U.S. patent application number 14/529402 was filed with the patent office on 2016-05-05 for tobacco product component recovery system.
This patent application is currently assigned to R. J. REYNOLDS TOBACCO COMPANY. The applicant listed for this patent is R. J. REYNOLDS TOBACCO COMPANY. Invention is credited to Balager Ademe, Darrell Thomas Dixon, John Larkin Nelson.
Application Number | 20160120213 14/529402 |
Document ID | / |
Family ID | 54540205 |
Filed Date | 2016-05-05 |
United States Patent
Application |
20160120213 |
Kind Code |
A1 |
Ademe; Balager ; et
al. |
May 5, 2016 |
TOBACCO PRODUCT COMPONENT RECOVERY SYSTEM
Abstract
A smoking article production apparatus and method for producing
smoking articles is provided, each smoking article including
serially engaged filter rod and tobacco rod sections. A rotatable
drum includes a longitudinally-extending receiving surface defining
a plurality of channels for receiving smoking articles arranged
parallel to the longitudinal axis of the drum. An inspection device
is arranged to inspect each smoking article in the channels of the
drum and to determine whether any of the smoking articles are
defective. Any defective smoking articles are directed away from
the drum. A rotatable sampling drum is in communication with the
drum and is configured to receive defective smoking articles
therefrom. A severing device is disposed adjacent the sampling drum
to sever each defective smoking article to separate a portion of
the tobacco rod section from the remainder of the defective smoking
article including the filter section. An associated method is also
provided.
Inventors: |
Ademe; Balager;
(Winston-Salem, NC) ; Nelson; John Larkin;
(Lewisville, NC) ; Dixon; Darrell Thomas;
(Clemmons, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R. J. REYNOLDS TOBACCO COMPANY |
Winston-Salem |
NC |
US |
|
|
Assignee: |
R. J. REYNOLDS TOBACCO
COMPANY
|
Family ID: |
54540205 |
Appl. No.: |
14/529402 |
Filed: |
October 31, 2014 |
Current U.S.
Class: |
131/281 |
Current CPC
Class: |
A24C 5/3424 20130101;
A24C 5/345 20130101; A24C 5/36 20130101; A24C 5/52 20130101 |
International
Class: |
A24C 5/36 20060101
A24C005/36; A24C 5/345 20060101 A24C005/345; A24C 5/52 20060101
A24C005/52; A24C 5/34 20060101 A24C005/34 |
Claims
1. A smoking article production apparatus for producing smoking
articles, each smoking article including a filter section serially
engaged with a tobacco rod section, said apparatus comprising: at
least one rotatable drum defining a longitudinal axis and a
receiving surface extending along the longitudinal axis, the
receiving surface defining a plurality of channels each being
configured to receive a smoking article such that the smoking
article is arranged in parallel with the longitudinal axis of the
at least one drum; an inspection device arranged to inspect each of
the smoking articles in the channels of the at least one drum and
to determine whether any of the smoking articles are defective, and
to direct any defective smoking articles away from the at least one
drum; a rotatable sampling drum in communication with the at least
one drum and configured to receive the defective smoking articles
therefrom; and a severing device disposed adjacent to the sampling
drum and configured to sever each of the defective smoking articles
received by the sampling drum so as to separate at least a portion
of the tobacco rod section from a remaining portion of the
defective smoking article including the filter section.
2. The apparatus according to claim 1, wherein the at least one
drum includes one of a final cutting drum, an inspection drum, and
a weight-related analysis drum.
3. The apparatus according to claim 1, wherein the at least one
drum comprises a weight-related analysis drum and the inspection
device comprises a weight-related sensor arrangement associated
therewith.
4. The apparatus according to claim 3, wherein the weight-related
sensor arrangement is configured to determine a density of at least
one of the filter section and the tobacco rod section of the
smoking article received by the weight-related analysis drum, and
to compare the determined density to a predetermined density range,
such that each smoking article received by the weight-related
analysis drum and having the determined density outside the
predetermined density range is one of the defective smoking
articles.
5. The apparatus according to claim 3, wherein the weight-related
sensor arrangement is configured to determine a density profile
along a length of the tobacco rod section of the smoking article
received by the weight-related analysis drum, and to compare the
determined density profile to a model density profile, such that
each smoking article received by the weight-related analysis drum
and having the determined density profile deviating from the model
density profile is one of the defective smoking articles.
6. The apparatus according to claim 3, wherein the weight-related
sensor arrangement comprises a microwave density transducer
arrangement.
7. The apparatus according to claim 1, wherein the at least one
drum comprises a final cutting drum interacting with a cutting
device to cut the smoking articles to a selected length and the
inspection device comprises a length-related sensor arrangement
associated therewith.
8. The apparatus according to claim 7, wherein the length-related
sensor arrangement is configured to determine an actual length of
at least one of the filter section of the smoking article, the
tobacco rod section of the smoking article, and the entire smoking
article, received by the final cutting drum and to compare the
determined actual length to a predetermined length range, such that
each smoking article received by the final cutting drum and having
the determined actual length outside the predetermined length range
is one of the defective smoking articles.
9. The apparatus according to claim 1, wherein the at least one
drum comprises a final cutting drum interacting with a cutting
device to cut the smoking articles to a selected length and the
inspection device comprises a counting arrangement associated
therewith.
10. The apparatus according to claim 9, wherein the counting
arrangement is configured to count a predetermined amount of the
smoking articles received by the final cutting drum and to
designate the predetermined amount of the smoking articles received
by the final cutting drum as the defective smoking articles.
11. The apparatus according to claim 1, wherein the at least one
drum comprises an inspection drum and the inspection device
comprises a length-related sensor arrangement associated
therewith.
12. The apparatus according to claim 11, wherein the length-related
sensor arrangement is configured to determine an actual length of
at least one of the filter section of the smoking article, the
tobacco rod section of the smoking article, and the entire smoking
article, received by the inspection drum and to compare the
determined actual length to a predetermined length range, such that
each smoking article received by the inspection drum and having the
determined actual length outside the predetermined length range is
one of the defective smoking articles.
13. The apparatus according to claim 1, wherein the at least one
drum comprises an integrity inspection drum and the inspection
device comprises one of a pressure-related sensor arrangement and a
flow-related sensor arrangement associated therewith.
14. The apparatus according to claim 13, wherein the one of the
pressure-related sensor arrangement and the flow-related sensor
arrangement is configured to determine a pressure drop and a flow
loss, respectively, along the smoking article received by the
integrity inspection drum from an air flow directed through and
along a length of the smoking article, and to compare one of the
pressure drop and the flow loss along the smoking article to a
predetermined one of a pressure drop range and a flow loss range
along the smoking article, such that each smoking article received
by the integrity inspection drum and having the one of the pressure
drop and the flow loss along the smoking article outside the
predetermined one of the pressure drop range and the flow loss
range along the smoking article is one of the defective smoking
articles.
15. The apparatus according to claim 13, wherein the
pressure-related sensor arrangement comprises a pressure transducer
arrangement.
16. The apparatus according to claim 13, wherein the flow-related
sensor arrangement comprises a flow transducer arrangement.
17. The apparatus according to claim 1, further comprising a
transfer arrangement configured to direct defective smoking
articles, following determination thereof, from the at least one
drum to the sampling drum.
18. The apparatus according to claim 1, wherein at least one of the
severing device and the sampling drum is configured to direct the
severed portion of the tobacco rod section away from the remaining
portion of the defective smoking article including the filter
section.
19. The apparatus according to claim 1, wherein the portion of the
tobacco rod section of each defective smoking article comprises
tobacco lengthwise-wrapped with a wrapping paper, and the apparatus
further comprises a slitting device configured to lengthwise slit
the wrapping paper.
20. The apparatus according to claim 19, further comprising a
recovery device configured to recover the tobacco from the portion
of the tobacco rod section of each defective smoking article
following slitting of the wrapping paper.
21. The apparatus according to claim 1, wherein the at least one
drum comprises an integrity inspection drum and wherein the
inspection device is configured to determine a condition of the
smoking article selected from the group consisting of: whether the
tobacco rod section of the smoking article includes a loose fill of
the tobacco about an end of the tobacco rod section opposite to the
filter section; whether the filter section is missing from the
smoking article; whether a wrapping paper lengthwise-wrapping
tobacco to form the tobacco rod section of the smoking article
includes a tear; whether the wrapping paper is improperly wrapped
about the tobacco whether the filter section includes improperly
formed air dilution perforations; and whether a tipping paper is
improperly wrapped about an interface between the filter section
and the tobacco rod section.
22. The apparatus according to claim 21, wherein the inspection
device comprises an optical sensor arrangement configured to
optically inspect the smoking articles, and wherein any smoking
article determined to affirmatively have one of the conditions is
one of the defective smoking articles.
