U.S. patent application number 14/988104 was filed with the patent office on 2016-07-07 for apparatus for use in the formation of a tobacco rod.
The applicant listed for this patent is ALTRIA CLIENT SERVICES INC.. Invention is credited to Dwight David Williams.
Application Number | 20160192698 14/988104 |
Document ID | / |
Family ID | 56285780 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160192698 |
Kind Code |
A1 |
Williams; Dwight David |
July 7, 2016 |
APPARATUS FOR USE IN THE FORMATION OF A TOBACCO ROD
Abstract
An apparatus for the formation of machine-made tobacco rods for
use in the production of cigars. The apparatus includes a lower
conveyor belt and an upper compression belt for receiving and
compressing the stream of tobacco, the lower conveyor belt and
upper compression belt driven by a plurality of pulleys; a pair of
squeeze bars for compressing the tobacco in a direction
perpendicular to the pair of transfer and compression belts, the
pair of squeeze bars coated with a poly-condensated silicone or a
polymeric silazane finish; a tongue for receiving the compressed
tobacco, the tongue coated with a poly-condensated silicone or a
polymeric silazane finish; and a short folder for folding a wrapper
material around the compressed tobacco so as to form a continuous
rod of tobacco for use in the production of cigars, the short
folder coated with a poly-condensated silicone or a polymeric
silazane finish.
Inventors: |
Williams; Dwight David;
(Powhatan, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ALTRIA CLIENT SERVICES INC. |
Richmond |
VA |
US |
|
|
Family ID: |
56285780 |
Appl. No.: |
14/988104 |
Filed: |
January 5, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62099890 |
Jan 5, 2015 |
|
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|
Current U.S.
Class: |
131/84.2 ;
131/84.1 |
Current CPC
Class: |
A24C 1/18 20130101; A24C
1/30 20130101; A24C 1/02 20130101 |
International
Class: |
A24C 1/18 20060101
A24C001/18; A24C 1/02 20060101 A24C001/02; A24C 1/30 20060101
A24C001/30 |
Claims
1. In the formation of machine-made tobacco rods for use in the
production of smoking articles from a tobacco having a tacky
material combined therewith, a method of decreasing tobacco waste,
comprising the steps of: a) providing a plurality of components of
a rod-making machine, the plurality of components coated with a
poly-condensated silicone or a polymeric silazane finish; and b)
reducing at least one clearance gap between at least one of the
plurality of components with an adjacent component of the
rod-making machine to reduce the amount of tobacco escaping through
the gap.
2. The method of claim 1, further comprising the step of: c)
operating the rod-making machine to produce rods from the tobacco
having a tacky material combined therewith, wherein tobacco wasted
in the production of cigar rods is decreased.
3. The method of claim 2, wherein tobacco wasted in the production
of cigar rods is decreased by at least 25%.
4. The method of claim 3, wherein tobacco wasted in the production
of cigar rods is decreased by at least 50%.
5. The method of claim 4, wherein tobacco wasted in the production
of cigar rods is decreased by at least 80%.
6. The method of claim 2, wherein the plurality of components are
selected from those components having surfaces that contact the
tobacco.
7. The method of claim 6, wherein the plurality of components are
selected from a pair of squeeze bars for compressing the tobacco,
one or more pulleys for advancing transfer and/or compression
belts, a tongue for guiding the tobacco, a short folder, a
transition piece or any combination thereof.
8. The method of claim 6, wherein the plurality of components are
selected from a vibratory waterfall feeder and/or a tobacco feed
section.
9. An apparatus for the formation of machine-made tobacco rods for
use in the production of cigars from tobacco having a tacky
material combined therewith, the apparatus comprising: (a) a lower
conveyor belt and an upper compression belt for receiving and
compressing the stream of tobacco, said lower conveyor belt and
upper compression belt driven by a plurality of pulleys; (b) a pair
of squeeze bars for compressing the tobacco in a direction
perpendicular to said pair of transfer and compression belts, said
pair of squeeze bars coated with a poly-condensated silicone or a
polymeric silazane finish; (c) a tongue for receiving the
compressed tobacco, said tongue coated with a poly-condensated
silicone or a polymeric silazane finish; and (d) a short folder for
folding a wrapper material around the compressed tobacco so as to
form a continuous rod of tobacco for use in the production of
cigars, said wrapper material provided from a source of wrapper
material, said short folder coated with a poly-condensated silicone
or a polymeric silazane finish.
