush 236 may be
positioned such that the axis of rotation of rotating brush 236 is
substantially perpendicular to threads 234 and may rotate in the
opposite direction of the motion of capsules 150. Brush 236 may
facilitate removing dust from capsules 150 that may have
accumulated during the manufacturing process and may also
facilitate the removal of capsules having a lower capsule mass than
desired. Capsules with mass that is lower than the desired mass may
not pass under the brush and are consequently sucked into upper
aspiration device 240 and removed via top extraction pipe 244.
Control device 242 may adjust the amount of negative air pressure
through top aspiration device 236, thereby allowing the user to
control the upper limit of the mass of the capsules that are
removed via top aspiration device 236. Consequently, capsules 150
that meet the desired size, shape and mass standards may pass
towards roller 232, where they may exit presorting device 230 and
may fall or be placed onto endless belt 204.
[0020] Turning to FIGS. 3a-3b, inlet pipe 210 may be substantially
cylindrical and include a cavity 302 defined by the inner surface
of inlet pipe 210. Inlet pipe 210 may also have a spiral ramp 304
disposed within cavity 302. Spiral ramp 304 may be adjacent to the
inner surface of inlet pipe 210 and may have a substantially
downward slope. Spiral ramp 304 may be configured to direct
capsules 150 from the top of tube 210 to the bottom of tube
210.
[0021] Disposed substantially horizontally within circular cavity
214 of, and concentric to insertion wheel 220 may be distribution
disk 310. Distribution disk 310 may include an axle 216. Axle 216
may be positioned substantially coaxial to axis of rotation 212 and
may include a spring 218 disposed therein. Capsules 150 exiting
from inlet pipe 210 may collect within circular cavity 214 and on
the top surface of distribution disk 310. The elevation of
distribution disk 310 within circular cavity 214 may be
automatically adjusted depending on the quantity of capsules 150
present on the top surface of distribution disk 310 to facilitate
smooth transfer of capsules from distribution disk 310 to insertion
wheel 220. Distribution disk 310 may oscillate around axis of
rotation 212, and may have an oscillation range of approximately
.+-.180.degree.. The top surface of distribution disk 310 may be
flat or may have grooves 312 defined therein. The oscillating
action and grooves 312 of distribution disk 310 may likewise
facilitate supplying capsules 150 to insertion wheel 220.
[0022] The oscillation of distribution disk 310 may be facilitated
by spring 218. The rotation of insertion wheel 220 around axis of
rotation 212 may impart rotational motion to distribution disk 310
via frictional contact between insertion wheel 220 and distribution
disk 310. As distribution disk 310 begins to rotate with insertion
wheel 220, spring 218 may be imparted with increasing tension. As
spring 218 reaches its limit of tension, it may decompress, thereby
returning distribution disk 310 to its original position. The
repetition of this motion may thus cause distribution disk to
oscillate, thereby facilitating the movement of capsules 150
towards the edges of distribution disk 310 and into insertion wheel
220.
[0023] Insertion wheel 220 may include radial channels 314 defined
in the interior thereof. Radial channels 314 may extend from
circular cavity 214 towards the periphery of insertion wheel 220.
Radial channels 314 may have a linear or arcuate profile; the
particular profile may be chosen depending on the shape of capsules
150 used in a particular application and the speed with which
capsules 150 pass through radial channels 314. Capsules 150 may
pass from distribution disk 310 into radial channels 314 of
insertion wheel 220. The rotation of insertion wheel 220 around
axis of rotation 212 provides centrifugal force to facilitate
maintenance of capsules 150 within radial channels 314 as well as
the movement of capsules 150 from circular cavity 214 to the outer
edge of insertion wheel 220 via radial channels 314.
[0024] Turning to FIGS. 4a-4b, insertion wheel 220 may include a
plurality of separation mechanisms 400 proximate to the outer edge
of insertion wheel 220. Each radial channel 314 may have a
corresponding separation mechanism 400 and a corresponding
insertion channel 408. Each separation channel 408 may terminate in
an aperture disposed on the outer edge of insertion wheel 220.