23. A method of producing smoking articles, each smoking article
including a filter section serially engaged with a tobacco rod
section, said method comprising: receiving a smoking article in
each of a plurality of channels defined by a receiving surface of
at least one rotatable drum, the receiving surface extending along
a longitudinal axis of the at least one drum, such that the smoking
article is arranged in parallel with the longitudinal axis of the
at least one drum; inspecting each of the smoking articles in the
channels of the at least one drum using an inspection device and
determining whether any of the smoking articles are defective;
receiving any defective smoking articles from the at least one drum
with a rotatable sampling drum in communication with the at least
one drum; and severing each of the defective smoking articles
received by the sampling drum using a severing device disposed
adjacent to the sampling drum, so as to separate at least a portion
of the tobacco rod section from a remaining portion of the
defective smoking article including the filter section.
24. The method according to claim 23, wherein receiving the smoking
article comprises receiving the smoking article in each of the
plurality of channels defined by the receiving surface of the at
least one rotatable drum selected from the group consisting of a
final cutting drum, an inspection drum, and a weight-related
analysis drum.
25. The method according to claim 23, wherein the at least one drum
comprises a weight-related analysis drum and the inspection device
comprises a weight-related sensor arrangement associated therewith,
wherein inspecting each of the smoking articles in the channels of
the at least one drum comprises determining a density of at least
one of the filter section and the tobacco rod section of the
smoking article received by the weight-related analysis drum, using
the weight-related sensor arrangement, and comparing the determined
density to a predetermined density range, and wherein each smoking
article received by the weight-related analysis drum and having the
determined density outside the predetermined density range is one
of the defective smoking articles.
26. The method according to claim 23, wherein the at least one drum
comprises a weight-related analysis drum and the inspection device
comprises a weight-related sensor arrangement associated therewith,
wherein inspecting each of the smoking articles in the channels of
the at least one drum comprises determining a density profile along
a length of the tobacco rod section of the smoking article received
by the weight-related analysis drum, using the weight-related
sensor arrangement, and comparing the determined density profile to
a model density profile, and wherein each smoking article received
by the weight-related analysis drum and having the determined
density profile deviating from the model density profile is one of
the defective smoking articles.
27. The method according to claim 23, wherein inspecting each of
the smoking articles in the channels of the at least one drum
comprises inspecting each of the smoking articles in the channels
of the at least one drum using a weight-related sensor arrangement
including a microwave density transducer arrangement.
28. The method according to claim 23, wherein the at least one drum
comprises a final cutting drum interacting with a cutting device to
cut the smoking articles to a selected length and the inspection
device comprises a length-related sensor arrangement associated
therewith, wherein inspecting each of the smoking articles in the
channels of the at least one drum comprises determining an actual
length, using the length-related sensor arrangement, of at least
one of the filter section of the smoking article, the tobacco rod
section of the smoking article, and the entire smoking article,
received by the final cutting drum, and comparing the determined
actual length to a predetermined length range, and wherein each
smoking article received by the final cutting drum and having the
determined actual length outside the predetermined length range is
one of the defective smoking articles.
29. The method according to claim 23, wherein the at least one drum
comprises a final cutting drum interacting with a cutting device to
cut the smoking articles to a selected length and the inspection
device comprises a counting arrangement associated therewith, and
wherein inspecting each of the smoking articles in the channels of
the at least one drum comprises counting a predetermined amount of
the smoking articles received by the final cutting drum, using the
counting arrangement, and designating the predetermined amount of
the smoking articles received by the final cutting drum as the
defective smoking articles.
30. The method according to claim 23, wherein the at least one drum
comprises an inspection drum and the inspection device comprises a
length-related sensor arrangement associated therewith, wherein
inspecting each of the smoking articles in the channels of the at
least one drum comprises determining an actual length, using the
length-related sensor arrangement, of at least one of the filter
section of the smoking article, the tobacco rod section of the
smoking article, and the entire smoking article, received by the
inspection drum, and comparing the determined actual length to a
predetermined length range, and wherein each smoking article
received by the inspection drum and having the determined actual
length outside the predetermined length range is one of the
defective smoking articles.
31. The method according to claim 23, wherein the at least one drum
comprises an integrity inspection drum and the inspection device
comprises one of a pressure-related sensor arrangement and a
flow-related sensor arrangement associated therewith, wherein
inspecting each of the smoking articles in the channels of the at
least one drum comprises determining a pressure drop and a flow
loss, using the one of the pressure-related sensor arrangement and
the flow-related sensor arrangement, respectively, along the
smoking article received by the integrity inspection drum from an
air flow directed through and along a length of the smoking
article, and comparing one of the pressure drop and the flow loss
along the smoking article to a predetermined one of a pressure drop
range and a flow loss range along the smoking article, and wherein
each smoking article received by the integrity inspection drum and
having the one of the pressure drop and the flow loss along the
smoking article outside the predetermined one of the pressure drop
range and the flow loss range along the smoking article is one of
the defective smoking articles.
32. The method according to claim 31, wherein inspecting each of
the smoking articles in the channels of the at least one drum
comprises determining a pressure drop and a flow loss, using the
one of a pressure transducer arrangement and a flow transducer
arrangement, respectively.
33. The method according to claim 23, further comprising directing
defective smoking articles, following determination thereof, from
the at least one drum to the sampling drum, using a transfer
arrangement.
34. The method according to claim 23, further comprising directing
the severed portion of the tobacco rod section away from the
remaining portion of the defective smoking article including the
filter section, using at least one of the severing device and the
sampling drum.
35. The method according to claim 23, wherein the portion of the
tobacco rod section of each defective smoking article comprises
tobacco lengthwise-wrapped with a wrapping paper, and the method
further comprises lengthwise slitting the wrapping paper using a
slitting device.
36. The method according to claim 35, further comprising recovering
the tobacco from the portion of the tobacco rod section of each
defective smoking article, using a recovery device, following
slitting of the wrapping paper.
37. The method according to claim 23, wherein the at least one drum
comprises an integrity inspection drum, and wherein inspecting each
of the smoking articles in the channels of the at least one drum
further comprises inspecting each of the smoking articles in the
channels of the integrity inspection drum using an inspection
device configured to determine a condition of the smoking article
selected from the group consisting of: whether the tobacco rod
section of the smoking article includes a loose fill of the tobacco
about an end of the tobacco rod section opposite to the filter
section; whether the filter section is missing from the smoking
article; whether a wrapping paper lengthwise-wrapping tobacco to
form the tobacco rod section of the smoking article includes a
tear; whether the wrapping paper is improperly wrapped about the
tobacco whether the filter section includes improperly formed air
dilution perforations; and whether a tipping paper is improperly
wrapped about an interface between the filter section and the
tobacco rod section.
38. The method according to claim 37, wherein inspecting each of
the smoking articles in the channels of the integrity inspection
drum using an inspection device further comprises inspecting each
of the smoking articles in the channels of the integrity inspection
drum using an an optical sensor arrangement configured to optically
inspect the smoking articles, and wherein any smoking article
determined to affirmatively have one of the conditions is one of
the defective smoking articles.
Description
BACKGROUND OF THE DISCLOSURE
[0001] 1. Field of the Disclosure
[0002] The present disclosure relates to products made or derived
from tobacco, or that otherwise incorporate tobacco, and are
intended for human consumption; and more particularly, to a
component recovery system and method for components of produced
smoking articles and/or portions thereof.
[0003] 2. Disclosure of Related Art
[0004] Popular smoking articles, such as cigarettes, have a
substantially cylindrical rod-shaped structure and include a
charge, roll or column of smokable material, such as shredded
tobacco (e.g., in cut filler form), surrounded by a paper wrapper,
thereby forming a so-called "smokable rod", "tobacco rod" or
"cigarette rod." Normally, a cigarette has a cylindrical filter
element aligned in an end-to-end relationship with the tobacco rod.
Preferably, a filter element comprises plasticized cellulose
acetate tow circumscribed by a paper material known as "plug wrap."
Preferably, the filter element is attached to one end of the
tobacco rod using a circumscribing wrapping material known as
"tipping paper." It also has become desirable to perforate the
tipping material and plug wrap, in order to provide dilution of
drawn mainstream smoke with ambient air. Descriptions of cigarettes
and the various components thereof are set forth in Tobacco
Production, Chemistry and Technology, Davis et al. (Eds.) (1999);
which is incorporated herein by reference. A traditional type of
cigarettes is employed by a smoker by lighting one end thereof and
burning the tobacco rod. The smoker then receives mainstream smoke
into his/her mouth by drawing on the opposite end (e.g., the filter
end or mouth end) of the cigarette.
[0005] Certain types of smoking articles can possess filter
elements that incorporate objects, such as pellets, beads and
breakable capsules. Various components of such filter elements, as
well as equipment and techniques for manufacturing such filter
elements, are set forth and referenced, for example, in U.S. Pat.
No. 4,862,905 to Green, Jr. et al.; U.S. Pat. No. 7,479,098 to
Thomas et al.; U.S. Pat. No. 7,833,146 to Deal; U.S. Pat. No.
7,984,719 to Dube et al.; U.S. Pat. No. 7,972,254 to Stokes et al.;
U.S. Pat. No. 8,262,550 to Barnes et al.;U.S. Pat. No. 8,303,474 to
Iliev et al.; U.S. Pat. No. 8,353,810 to Garthaffner et al.; U.S.
Pat. No. 8,381,947 to Garthaffner et al. and U.S. Pat. No.