10. The apparatus of claim 9, further comprising a tobacco feed
section for providing a stream of tobacco in a substantially
uniform format.
11. The apparatus of claim 10, further comprising a vibratory
waterfall feeder positioned downstream of said tobacco feed section
for receiving the stream of tobacco from said tobacco feed
section.
12. The apparatus of claim 11, wherein the vibratory waterfall
feeder and/or the tobacco feed section are coated with a
poly-condensated silicone or a polymeric silazane finish.
13. The apparatus of claim 9, wherein each of said plurality of
pulleys are coated with a poly-condensated silicone or a polymeric
silazane finish.
14. The apparatus of claim 13, further comprising a source of
binder material for wrapping the compressed tobacco prior to
further wrapping with the wrapper material.
15. The apparatus of claim 10, further comprising a glue applicator
for applying glue to the wrapper material prior to folding the
wrapper material around the compressed tobacco.
16. A method for the formation of machine-made tobacco rods for use
in the production of cigars from tobacco having a tacky material
combined therewith, the method comprising: (a) providing a stream
of tobacco in a substantially uniform format; (b) receiving and
compressing the stream of tobacco between a lower conveyor belt and
an upper compression belt, the lower conveyor belt and upper
compression belt driven and guided by a plurality of pulleys; (c)
compressing the tobacco in a direction perpendicular to the pair of
transfer and compression belts between a pair of squeeze bars, the
pair of squeeze bars coated with a poly-condensated silicone or a
polymeric silazane finish; (d) conveying the compressed tobacco
downstream to a tongue, the tongue coated with a poly-condensated
silicone or a polymeric silazane finish; (e) providing a wrapper
material from a source of wrapper material; and (f) folding the
wrapper material around the compressed tobacco so as to form a
continuous rod of tobacco for use in the production of cigars.
17. The method of claim 16, wherein said step of folding the
wrapper material around the compressed tobacco so as to form a
continuous rod of tobacco for use in the production of cigars
utilizes a short folder coated with a poly-condensated silicone or
a polymeric silazane finish.
18. The method of claim 16, wherein each of the plurality of
pulleys are coated with a poly-condensated silicone or a polymeric
silazane finish.
19. The method of claim 16, wherein the step of providing a stream
of tobacco in a substantially uniform format employs a vibratory
waterfall feeder and a tobacco feed section that are coated with a
poly-condensated silicone or a polymeric silazane finish.
20. In the machine formation of a formed body from a tacky shredded
material, a method of decreasing the waste of the tacky shredded
material, comprising the steps of: a) providing a plurality of
forming machine components, the plurality of components coated with
a poly-condensated silicone or a polymeric silazane finish and
characterized by a resistance to collecting the tacky shredded
material and having a degree of wear resistance; and b) reducing at
least one clearance gap between at least one of the plurality of
components with an adjacent component of the forming machine to
reduce the possibility that the tacky shredded material escapes
through the gap.
21. A method of forming a rod from a shredded material and a
wrapper, said shredded material including a tacky constituent, said
method comprising: establishing a moving column of the shredded
material; compressing said column by moving said column along
opposing converging guides coated with a poly-condensated silicone
or a polymeric silazane finish; forming the rod by drawing said
compressed column and the wrapper through a folding surface coated
with a poly-condensated silicone or a polymeric silazane
finish.
22. The method of claim 21, wherein said establishing step includes
moving a lower endless belt adjacent a feeder while guiding said
lower belt with a guide plate coated with a poly-condensated
silicone or a polymeric silazane finish.
23. The method of claim 22, wherein said compressing step includes
compressing the column with convergent, opposing endless belts.
24. The method of claim 23, further comprising abating accumulation
of shredded material by providing a guide piece coated with a
poly-condensated silicone or a polymeric silazane finish at a
transition space between sets of convergent, opposing endless
belts.