Separation mechanism 400 may facilitate separating a single capsule
150 from the sequence of capsules 150 disposed within a radial
channel 314. Separation mechanism 400 may include a sliding member
402 having a cavity 404, and disposed within a vertical channel
406. Separation mechanism 400 may also include a bearing assembly
410 and a closed cam 420. Cavity 404 may be configured to receive a
single capsule 150 from a radial channel 314. When sliding member
402 is in a raised position, a capsule 150 may pass from radial
channel 314 into cavity 404. When a capsule 150 is fully disposed
within cavity 404, further outward movement of capsule 150 is
prevented by the upper edge of insertion channel 408. At a
predetermined point along the rotation of insertion wheel 220,
sliding member 402 may be moved to a lower position within vertical
channel 406. When sliding member 402 is in the lower position,
capsule 150 may pass from cavity 404 into insertion channel 408 due
to the centrifugal force generated by the rotation of insertion
wheel 220. Simultaneously, capsules 150 that are located within
radial channel 314 are generally inhibited from passing into cavity
404 by sliding member 402 when sliding member 402 is in the lower
position. The movement of sliding member 402 may be facilitated by
closed cam 420. Cam 420 may include a groove 422. Groove 422 may
receive bearing assembly 410 therein and may have an undulating
profile. As bearing assembly 410 slides through groove 422 of cam
420, it may impart precise vertical movement to sliding member 402.
The shape of the profile of groove 422 may therefore facilitate
precise control of the point at which the capsules are separated
and inserted in tow 120.
[0025] Turning to FIGS. 5a-5b, the edge of insertion wheel 220 may
be received in slit 218 of tow gathering funnel 216. Tow gathering
funnel 216 may include tongues 214, at least two static guides 502,
inlet aperture 506 and outlet aperture 508. Tow 120 may be drawn
into tow gathering funnel 216 via inlet aperture 506. Within tow
gathering funnel 216, tow 120 may be compacted by tongues 214 such
that tow 120 exits through outlet aperture 508 having a
substantially rod-like shape. As tow 120 passes through tow
gathering funnel 216, capsules 150 pass from insertion channels 408
of insertion wheel 220 into tow gathering funnel 216. The transfer
of capsules from insertion channels 408 into filter tow 120 is
facilitated by the centrifugal force generated by the rotation of
insertion wheel 220. Guides 502 may facilitate the transfer of a
capsule 150 from the insertion wheel 220 into the tow 120. As shown
in FIG. 5b, guides 502 may also facilitate the precise support and
positioning of capsules in tow 120. As capsules enter tow 120,
guides 502 may facilitate precisely positioning capsules 150 at the
desired position within tow 120. Guides 502 may also include an
opening 520. Opening 520 may allow the user to precisely set the
horizontal and vertical position of guides 502.
[0026] The motion of tow 120 and the rotation of insertion wheel
220 may be synchronized such that the linear speed of tow 120 may
be substantially equal to the tangential speed of insertion wheel
220. Such synchronization facilitates the insertion of capsules 150
into tow 120 at equal intervals, thereby allowing capsules 150 to
be equally spaced relative to each other. The tow may be
simultaneously shaped into a substantially rod-like configuration
by tongues 214. Consequently, when tow 120 exits through tow outlet
aperture 508, capsules 150 are embedded at the desired regular
intervals within tow 120.
[0027] Turning to FIG. 6, insertion wheel 220 may also include at
least one sensor 610. Sensor 610 may measure the quality of the
capsules disposed within insertion wheel 220 prior to insertion. At
least one sensor 610 may include an optical sensor, a laser sensor,
a microwave sensor, an induction sensor, a capacitive sensor, or
any other sensor known to one having ordinary skill in the art. At
least one sensor 610 may also include a video camera. Capsules that
do not meet desired quality standards may then be ejected from
insertion wheel 220.