8,459,272 to Karles et al.; and US Pat. App. Pub. Nos. 2010/0184576
to Prestia et al.; 2012/0245007 to Henley et al. and 2014/0053855
to Hartmann et al.; which are incorporated herein by reference.
Representative cigarette products that possess filter elements
incorporating breakable capsules have been marketed throughout the
world under the brand names such as, for example, "Marlboro W-Burst
5," "Camel Crush," "Kent iSwitch," and "Kool Boost."
[0006] During manufacture of such smoking articles as cigarettes,
certain defects may be encountered. For example, the cigarette may
be missing the filter section; the tipping paper may be torn or
improperly/incompletely applied; the air dilution perforations may
be incompletely or improperly formed; the wrapping paper for the
tobacco rod section may be torn or improperly formed; the tobacco
rod section may have a low weight/density, a high weight/density, a
soft spot, a hard spot, loose tobacco about the lighting end of the
tobacco rod section, an improper density profile along the tobacco
rod section; and/or wherein the cigarette may include a visible
defect. In instances of such defects, it may be impractical to
"re-work" the defective cigarette. As such, cigarettes with
detected defects are often rejected as scrap or waste. However,
disposing of such defective cigarettes may represent a significant
monetary loss in terms of the valuable tobacco within the tobacco
rod section thereof. It may be difficult or impractical to recover
the tobacco from such defective cigarettes, as the recovered
tobacco must desirably be free of contaminants (i.e., the filter
section, the tipping paper, the wrapping paper, etc.), and the
recovered tobacco must be of the same blend, so as to be
"re-usable" for manufacturing other non-defective cigarettes.
[0007] It would be highly desirable to provide a manner or method,
and associated apparatus, for inspecting smoking articles and
identifying any defective smoking articles such as cigarettes, at
various points during the manufacture of a certain type of
cigarette, and then for consolidating such defective cigarettes in
a particular manner such that the defective cigarettes may be
subject to a tobacco recovery process. Further, it would be
desirable for the defective cigarette consolidation process and/or
the tobacco recovery process to be automated and capable of
recovering the tobacco from the certain type of cigarette, without
contaminating the recovered tobacco.
BRIEF SUMMARY OF THE DISCLOSURE
[0008] The above and other needs are met by aspects of the present
disclosure which, in one aspect, provides a smoking article
production apparatus for producing smoking articles, wherein each
smoking article includes a filter section serially engaged with a
tobacco rod section. Such an apparatus comprises at least one
rotatable drum defining a longitudinal axis and a receiving surface
extending along the longitudinal axis. The receiving surface
defines a plurality of channels, wherein each channel is configured
to receive a smoking article such that the smoking article is
arranged in parallel with the longitudinal axis of the at least one
drum. An inspection device is arranged to inspect each of the
smoking articles in the channels of the at least one drum and to
determine whether any of the smoking articles are defective. Any
defective smoking articles are directed away from the at least one
drum. A rotatable sampling drum is in communication with the at
least one drum and is configured to receive the defective smoking
articles therefrom. A severing device is disposed adjacent to the
sampling drum and is configured to sever each of the defective
smoking articles received by the sampling drum so as to separate at
least a portion of the tobacco rod section from a remaining portion
of the defective smoking article including the filter section.
[0009] Another aspect of the present disclosure provides a method
of producing smoking articles, wherein each smoking article
includes a filter section serially engaged with a tobacco rod
section. Such a method comprises receiving a smoking article in
each of a plurality of channels defined by a receiving surface of
at least one rotatable drum, wherein the receiving surface extends
along a longitudinal axis of the at least one drum, such that the
smoking article is arranged in parallel with the longitudinal axis
of the at least one drum. Each of the smoking articles in the
channels of the at least one drum is inspected using an inspection
device and it is determined whether any of the smoking articles are
defective. Any defective smoking articles from the at least one
drum are received with a rotatable sampling drum in communication
with the at least one drum. Each of the defective smoking articles
received by the sampling drum is severed using a severing device
disposed adjacent to the sampling drum, so as to separate at least
a portion of the tobacco rod section from a remaining portion of
the defective smoking article including the filter section.
[0010] Embodiments of the present disclosure thus relate to smoking
article productions apparatuses and methods, in particular, for
rod-shaped smoking articles, such as cigarettes, wherein the
smoking article includes a lighting end (i.e., an upstream end)
associated with a tobacco rod section and a mouth end (i.e., a
downstream end) associated with a filter section. In a general
aspect, embodiments of the present disclosure may broadly implement
apparatuses and methods for inspecting cigarettes and identifying
any defective smoking cigarettes therein, at various points during
the manufacture of a certain type of cigarette. Such defects may
include, for example, instances wherein the cigarette may be
missing the filter section; the tipping paper may be torn or
improperly/incompletely applied; the air dilution perforations may
be incompletely or improperly formed; the wrapping paper for the
tobacco rod section may be torn or improperly formed; the tobacco
rod section may have a low weight/density, a high weight/density, a
soft spot, a hard spot, loose tobacco about the lighting end of the
tobacco rod section, an improper density profile along the tobacco
rod section; and/or wherein the cigarette may include a visible
defect. Such an apparatus and method may then be configured for
consolidating such defective cigarettes in a particular manner such
that the defective cigarettes may be subject to a tobacco recovery
process. Aspects of the present disclosure may further allow the
defective cigarette consolidation process and/or the tobacco
recovery process to be automated, and to be capable of recovering
the tobacco from the certain type of cigarette, without
contaminating the recovered tobacco.
[0011] Further features and advantages of the present disclosure
are set forth in more detail in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0013] FIG. 1 schematically illustrates a representative smoking
article, such as a cigarette, possessing certain representative
components of a smoking article;
[0014] FIG. 2 schematically illustrates a smoking article
production apparatus for producing smoking articles such as, for
example, cigarettes, according to one aspect of the present
disclosure;
[0015] FIG. 3 schematically illustrates at least one inspection
device arranged in relation to the smoking articles/cigarettes in
the channels of at least one drum of a smoking article production
apparatus for producing smoking articles, according to one aspect
of the present disclosure;
[0016] FIG. 4 schematically illustrates a rotatable sampling drum
in communication with the at least one drum of a smoking article
production apparatus for producing smoking articles, according to
one aspect of the present disclosure, and configured to receive the
defective smoking articles therefrom;
[0017] FIG. 5 schematically illustrates a severing device disposed
adjacent to the sampling drum, and arranged and configured to sever
each of the defective smoking articles received by the sampling
drum, according to one aspect of the present disclosure;
[0018] FIG. 6A schematically illustrates an exemplary model density
profile of the tobacco rod portion of a smoking article, such as a
cigarette;
[0019] FIGS. 6B and 6C schematically illustrate determined density
profiles of the tobacco rod portions of certain defective smoking
articles;
[0020] FIG. 7 schematically illustrates an inspection device of a
smoking article production apparatus for producing smoking
articles, according to one aspect of the present disclosure,
comprising one of a pressure-related sensor arrangement and a
flow-related sensor arrangement;
[0021] FIG. 8 schematically illustrates a severing device disposed
adjacent to the sampling drum of a smoking article production
apparatus for producing smoking articles, according to one aspect
of the present disclosure, with the severing device arranged and
configured to sever each of the defective smoking articles received
by the sampling drum;
[0022] FIG. 9 schematically illustrates a slitting device
configured to lengthwise slit the wrapping paper of each tobacco
rod segment/section portion of a defective smoking article so as to
render the tobacco therein recoverable; and
[0023] FIG. 10 schematically illustrates a continuously operable
tobacco product component recovery system, according to one aspect
of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present disclosure now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all aspects of the disclosure are shown. Indeed, the
disclosure may be embodied in many different forms and should not
be construed as limited to the aspects set forth herein; rather,
these aspects are provided so that this disclosure will satisfy
applicable legal requirements. Like numbers refer to like elements
throughout.
[0025] Aspects and embodiments of the present disclosure may
relate, for example, to smoking article productions apparatuses and
methods, in particular, for rod-shaped smoking articles, such as
cigarettes, wherein the smoking article includes a lighting end
(i.e., an upstream end) associated with a tobacco rod section and a
mouth end (i.e., a downstream end) associated with a filter
section. In a general aspect, embodiments of the present disclosure
may broadly implement apparatuses and methods for inspecting
cigarettes and identifying any defective smoking cigarettes
therein, at various points during the manufacture of a certain type
of cigarette. Such an apparatus and method may then be configured
for consolidating such defective cigarettes in a particular manner
such that the defective cigarettes may be subject to a tobacco
recovery process. Aspects of the present disclosure may further
allow the defective cigarette consolidation process and/or the
tobacco recovery process to be automated, and to be capable of
recovering the tobacco from the certain type of cigarette, without
contaminating the recovered tobacco.
[0026] FIG. 1 illustrates a representative smoking article 10, such
as a cigarette, possessing certain representative components of a
smoking article. The cigarette 10 includes a generally cylindrical
rod 15 of a charge or roll of smokable filler material 16, such as
tobacco, contained in a circumscribing wrapping material 20. The
rod 15 is conventionally referred to as a "tobacco rod." The ends
of the tobacco rod are open to expose the smokable filler material.