25. An apparatus capable of forming a rod from a shredded material
and a wrapper, said shredded material including a tacky
constituent, said apparatus comprising: a feeder that establishes a
moving column of the shredded material; opposing converging guides
that compress said column as said column moves along said opposing
converging guides, said opposing converging guides coated with a
poly-condensated silicone or a polymeric silazane finish; a folding
surface that forms the rod as said compressed column and the
wrapper are drawn through said folding surface, said folding
surface coated with a poly-condensated silicone or a polymeric
silazane finish.
26. The apparatus of claim 25, wherein said feeder includes moving
a lower endless belt and a guide plate that guides said lower
endless belt, said guide plate coated with a poly-condensated
silicone or a polymeric silazane finish.
27. The apparatus of claim 26, wherein said opposing converging
guides cooperate with convergent, opposing endless belts to
compress the column.
28. The apparatus of claim 27, further comprising a transition
guide at a transition space between sets of convergent, opposing
endless belts, said transition guide abating accumulation of
shredded material and coated with a poly-condensated silicone or a
polymeric silazane finish.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. Provisional Application No. 62/099,890 filed Jan. 5, 2015, the
contents of which are hereby incorporated by reference in their
entirety.
FIELD
[0002] The present invention generally relates to the manufacture
of smoking articles, more specifically, cigar manufacturing and, in
particular, to a method and apparatus for the formation of
machine-made tobacco rods for use in the production of cigars.
ENVIRONMENT
[0003] In the manufacture of machine-made cigars, it is essential
that tobacco be utilized as efficiently as possible due to its
relatively high cost. In modern cigar manufacturing, it is also
desirable to closely control the quantity of tobacco contained in
each cigar, so as to provide a cigar that is considered well filled
and is well filled on a consistent basis.
[0004] The manufacture of machine-made cigars may present a further
problem impacting tobacco utilization, which relates to the
particular tobacco blend sought to be employed. Machine-made cigars
produced from pipe-tobacco blends have achieved wide acceptance in
the market place. However, pipe-tobacco blends may have a degree of
tackiness imparted thereto by the flavorants and other additives
employed to enhance smoking enjoyment. The tacky, tobacco borne
materials tend to stick to and accumulate along, guides, plows,
garniture folding surfaces and the like of tobacco rod forming
machines and other tobacco handling apparatus. Machines for making
tobacco rods from pipe-tobacco blends are often modified to
increase the clearances between parts (such as between a belt and a
guide adjacent the belt) to accommodate the tacky pipe-tobacco
blends, increasing the likelihood that the tobacco will escape and
be utilized less efficiently, with greater tobacco waste.
[0005] There is a need for an improved method and apparatus for the
manufacture of tobacco products, including machine-made cigars from
tacky tobaccos, which will provide satisfactory cigars and be
efficient in the use of tobacco.
SUMMARY
[0006] In one aspect, provided is a method of decreasing tobacco
waste during the formation of machine-made tobacco rods for use in
the production of cigars from tobacco having a tacky material
combined therewith, The method includes the steps of providing a
plurality of components of a cigar rod-making machine, the
plurality of components coated with a poly-condensated silicone or
a polymeric silazane finish; and reducing at least one clearance
gap between at least one of the plurality of components with an
adjacent component of the cigar rod-making machine to reduce the
amount of tobacco escaping through the gap.
[0007] In one form, the method further includes the step of
operating the cigar rod-making machine to produce cigar rods from
the tobacco having a tacky material combined therewith, wherein
tobacco wasted in the production of cigar rods is decreased.
[0008] In another form, the tobacco wasted in the production of
cigar rods is decreased by at least 25%.
[0009] In yet another form, the tobacco wasted in the production of
cigar rods is decreased by at least 50%.
[0010] In still yet another form, the tobacco wasted in the
production of cigar rods is decreased by at least 80%.
[0011] In one form, the plurality of components include components
having surfaces that contact the tobacco.
[0012] In a further form, the plurality of components are selected
from a pair of squeeze bars (or guides or plows or rails) for
compressing the tobacco, one or more pulleys for advancing transfer
and/or compression belts, a tongue for guiding the tobacco, a short
folder, or any combination thereof.