[0028] In operation, capsules 150 may be stored in hopper 202 and
be withdrawn there from by presorting device 230, as shown in FIGS.
2a-2b. Capsules 150 may have a diameter between approximately 0.5
mm and approximately 8 mm, and may have a spherical, elliptical,
irregular, or any other desired shape. Capsules 150 may also be
filled with a liquid or any other desired substance. Presorting
device 230 may remove dust from capsules 150 and may also remove
any capsule fragments, empty capsules, irregularly shaped capsules
and any other capsules that do not meet desired quality standards.
Upon exiting presorting device 230, capsules 150 may be deposited
on belt 204. Belt 204 may transfer capsules 150 from presorting
device 230 to inlet pipe 206. Capsules 150 may then be deposited
via spiral ramp 304 disposed within cavity 302 of inlet pipe 206
into circular cavity 214 of insertion wheel 220, as shown in FIG.
3a. Capsules 150 may thus be deposited onto the top surface of
distribution disk 310, which is disposed within circular cavity
214. As distribution disk 310 oscillates around axis of rotation
212, capsules 150 are driven from distribution disk 310 into radial
channels 314 of insertion wheel 220. Insertion wheel 220 may be
driven by motor 208 and rotate around axis of rotation 212. As
insertion wheel 220 rotates, capsules 150 may be driven through
radial channels 314 by the centrifugal force generated from the
rotation of insertion wheel 220. During the rotation of the
insertion disk 220, the capsules 150 pass through sensor 610, which
may determine the quality of capsules 150 and may eject any
capsules not meeting desired quality standards. While a particular
radial channel 314 is not in proximity to tow gathering funnel 216,
sliding member 402 of a corresponding separation mechanism 400 may
be located in a raised position, reducing the likelihood of
capsules 150 passing from radial channel 314 into insertion channel
408. As a particular radial channel 314 approaches tow gathering
funnel 216, sliding member 402 of a corresponding separation
mechanism 400 may move into a lowered position, thereby allowing a
capsule 150 to pass via cavity 404 from radial channel 314 into
insertion channel 408, as shown in FIG. 4a and FIG. 4b. As a radial
channel 314 departs from tow gathering funnel 216, sliding member
402 of a corresponding separation mechanism 400 may return to a
raised position, thereby reducing the likelihood of remaining
capsules 150 passing from radial channel 314 into insertion channel
408.
[0029] A capsule 150 may then be carried by insertion wheel 220
towards tow gathering funnel 216. As a particular insertion channel
408 approaches slit 218 of tow gathering funnel 216, a capsule 150
may pass from insertion channel 408 into tow 120, as shown in FIG.
5. Guides 502 may then adjust the position of capsule 150 within
tow 120 so that capsule 150 is placed in the desired position
within tow 120. As tow 120 exits tow gathering funnel 216, tongues
214 facilitate the formation of tow 120 into a substantially
rod-like configuration.
[0030] Turning back to FIG. 1, filter tow 120 with capsules 150
disposed at regular intervals therein may then exit capsule
insertion unit 200 and be directed to rod making unit 122. Tow 120
may then be deposited on garniture bed 124 wherein it may be formed
into a continuous filter rod. The continuous filter rod may then be
directed towards sensor 126 and knife carrier 128, where the
continuous filter rod may be cut into individual filter portions by
knives (not shown) within knife carrier 128. The individual filter
portions may be evaluated by sensor 126 and filter portions that do
not conform to desired specifications may be discarded via ejector
130.
[0031] The foregoing description and accompanying figures
illustrate the principles, preferred embodiments and modes of
operation of the invention. However, the invention should not be
construed as being limited to the particular embodiments discussed
above. Additional variations of the embodiments discussed above
will be appreciated by those skilled in the art.
[0032] Therefore, the above-described embodiments should be
regarded as illustrative rather than restrictive. Accordingly, it
should be appreciated that variations to those embodiments can be
made by those skilled in the art without departing from the scope
of the invention as defined by the following claims.
* * * * *