The cigarette 10 is shown as having one optional band 25 (e.g., a
printed coating including a film-forming agent, such as starch,
ethylcellulose, or sodium alginate) applied to the wrapping
material 20, and that band circumscribes the cigarette rod in a
direction transverse to the longitudinal axis of the cigarette.
That is, the band provides a cross-directional region relative to
the longitudinal axis of the cigarette. The band can be printed on
the inner surface of the wrapping material (i.e., facing the
smokable filler material) as shown, or less preferably, on the
outer surface of the wrapping material. Although the cigarette can
possess a wrapping material having one optional band, the cigarette
also can possess wrapping material having further optional spaced
bands numbering two, three, or more.
[0027] The wrapping material 20 of the tobacco rod 15 can have a
wide range of compositions and properties. The selection of a
particular wrapping material will be readily apparent to those
skilled in the art of cigarette design and manufacture. Tobacco
rods can have one layer of wrapping material; or tobacco rods can
have more than one layer of circumscribing wrapping material, such
as is the case for the so-called "double wrap" tobacco rods.
Exemplary types of wrapping materials, wrapping material components
and treated wrapping materials are described in U.S. Pat, No.
5,220,930 to Gentry; U.S. Pat. No. 7,275,548 to Hancock et al.; and
U.S. Pat. No. 7,281,540 to Barnes et al.; and PCT Application Pub.
Nos. WO 2004/057986 to Hancock et al.; and WO 2004/047572 to
Ashcraft et al.; which are incorporated herein by reference in
their entireties.
[0028] At one end of the tobacco rod 15 is the lighting end 28, and
at the other end is positioned a filter element 30. The filter
element 30 positioned adjacent one end of the tobacco rod 15 such
that the filter element and tobacco rod are axially aligned in a
serial or end-to-end relationship, preferably abutting one another.
Filter element 30 may have a generally cylindrical shape, and the
diameter thereof may be essentially equal to the diameter of the
tobacco rod. The ends of the filter element permit the passage of
air and smoke therethrough. The filter element 30 includes filter
material 40 (e.g., cellulose acetate tow impregnated with triacetin
plasticizer) that is over-wrapped along the longitudinally
extending surface thereof with circumscribing plug wrap material
45. That is, the filter element 30 is circumscribed along its outer
circumference or longitudinal periphery by a layer of plug wrap 45,
and each end is open to expose the filter material 40.
[0029] Within the filter element 30 may be positioned at least one
object 50 (including, for example, capsules, pellets, strands), or
various combinations of different objects 50. The number of objects
within each filter element is often a pre-determined number, and
that number can be 1, 2, 3, or more (i.e., at least one). In some
aspects, each filter element may contain a plurality of objects
disposed within the filter material 40 of the filter element, in
some instances, particularly towards the central radial region of
the filter element. In particular aspects, the nature of the filter
material 40 is such that the objects 50 are secured or lodged in
place within the filter element 30.
[0030] In some instances, some of the at least one object 50 (or
plurality of objects 50) may be hollow, such as a breakable
capsule, that may carry a payload incorporating a compound that is
intended to introduce some change to the nature or character of
mainstream smoke drawn through that filter element (e.g., a
flavoring agent). That is, the shell of some hollow objects 50 may
be ruptured at the discretion of the smoker to release the object
payload. Alternatively, some objects 50 may be a solid, porous
material with a high surface area capable of altering the smoke
and/or air drawn through the filter element. Some objects may be a
solid material, such as a polyethylene bead, acting as a substrate
or matrix support for a flavoring agent. Some objects are capable
of releasing the agent at the command of the user. For example, a
breakable hollow object containing a liquid payload is resistant to
the release of the payload until the time that the smoker applies a
purposeful application of physical force to the filter element
sufficient to rupture the hollow object. Typically, a filter
material, such as cellulose acetate tow, or an inserted strand, is
generally absorbent of liquid materials of the type that comprise
the payload, and hence the released payload components are capable
of undergoing wicking (or otherwise experiencing movement or
transfer) throughout the filter element. Since at least one object,
and preferably a plurality of objects, is included in each filter
element, the filter element may include combinations of various
types of objects, as appropriate or desired.
[0031] The filter element 30 is attached to the tobacco rod 15
using tipping material 58 (e.g., essentially air impermeable
tipping paper), that circumscribes both the entire length of the
filter element 30 and an adjacent region of the tobacco rod 15. The
inner surface of the tipping material 58 is fixedly secured to the
outer surface of the plug wrap 45 and the outer surface of the
wrapping material 20 of the tobacco rod, using a suitable adhesive;
and hence, the filter element and the tobacco rod are connected to
one another.
[0032] The tipping material 58 connecting the filter element 30 to
the tobacco rod 15 can have indicia (not shown) printed thereon.
For example, a band on the filter end of a cigarette (not shown)
can visually indicate to a smoker the general locations or
positions of the objects 50 within the filter element 30. These
indicia may help the smoker to locate some objects 50 so that they
can, for example, be more easily ruptured by squeezing the filter
element 30 directly outside the position of any such rupturable
object. The indicia on the tipping material 58 may also indicate
the nature of the payload carried by each object. For example, the
indicia may indicate that the particular payload is a spearmint
flavoring by having a particular color, shape, or design. If
desired, the inner surface (i.e., the surface facing the plug wrap)
of the tipping material can be coated with a material that can act
to retard the propensity of rupturable object contents from
migration, wicking or bleeding from the filter material 40 into the
tipping material, and hence causing what might be perceived as
unsightly visible staining of the tipping material. Such a coating
can be provided using a suitable film-forming agent (e.g.,
ethylcellulose, or a so-called lip release coating composition of
the type commonly employed for cigarette manufacture).
[0033] A ventilated or air diluted smoking article can be provided
with an optional air dilution means, such as a series of
perforations 62, each of which extend through the tipping material
and plug wrap. The optional perforations 62 can be made by various
techniques known to those of ordinary skill in the art, such as
laser perforation techniques. As these techniques are carried out
after insertion of any objects 50 into the filter element 30, care
is taken to avoid damaging the objects during the formation of the
perforations 62. One way to avoid damage from air dilution
techniques, such as those employing laser perforation technologies,
involves locating the perforations at a position adjacent to the
positions of the objects 50. In such a manner, radiation, heat or
physical forces acting upon the filter element during perforation
processes do not have such a great propensity to damage the
objects. Alternatively, so-called off-line air dilution techniques
can be used (e.g., through the use of porous paper plug wrap and
pre-perforated tipping paper). The perforated region can be
positioned upstream of any object (as shown), or the perforated
region can be positioned downstream of any object (i.e., towards
the extreme mouth-end of the filter element).
[0034] The plug wrap 45 can vary. See, for example, U.S. Pat. No.
4,174,719 to Martin. Typically, the plug wrap is a porous or
non-porous paper material. Plug wrap materials are commercially
available. Exemplary plug wrap papers are available from
Schweitzer-Maudit International as Porowrap Plug Wrap 17-M1, 33-M1,
45-M1, 65-M9, 95-M9, 150-M4, 260-M4 and 260-M4T. Preferred plug
wrap materials are non-porous in nature. Non-porous plug wraps
exhibit porosities of less than about 10 CORESTA units, and
preferably less than about 5 CORESTA units. Exemplary non-porous
plug wrap papers are available as Ref. No. 646 Grade from Olsany
Facility (OP Paprina) of the Czech Republic (Trierendberg Holding).
Plug wrap paper can be coated, particularly on the surface that
faces the filter material, with a layer of a film-forming material.
Such a coating can be provided using a suitable polymeric
film-forming agent (e.g., ethylcellulose, ethylcellulose mixed with
calcium carbonate, or a so-called lip release coating composition
of the type commonly employed for cigarette manufacture).
Alternatively, a plastic film (e.g., a polypropylene film) can be
used as a plug wrap material. For example, non-porous polypropylene
materials that are available as ZNA-20 and ZNA-25 from Treofan
Germany GmbH & Co. KG can be employed as plug wrap
materials.
[0035] The use of non-porous plug wrap materials is desirable in
order to avoid the contents of rupturable objects within filter
elements from causing what might be perceived as unsightly visible
staining of the tipping material 58. For example, highly non-porous
plug wrap materials can act to retard or block the propensity of
liquid contents of the rupturable objects from migration, wicking
or bleeding from the filter material 40 into the tipping
material.
[0036] Tobacco materials 16 useful for forming a smoking article
can vary. Tobacco materials can be derived from various types of
tobacco, such as flue-cured tobacco, burley tobacco, Oriental
tobacco or Maryland tobacco, dark tobacco, dark-fired tobacco and
Rustica tobaccos, as well as other rare or specialty tobaccos, or
blends thereof. Descriptions of various types of tobaccos, growing
practices, harvesting practices and curing practices are set for in
Tobacco Production, Chemistry and Technology, Davis et al. (Eds.)
(1999). Most preferably, the tobaccos are those that have been
appropriately cured and aged.
[0037] Typically, tobacco materials for cigarette manufacture are
used in a so called "blended" form. For example, certain popular
tobacco blends, commonly referred to as "American blends," comprise
mixtures of flue-cured tobacco, burley tobacco and Oriental
tobacco. Such blends, in many cases, contain tobacco materials that
have a processed form, such as processed tobacco stems (e.g.,
cut-rolled or cut-puffed stems), volume expanded tobacco (e.g.,
puffed tobacco, such as dry ice expanded tobacco (DIET), preferably
in cut filler form). Tobacco materials also can have the form of
reconstituted tobaccos (e.g., reconstituted tobaccos manufactured
using paper-making type or cast sheet type processes). The precise
amount of each type of tobacco within a tobacco blend used for the
manufacture of a particular cigarette brand varies from brand to
brand. See, for example, Tobacco Encyclopedia, Voges (Ed.) p. 44-45
(1984), Browne, The Design of Cigarettes, 3rd Ed., p. 43 (1990) and
Tobacco Production, Chemistry and Technology, Davis et al. (Eds.)
p. 346 (1999). Other representative tobacco types and types of
tobacco blends also are set forth in US Pat. No. 4,836,224 to
Lawson et al.; U.S. Pat. No. 4,924,888 to Perfetti et al.; U.S.
Pat. No. 5,056,537 to Brown et al.; U.S. Pat. No. 5,220,930 to
Gentry; U.S. Pat. No. 5,360,023 to Blakley et al.; U.S. Pat. No.
6,701,936 to Shafer et al.; U.S. Pat. No. 7,025,066 to Lawson et
al.; U.S. Pat. No. 7,240,678 to Crooks et al.; and U.S. Pat. No.
7,836,895 to Dube et al.; US Pat. Application Pub. Nos.
2004/0255965 to Perfetti et al; and 2005/0066986 to Nestor et al.;
PCT Application Pub. No. WO 02/37990; and Bombick et al., Fund.
Appl. Toxicol., 39, p. 11-17 (1997).
[0038] Tobacco materials typically are used in forms, and in
manners, that are traditional for the manufacture of smoking
articles, such as cigarettes. The tobacco normally is used in cut
filler form (e.g., shreds or strands of tobacco filler cut into
widths of about 1/10 inch to about 1/60 inch, preferably about 1/20
inch to about 1/35 inch, and in lengths of about 1/4 inch to about
3 inches). The amount of tobacco filler normally used within the
tobacco rod of a cigarette ranges from about 0.6 g to about 1 g.
The tobacco filler normally is employed so as to fill the tobacco
rod at a packing density of about 100 mg/cm3 to about 300 mg/cm3,
and often about 150 mg/cm3 to about 275 mg/cm3.
[0039] If desired, the tobacco materials of the tobacco rod can
further include other components. Other components include casing
materials (e.g., sugars, glycerin, cocoa and licorice) and top
dressing materials (e.g., flavoring materials, such as menthol).
The selection of particular casing and top dressing components is
dependent upon factors such as the sensory characteristics that are
desired, and the selection of those components will be readily
apparent to those skilled in the art of cigarette design and
manufacture. See, Gutcho, Tobacco Flavoring Substances and Methods,
Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring
for Smoking Products (1972).
[0040] The dimensions of a representative cigarette 10 can vary.
Preferred cigarettes are rod shaped, and can have diameters of
about 7.5 mm (e.g., circumferences of about 22.5 mm to about 25
mm); and can have total lengths of about 80 mm to about 100 mm. The
length of the filter element 30 can vary. Typical filter elements
can have lengths of about 20 mm to about 40 mm. In some instances,
the length of the filter element 30 is about 27 mm, and the length
of the tobacco rod 15 is about 56 mm to about 57 mm. In other
instances, the length of the filter element is about 31 mm, and the
length of the tobacco rod is about 67 mm to about 68 mm. The
tipping paper 58 can circumscribe the entire filter element and
about 4 mm of the length of the tobacco rod in the region adjacent
to the filter element.
[0041] Preferred cigarettes exhibit desirable resistance to draw,
whether or not any hollow objects within their filter elements are
broken. For example, an exemplary cigarette exhibits a pressure
drop of between about 50 mm and about 200 mm water pressure drop at
17.5 cc/sec. air flow. Preferred cigarettes exhibit pressure drop
values of between about 70 mm and about 180 mm, more preferably
between about 80 mm to about 150 mm water pressure drop at 17.5
cc/sec. air flow. Typically, pressure drop values of cigarettes are
measured using a Filtrona Filter Test Station (CTS Series)
available from Filtrona Instruments and Automation Ltd.
[0042] In use, the smoker lights the lighting end 28 of the
cigarette 10 and draws smoke into his/her mouth through the filter
element 30 at the opposite end of the cigarette. The smoker can
smoke all or a portion of the cigarette with the objects 50 intact.
During the portion of the smoking experience that any objects 50
remain intact, smoke generated in the tobacco rod 15 is drawn to
the smoker through the filter material 40 of the filter element.
Generally, the overall character or nature of the drawn smoke is
virtually unaffected to any significant degree as a result of the
presence of the intact object(s) within the filter element, unless
particular objects are configured to be activated by or otherwise
affect the drawn smoke. If desired, the smoker may rupture any or
all of the rupturable objects 50 at any time before, during, or
even after, the smoking experience. Breakage of any rupturable
object acts to release the contents that are contained and sealed
therewithin. Release of the contents of any rupturable object into
the filter element thus enables the smoker to achieve the intended
benefit of action of certain of those contents, whether that
benefit results from flavoring or scenting the smoke, cooling or
moistening the smoke, freshening the scent of the cigarette butt,
or achieving some other goal associated with modifying the overall
composition of the smoke or altering the performance
characteristics of the cigarette. That is, the contents of any
rupturable object are not released into the filter element until
the particular object is purposefully physically broken; but when a
rupturable object is ruptured, a portion of component contained
within the rupturable object (e.g., portions of a flavoring agent)
that is consequently released into the filter element is
incorporated into each subsequent puff of mainstream smoke that is
received through that filter element. In this manner, any
rupturable object can be ruptured by the smoker at their
discretion. Multiple flavors or scents in or otherwise associated
with the individual objects allows for different taste in each puff
of the cigarette, or an increased amplitude of sensory response in
each puff may be experienced by the smoker, if the flavor is the
same in all objects. In some instances, relatively small objects
may be incorporated in each filter element, due to the different
manners in, and the different extent to, which the sensory
responses may be affected when smoking the cigarette.
[0043] Cigarette rods and cigarette assemblies are manufactured
using a cigarette making machine, such as a conventional automated
cigarette rod making machine. Exemplary cigarette rod making
machines are of the type commercially available from Molins PLC or
Hauni-Werke Korber & Co. KG. For example, cigarette rod making
machines of the type known as MkX (commercially available from
Molins PLC) or PROTOS (commercially available from Hauni-Werke
Korber & Co. KG) can be employed. A description of a PROTOS
cigarette making machine is provided in U.S. Pat. No. 4,474,190 to
Brand, at col. 5, line 48 through col. 8, line 3, which is
incorporated herein by reference. Types of equipment suitable for
the manufacture of cigarettes also are set forth in U.S. Pat. No.
4,781,203 to La Hue; U.S. Pat. No. 4,844,100 to Holznagel; U.S.
Pat. No. 5,156,169 to Holmes et al.; U.S. Pat. No. 5,191,906 to
Myracle, Jr. et al.; U.S. Pat. No. 6,647,870 to Blau et al.; U.S.
Pat. No. 6,848,449 to Kitao et al.; U.S. Pat. No. 6,904,917 to
Kitao et al.; U.S. Pat. No. 7,210,486 to Hartmann; U.S. Pat. No.
7,234,471 to Fitzgerald et al.; U.S. Pat. No. 7,275,548 to Hancock
et al.; and U.S. Pat. No. 7,281,540 to Barnes et al.; each of which
is incorporated herein by reference.
[0044] Filter rods can be manufactured using a rod-making
apparatus, and an exemplary rod-making apparatus includes a
rod-forming unit. Representative rod-forming units are available as
KDF-2 and KDF-3E from Hauni-Werke Korber & Co. KG; and as
Polaris-ITM Filter Maker from International Tobacco Machinery.
Filter material, such as cellulose acetate filamentary tow,
typically is processed using a conventional filter tow processing
unit. For example, filter tow can be bloomed using bussel jet
methodologies or threaded roll methodologies. An exemplary tow
processing unit has been commercially available as E-60 supplied by
Arjay Equipment Corp., Winston-Salem, N.C. Other exemplary tow
processing units have been commercially available as AF-2, AF-3 and
AF-4 from Hauni-Werke Korber & Co. KG. and as Candor-ITM Tow
Processor from International Tobacco Machinery. Other types of
commercially available tow processing equipment, as are known to
those of ordinary skill in the art, can be employed. Multi-segment
cigarette filter rods can be manufactured using a cigarette filter
rod making device available under the brand name Mulfi from
Hauni-Werke Korber & Co. KG.
[0045] Six-up rods, four-up filter rods and two-up rods that are
conventionally used for the manufacture of filtered cigarettes can
be handled using conventional-type or suitably modified cigarette
rod handling devices, such as tipping devices available as Lab MAX,
MAX, MAX S or MAX 80 from Hauni-Werke Korber & Co. KG. See, for
example, the types of devices set forth in U.S. Pat. No. 3,308,600
to Erdmann et al.; U.S. Pat. No. 4,281,670 to Heitmann et al.; U.S.
Pat. No. 4,280,187 to Reuland et al.; U.S. Pat. No. 6,229,115 to
Vos et al.; U.S. Pat. No. 7,296,578 to Read, Jr.; and U.S. Pat. No.
7,434,585 to Holmes; each of which is incorporated herein by
reference. The operation of those types of devices will be readily
apparent to those skilled in the art of automated cigarette
manufacture.
[0046] The components and operation of conventional automated
cigarette making machines will be readily apparent to those skilled
in the art of cigarette making machinery design and operation,
given the exemplary equipment disclosed herein. For example,
descriptions of the components and operation of several types of
chimneys, tobacco filler supply equipment, suction conveyor systems
and garniture systems are set forth in U.S. Pat. No. 3,288,147 to
Molins et al.; U.S. Pat. No. 3,915,176 to Heitmann et al; U.S. Pat.
No. 4,291,713 to Frank; U.S. Pat. No. 4,574,816 to Rudszinat; U.S.
Pat. No. 4,736,754 to Heitmann et al. U.S. Pat. No. 4,878,506 to
Pinck et al.; U.S. Pat. No. 5,060,665 to Heitmann; U.S. Pat. No.
5,012,823 to Keritsis et al. and U.S. Pat. No. 6,360,751 to Fagg et
al.; and U.S. Patent Application Publication No. 2003/0136419 to
Muller; each of which is incorporated herein by reference. The
automated cigarette making machines of the type set forth herein
provide a formed continuous cigarette rod or smokable rod that can
be subdivided into formed smokable rods of desired lengths.
[0047] Various types of cigarette components, including tobacco
types, tobacco blends, top dressing and casing materials, blend
packing densities; types of paper wrapping materials for tobacco
rods, types of tipping materials, and levels of air dilution, can
be employed for making cigarettes with such automated cigarette
making machines. See, for example, the various representative types
of cigarette components, as well as the various cigarette designs,
formats, configurations and characteristics, which are set forth in
U.S. Pat. No. 5,220,930 to Gentry; U.S. Pat. No. 6,779,530 to
Kraker; U.S. Pat. No. 7,237,559 to Ashcraft et al.; and U.S. Pat.
No. 7,565,818 to Thomas et al.; and U.S. Patent Application
Publication Nos. 2005/0066986 to Nestor et al.; and 2007/0246055 to
Oglesby; each of which is incorporated herein by reference.
[0048] With such mass-production processes, there may be instances
in which at least some of the produced cigarettes may exhibit
defects that may render those cigarettes unsaleable. For example,
the cigarette may be missing the filter section; the tipping paper
may be torn or improperly/incompletely applied; the air dilution
perforations may be incompletely or improperly formed; the wrapping
paper for the tobacco rod section may be torn or improperly formed;
the tobacco rod section may have a low weight/density, a high
weight/density, a soft spot, a hard spot, loose tobacco about the
lighting end of the tobacco rod section, an improper density
profile along the tobacco rod section; and/or wherein the cigarette
may include a visible defect. In such instances, the defective
cigarettes may be directed to re-work or otherwise discarded. In
some cases, attempts may be made to recover the valuable tobacco
from the defective/discarded cigarettes. Various tobacco
reclamation schemes are disclosed, for example, in U.S. Pat. No.
4,278,100 to Thatcher; U.S. Pat. No. 4,191,199 to Sullivan; U.S.
Pat. No. 4,221,035 to Thatcher; U.S. Pat. No. 4,763,673 to Barnes
et al.; U.S. Pat. No. 4,867,179 to Leonard; U.S. Pat. No. 5,000,196
to Stewart et al.; U.S. Pat. No. 5,001,951 to Eisenlohr et al.;
U.S. Pat. No. 5,117,843 to Holmes et al. and U.S. Pat. No.
6,510,855 to Korte et al. However, such tobacco reclamation schemes
may have some drawbacks such as, for example, lack of automation
and the inability to recover tobacco from cigarettes having
different defects.
[0049] Aspects of the present disclosure this provide, in one such
aspect as schematically illustrated in FIG. 2, a smoking article
production apparatus 100 for producing smoking articles 10 such as,
for example, cigarettes. As shown in FIG. 1, each smoking article
10 generally includes a filter section or segment 30 serially
engaged with a tobacco rod section or segment 15, with the segments
serially joined together by a tipping paper 58. Such an apparatus
100 may, in some instances, comprise at least one rotatable drum
350 defining a longitudinal axis 375 and a receiving surface 400
extending along the longitudinal axis 375. The receiving surface
400 may be further configured to define a plurality of channels
450, each being configured to receive a smoking article 10 such
that the smoking article 10 in a channel 450 is arranged in
parallel with the longitudinal axis 375 of the at least one drum
350.
[0050] As schematically shown in FIG. 3, at least one inspection
device 500 may be arranged in relation to the smoking
articles/cigarettes 10 in the channels 450 of the at least one drum
350. In such a relation, the inspection device 500 may be further
configured to inspect each of the smoking articles 10 in the
channels 450 of the at least one drum 350 and/or to determine
whether any of the smoking articles 10 are defective. The
inspection device 500 may be further configured to direct any
defective smoking articles 550 away from the at least one drum
350.
[0051] In some aspects, as schematically illustrated in FIG. 4, a
rotatable sampling drum 600 may be in communication with the at
least one drum 350 and configured to receive the defective smoking
articles 550 therefrom. That is, the sampling drum 600 may be
disposed and arranged to interact directly with the at least one
drum 350 to receive the defective smoking articles 550 directly
therefrom. In other instances, one or more intermediate rotatable
drums (not shown) may be disposed between the sampling drum 600 and
the at least one drum 350, wherein the defective smoking articles
550 are conveyed from the at least one drum 350, to one or more of
the intermediate drums, and then to the sampling drum 600. In yet
other aspects, the defective smoking articles 550 may be directed
to the sampling drum 600 from the at least one drum 350 by another
suitable mechanism, device, or arrangement that may or may not
include the intermediate drum(s). For example, a transfer
arrangement (not shown) may be configured to direct defective
smoking articles 550, following determination thereof, from the at
least one drum 350 to the sampling drum 600
[0052] As schematically illustrated in FIG. 5, a severing device
650 may be disposed adjacent to the sampling drum 600, with the
severing device 650 being arranged and configured to sever each of
the defective smoking articles 550 received by the sampling drum
600, along the length of the respective defective smoking article
10, so as to separate at least a portion 225 of the tobacco rod
segment/section 15 from a remaining portion 250 of the defective
smoking article 550 including the filter segment/section 30.
[0053] The at least one rotatable drum 350 may be associated with
one or more different processes in the overall smoking article
production procedure and/or with one or more different pieces of
production equipment associated with the production apparatus 100.
For example, the at least one rotatable drum 350 may be a final
cutting drum associated with equipment for cutting a two-up
cigarette assembly into individual cigarettes. In other instances,
the at least,one rotatable drum 350 may be an inspection drum for
visually inspecting, or otherwise inspecting, assembled cigarettes
or components thereof. In still further instances, the at least one
rotatable drum 350 may be a weight-related analysis drum configured
or arranged to determine a weight or density of the tobacco rod
segment 15, the filter segment 30, and/or the assembled smoking
article 10.
[0054] More particularly, in one aspect of the present disclosure,
the at least one drum 350 may comprise a weight-related analysis
drum and the inspection device 500 may comprise a weight-related
sensor arrangement associated therewith. In such instances, the
weight-related sensor arrangement may be configured to determine a
density of at least one of the filter section/segment 30 and the
tobacco rod section/segment 15 of the smoking article 10 received
by the weight-related analysis drum, and to compare the determined
density to a predetermined density range, such that each smoking
article 10 received by the weight-related analysis drum, and having
the determined density outside the predetermined density range, is
one of the defective smoking articles 550.
[0055] The weight-related sensor arrangement may be configured in
different manners, according to various aspects of the present
disclosure. For example, the weight-related sensor arrangement may
be configured to determine a density profile (see, e.g., FIGS. 6B
and 6C) along a length of the tobacco rod section/segment 15 of the
smoking article 10 received by the weight-related analysis drum,
and to compare the determined density profile to a model density
profile (see, e.g., FIG, 6A), such that each smoking article 10
received by the weight-related analysis drum, and having the
determined density profile deviating from the model density
profile, is one of the defective smoking articles 550. For example,
FIG. 6B schematically illustrates a determined density profile of a
tobacco rod section/segment 15 demonstrating a "hard spot" 700
indicated by an increase in density compared to the model density
profile, while FIG. 6C schematically illustrates a determined
density profile of a tobacco rod section/segment 15 demonstrating a
"soft spot" 750 indicated by a decrease in density compared to the
model density profile. In some particular aspects, the
weight-related sensor arrangement may comprise, for example, a
microwave density transducer arrangement.
[0056] In another aspect of the present disclosure, the at least
one drum 350 may comprise a final cutting drum configured to
interact with a cutting device so to cut the smoking articles 10 to
a selected length. In such instances, the inspection device 500 may
comprise, for example, a length-related sensor arrangement
associated therewith. The length-related sensor arrangement may be
configured to determine an actual length of at least one of the
filter section/segment 30 of the smoking article 10, the tobacco
rod section/segment 15 of the smoking article 10, and/or the entire
smoking article 10, received by the final cutting drum, and to
compare the determined actual length to a predetermined length
range, such that each smoking article 10 received by the final
cutting drum and having the determined actual length outside the
predetermined length range is one of the defective smoking articles
550.
[0057] In yet another aspect of the present disclosure, the at
least one drum 350 may comprise a final cutting drum configured to
interact with a cutting device to cut the smoking articles 10 to a
selected length. In such instances, the inspection device 500 may
comprise a counting arrangement associated therewith. The counting
arrangement may be configured to count a predetermined amount of
the smoking articles 10 received by the final cutting drum and to
designate the predetermined amount of the smoking articles 10
received by the final cutting drum as the defective smoking
articles 550.
[0058] In a further aspect of the present disclosure, the at least
one drum 350 may comprise an inspection drum. In such instances,
the inspection device 500 may comprise a length-related sensor
arrangement associated therewith. The length-related sensor
arrangement may be configured to determine an actual length of at
least one of the filter section/segment 30 of the smoking article
10, the tobacco rod section/segment 15 of the smoking article 10,
and the entire smoking article 10, received by the inspection drum,
and to compare the determined actual length to a predetermined
length range, such that each smoking article 10 received by the
inspection drum and having the determined actual length outside the
predetermined length range is one of the defective smoking articles
550.
[0059] In another aspect of the present disclosure, the at least
one drum 350 may comprise an integrity inspection drum. In such
instances, the inspection device 500 may comprise one of a
pressure-related sensor arrangement and a flow-related sensor
arrangement (see, e.g., FIG. 7, element 800) associated therewith.
The one of the pressure-related sensor arrangement and the
flow-related sensor arrangement 800 may be configured to determine
a pressure drop and a flow loss, respectively, along the smoking
article 10 received by the integrity inspection drum from an air
flow (e.g., from air flow supply element 850 in FIG. 7) directed
through and along a length of the smoking article 10, and to
compare one of the pressure drop and the flow loss along the
smoking article 10 to a predetermined one of a pressure drop range
and a flow loss range along the smoking article. As such, each
smoking article 10 received by the integrity inspection drum and
having the one of the pressure drop and the flow loss along the
smoking article 10 outside the predetermined one of the pressure
drop range and the flow loss range along the smoking article 10, is
one of the defective smoking articles 550. The pressure-related
sensor arrangement may, in some instances, comprise a pressure
transducer arrangement, and/or the flow-related sensor arrangement
may, in some instances, comprise a flow transducer arrangement.
[0060] In still another aspect, the at least one drum 350 may
comprise an integrity inspection drum. In such instances, the
inspection device 500 may be configured to determine a condition of
the smoking article 10, wherein such a condition may be, for
example, whether the tobacco rod section of the smoking article
includes a loose fill of the tobacco about an end of the tobacco
rod section opposite to the filter section; whether the filter
section is missing from the smoking article; whether a wrapping
paper lengthwise-wrapping tobacco to form the tobacco rod section
of the smoking article includes a tear; whether the wrapping paper
is improperly wrapped about the tobacco whether the filter section
includes improperly formed air dilution perforations; and/or
whether a tipping paper is improperly wrapped about an interface
between the filter section and the tobacco rod section. In some
instances, the inspection device 500 may comprise, for example, an
optical sensor arrangement configured to optically inspect the
smoking articles 10, and wherein any smoking article 10 determined
to affirmatively have at least one of the conditions, from the
optical inspection thereof, is one of the defective smoking
articles 550.
[0061] As previously disclosed, the inspection device 500 may be
arranged in relation to the smoking articles/cigarettes 10 in the
channels 450 of the at least one drum 350. In being so arranged,
the inspection device 500 may be further configured to inspect or
otherwise interact with each of the smoking articles 10 in the
channels 450 of the at least one drum 350 and/or to determine
whether any of the smoking articles 10 are defective. The
inspection device 500 may be further configured to direct any
defective smoking articles 550 away from the at least one drum 350.
That is, the inspection device 500 may be, for example, in
communication with a rejection device (not shown, but e.g., a
mechanical plunger engaged with a channel and configured to
mechanically extend and urge the defective cigarette 550 out of the
channel 450, or an air valve engaged with a channel 450 and
configured to release pressurized air to urge the defective
cigarette 550 out of the channel 450) operably engaged with the at
least one drum 350, in some instances, by way of an appropriate
controller 300. In the event that the inspection device 500
determines that a smoking article 10 is to be removed from the at
least one drum 350 (i.e., in accordance with any one of the
exemplary arrangements disclosed herein), the inspection device 500
may be configured to direct an appropriate signal to the rejection
device, via the controller 300 as appropriate, to actuate the
rejection device to eject the indicated smoking article 10 (i.e., a
"defective" smoking article 550) from the corresponding channel 450
of the at least one drum 350.
[0062] In some particular aspects, the rotatable sampling drum 600
may be in communication with the at least one drum 350 and
configured to receive the defective smoking articles 550 therefrom.
As with the at least one drum 350, the sampling drum 600 may be
configured to define a longitudinal axis 375 and a receiving
surface 400 extending along the longitudinal axis 375. The
receiving surface 400 may be further configured to define a
plurality of channels 450, each being configured to receive a
smoking article 10 (i.e., a "defective" smoking article 550), such
that the smoking article in a channel 450 is arranged in parallel
with the longitudinal axis 375 of the sampling drum 600.
[0063] The sampling drum 600 may be disposed and arranged to
interact directly with the at least one drum 350 to receive the
defective smoking articles 550 directly therefrom into the channels
450 defined by the receiving surface 400 of the sampling drum 600.
In other instances, one or more intermediate rotatable drums (not
shown) may be disposed between the sampling drum 600 and the at
least one drum 350, wherein the defective smoking articles 550 are
conveyed from the at least one drum 350, to one or more of the
intermediate drums, and then to the sampling drum 600. In yet other
aspects, the defective smoking articles 550 may be directed to the
sampling drum 600 from the at least one drum 350 by another
suitable mechanism, device, or arrangement that may or may not
include the intermediate drum(s) (i.e., the rejection device
associated with the at least one drum 350). For example, a transfer
arrangement (not shown) may be configured to direct defective
smoking articles 550, following determination thereof, from the at
least one drum 350 to the sampling drum 600.
[0064] Once the defective smoking articles 550, or any other
smoking article 10 directed from the at least one drum 350, are
received by the sampling drum 600, such smoking articles are
generally not readily re-worked and, as such, are not returned to
the production process. According to one aspect of the present
disclosure, these smoking articles received by the sampling drum
600 include valuable tobacco, which is usually not the origin of
the defect or other reason for transferring the smoking article to
the sampling drum 600. As such, in some instances, it may be
advantageous to recover as much of the tobacco as possible from the
smoking articles received by the sampling drum 600. Further, in
some instances, it would also be advantageous to recover the
tobacco from the smoking articles in a manner that the recovered
tobacco is free from contaminants. Contaminant-free tobacco, in
certain instances, may be returned to the smoking article/tobacco
rod production process and used to produce further smoking
articles. In those instances, however, the same type and/or blend
of tobacco must be recovered to be returned to the smoking article
production process, as a mix of types and/or blends of tobacco may
be seen as "contaminated" tobacco in itself.
[0065] As such, once the identified smoking articles 550 have been
received by the sampling drum 600, the production apparatus 100 may
further include a severing device 650 disposed adjacent to the
sampling drum 600 (see, .e.g., FIG. 8). Such a severing device 650
may be arranged and configured to sever each of the defective
smoking articles 550 received by the sampling drum 600, at a
location along the length of the respective defective smoking
article 550, so as to separate at least a portion 225 of the
tobacco rod segment/section 15 from a remaining portion of the
defective smoking article 550, wherein the remaining portion 250
includes the filter segment/section 30. For example, the receiving
surface 400 of the sampling drum 600 may define a groove 625
extending about a circumference thereof, perpendicularly to the
channels 450, with the groove 625 extending to at least the depth
of the channels 450. The groove 625 may be longitudinally disposed
so as to correspond to a longitudinal location along the tobacco
rod segment/section 15 of a smoking article received in the
channels 450. The severing device 650, such as severing blade, may
be disposed adjacent to the groove 625 of the sampling drum 600 and
configured/arranged to be movable into and out of the groove 625.
In this manner, the severing device 650 can be actuated, as
necessary (i.e., when each of the channels 450 of the sampling drum
600 includes a smoking article received therein), to sever/separate
at least a portion 225 of the tobacco rod segment/section 15 from a
remaining portion of the defective smoking article 550, wherein the
remaining portion 250 includes the filter segment/section 30. In
other instances, the severing device 650 may be disposed in a fixed
position with respect to the sampling drum 600 and the groove 625
defined thereby, such that any smoking article received by the
sampling drum 600 will be severed as the sampling drum 600 is
rotated with respect to the severing device 650. In some instances,
for example, the severing device 650 may be configured and arranged
to sever a smoking article approximately 2 mm along the tobacco rod
segment/ section 15 away from the filter rod segment/section 30.
That is, the severed portion 250 of the smoking article including
the filter rod segment/section 30 may also include approximately 2
mm in length of the tobacco rod segment/section 15.
[0066] Once the smoking articles received by the sampling drum 600
are severed by the severing device 650, the severed smoking
articles may be released or otherwise directed outwardly of the
channels 450 of the sampling drum 600. In such instances, at least
one of the severing device 650 and the sampling drum 600 may be
configured to direct the severed portion 225 of the tobacco rod
segment/section 15 away from the remaining portion 250 of the
defective smoking article including the filter segment/section 30.
That is, a possible source of contamination of the recovered
tobacco (i.e., the filter segment/section 30) is removed and
separated from the remaining portion 225 of the tobacco rod
segment/section 15, following severance by the severing device 650.
In some instances, the severing device 650, itself, may be
configured and arranged to provide the required separation of the
severed portions of the smoking article. In some instances, a
partition device 900 may be provided in addition to, or instead of
the severing device 650. In still other examples, separate
gravity-fed chute arrangements (not shown) may be provided to
collect the respective severed portions of the smoking articles.
That is, one chute arrangement may be provided to collect the
severed portion 250 of the smoking article including the filter
segment/section 30, while the other chute arrangement may be
provided to collect the remaining portion 225 including the severed
tobacco rod segment/section 15 of the smoking article. One skilled
in the art, however, will appreciate that many different
arrangements may be provided for separating and segregating the
respective severed portions of the smoking articles such that at
least the severed portions 225 of the tobacco rod segments/sections
15 (not including the filter rod segments/sections 30) can be
separately collected.
[0067] The collected severed portions 225 of the tobacco rod
segments/sections 15 (not including the filter rod
segments/sections 30) each includes tobacco lengthwise-wrapped with
a wrapping paper. As such, in some instances, the production
apparatus 100 may further comprise a slitting device 975 (see,
e.g., FIG. 9) configured to lengthwise slit the wrapping paper of
each tobacco rod segment/section 15 portion so as to render the
tobacco therein recoverable. In this regard, one skilled in the art
will appreciate that the production apparatus 100 may also include,
for example, a collection/orienting device (not shown) operably
disposed between the severing device 650 and the slitting device
975. Such a collection/orienting device may be configured and
arranged, for example, to collect the portions of the severed
portions 225 of the tobacco rod segments/sections 15 (not including
the filter rod segments/sections 30) in a particular orientation
(i.e., with the longitudinal axes thereof arranged in parallel with
each other), and to then feed the severed portions 225 of the
tobacco rod segments/sections 15 (not including the filter rod
segments/sections 30) individually in a direction along the
respective longitudinal axes thereof, toward the slitting device
975 for lengthwise slitting the wrapping paper. Following
lengthwise slitting of the wrapping paper, the production apparatus
100 may also include, for example, a recovery device (not shown)
configured and arranged to recover the tobacco from the respective
portions 225 of the tobacco rod segment/section 15 of each smoking
article. Such lengthwise slitting of the wrapping paper and
recovery of the tobacco may be accomplished, in some instances, by
implementing a commercially available machine such as, for example,
a Delphini tobacco reclaimer device from the ITM Group. The
received tobacco may subsequently be re-directed at least back to
the tobacco rod forming portion of the production apparatus 100 so
as to be used in the further production of new smoking articles,
which may then be subjected to the inspection processes disclosed
herein.
[0068] In some aspects of the present disclosure, the process for
recovery of the tobacco material, as disclosed herein, may be
accomplished in a continuous process, with the associated apparatus
being appropriately configured and arranged for performing such a
continuous process, as shown, for example, in FIG. 10. For example,
such a continuous process may involve an online production system
comprised of a plurality of cooperating and interacting machines or
devices. In other instances, the continuous process may be
incorporated into a single online production machine or device
(i.e., by suitably modifying a production device such as a Protos
device commercially available from Hauni). In such aspects, the
smoking article manufacturing process and inspection provisions, as
well as the identification and segregation of "defective" smoking
articles and deconstruction of the defective smoking articles for
the recovery of the tobacco material, may be accomplished in an
automated manner and at normal production rate of the device/system
(i.e., at speeds normally associated with the operating
device/system for producing such smoking articles).
[0069] As schematically illustrated in FIG. 10, one such
implementation of the methods and apparatuses disclosed herein may
implement at least one rotatable drum 350 (in this instance, a
series of drums 350) between which the smoking articles 10 are
transferred during the production or handling process. Upon being
inspected/identified by at least one inspection device (not shown),
any "defective" or otherwise designated smoking articles may be
transferred to a sampling drum 600. The smoking articles received
by the sampling drum 600 may subsequently be severed by a severing
device 650 arranged adjacent to the sampling drum 600 and arranged
to sever the smoking article along the tobacco rod portion 15
thereof. Once severed, the portion of the tobacco rod 15 without
the filter 30 attached thereto is directed in one direction away
from the sampling drum 600, for example, merely by way of gravity
or by way of a gravity-fed chute 1000. The portion of the tobacco
rod 15 with the filter 30 attached thereto is directed in another
direction away from the sampling drum 600, for example, by a
partition device 900.
[0070] As shown, the gravity-fed chute 1000 may be configured and
arranged to collect the portions of the tobacco rod 15 without the
filter 30 attached thereto, such that those rod-like portions are
arranged with the longitudinal axes thereof generally parallel to
each other. In some instances, those portions of the tobacco rod 15
(without the filter 30 attached thereto) may be directed
individually (i.e., one at a time) to receiving channel 1050
arranged adjacent to the chute 1000 and aligned to receive the
tobacco rod 15 along the longitudinal axis thereof. The individual
tobacco rod 15 portions may be serially fed into the receiving
channel 1050, for example, by way of a conveyor device or a
pneumatic nozzle (i.e., air pulse nozzle). A slitting device 975
may be arranged lengthwise along the receiving channel 1050 so as
to slit or cut at least one surface of the wrapping paper portion
of the tobacco rod 15 enclosing the tobacco material. In some
instances, the tobacco rod 15 may be fed along the receiving
channel 1050, for example, by rotatable feed members 1100A, 1100B
arranged on opposing sides of the receiving channel 1050. More
particularly, the rotatable feed members 1100A, 1100B may each be
rotated in the feed direction of the receiving channel 1050, and
sufficiently spaced apart on either side of the receiving channel
1050, so as to grip each tobacco rod 15 and move the tobacco rod 15
into engagement with the slitting device 975.
[0071] Following engagement with the slitting device 975, the slit
tobacco rod 15 may be further directed along the receiving channel
1050 and collected by a collection device 1200. The collection
device 1200 may be further arranged and configured to direct the
slit tobacco rods 15 to a separator device 1250. The separator
device 1250 may comprise, for example, a grate or sieve disposed
over a collection box. The grate/sieve may be configured, arranged,
and sized so as to allow the tobacco material to pass therethrough
into the collection box, while preventing the wrapping paper from
passing therethrough into the collection box. In order to
facilitate the tobacco material/wrapping paper separation process,
the grate/sieve and/or the collection box may be vibrated, for
example, by a vibrating device 1300. Once the wrapping paper is
separated from the tobacco material, the wrapping paper waste may
be collected from the grate/sieve and discarded. The tobacco
material collected by the collection box may be re-directed at
least back to the tobacco rod forming portion of the production
apparatus 100 so as to be used in the further production of new
smoking articles. Such re-direction may be accomplished, for
example, through physical transportation of the collection box, or
by way of a chute or channel leading from the collection box back
to the tobacco rod forming portion of the production apparatus
100.
[0072] In light of possible interrelationships between aspects of
the present disclosure in providing the noted benefits and
advantages associated therewith, the present disclosure thus
particularly and explicitly includes, without limitation,
embodiments representing various combinations of the disclosed
aspects. Thus, the present disclosure includes any combination of
two, three, four, or more features or elements set forth in this
disclosure, regardless of whether such features or elements are
expressly combined or otherwise recited in a specific embodiment
description herein. This disclosure is intended to be read
holistically such that any separable features or elements of the
disclosure, in any of its aspects and embodiments, should be viewed
as intended, namely to be combinable, unless the context of the
disclosure clearly dictates otherwise.
[0073] Many modifications and other aspects of the disclosures set
forth herein will thus come to mind to one skilled in the art to
which these disclosures pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, those of skill in the art will appreciate
that embodiments not expressly illustrated herein may be practiced
within the scope of the present disclosure, including that features
described herein for different embodiments may be combined with
each other and/or with currently-known or future-developed
technologies while remaining within the scope of the claims
presented here. Therefore, it is to be understood that the
disclosures are not to be limited to the specific aspects disclosed
and that equivalents, modifications, and other aspects are intended
to be included within the scope of the appended claims. Although
specific terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation.
* * * * *