[0013] In another aspect, provided is an apparatus for the
formation of machine-made tobacco rods for use in the production of
cigars from tobacco having a tacky material combined therewith. The
apparatus includes a lower conveyor belt and an upper compression
belt for receiving and compressing the stream of tobacco, the lower
conveyor belt and upper compression belt driven by a plurality of
pulleys; a pair of squeeze bars for compressing the tobacco in a
direction perpendicular to the pair of transfer and compression
belts, the pair of squeeze bars coated with a poly-condensated
silicone or a polymeric silazane finish; a tongue for receiving the
compressed tobacco, the tongue coated with a poly-condensated
silicone or a polymeric silazane finish; and a short folder for
folding a wrapper material around the compressed tobacco so as to
form a continuous rod of tobacco for use in the production of
cigars, the wrapper material provided from a source of wrapper
material, the short folder coated with a poly-condensated silicone
or a polymeric silazane finish.
[0014] In one form, each of the plurality of pulleys is coated with
a poly-condensated silicone or a polymeric silazane finish.
[0015] In yet another form, the apparatus includes a second heater
bar for further curing the glue and sealing the wrapper material to
form the continuous rod of tobacco for use in the production of
cigars.
[0016] In another aspect, provided is a method for the formation of
machine-made tobacco rods for use in the production of cigars from
tobacco having a tacky material combined therewith. The method
includes providing a stream of tobacco in a substantially uniform
format; receiving and compressing the stream of tobacco between a
lower conveyor belt and an upper compression belt, the lower
conveyor belt and upper compression belt driven and guided by a
plurality of pulleys; compressing the tobacco in a direction
perpendicular to the pair of transfer and compression belts between
a pair of squeeze bars, the pair of squeeze bars coated with a
poly-condensated silicone or a polymeric silazane finish; conveying
the compressed tobacco downstream to a tongue, the tongue coated
with a poly-condensated silicone or a polymeric silazane finish;
providing a wrapper material from a source of wrapper material; and
folding the wrapper material around the compressed tobacco so as to
form a continuous rod of tobacco for use in the production of
cigars.
[0017] In one form, the step of folding the wrapper material around
the compressed tobacco so as to form a continuous rod of tobacco
for use in the production of cigars utilizes a short folder coated
with a poly-condensated silicone or a polymeric silazane
finish.
[0018] In another form, each of the plurality of pulleys is coated
with a poly-condensated silicone or a polymeric silazane
finish.
[0019] In yet another aspect, provided is a method of decreasing
the waste of a tacky shredded material in the machine formation of
a formed body. The method comprises the steps of providing a
plurality of forming machine components, the plurality of
components coated with a poly-condensated silicone or a polymeric
silazane finish and characterized by a resistance to collecting the
tacky shredded material and having a degree of wear resistance; and
reducing at least one clearance gap between at least one of the
plurality of components with an adjacent component of the forming
machine to reduce the possibility that the tacky shredded material
escapes through the gap.
[0020] In still yet another aspect, provided is a method of forming
a rod from a shredded material and a wrapper, the shredded material
including a tacky constituent, the method comprising: establishing
a moving column of the shredded material; compressing the column by
moving the column along opposing converging guides coated with a
poly-condensated silicone or a polymeric silazane finish; forming
the rod by drawing the compressed column and the wrapper through a
folding surface coated with a poly-condensated silicone or a
polymeric silazane finish.
[0021] In one form, the step of establishing includes moving a
lower endless belt adjacent a feeder while guiding the lower belt
with a guide plate coated with a poly-condensated silicone or a
polymeric silazane finish.
[0022] In another form, the step of compressing includes
compressing the column with convergent, opposing endless belts.
[0023] In still another form, the method includes the step of
abating accumulation of shredded material by providing a guide
piece coated with a poly-condensated silicone or a polymeric
silazane finish at a transition space between sets of convergent,
opposing endless belts.
[0024] In a further aspect, provided is an apparatus capable of
forming a rod from a shredded material and a wrapper, the shredded
material including a tacky constituent. The apparatus includes a
feeder that establishes a moving column of the shredded material;
opposing converging guides that compress the column as the column
moves along the opposing converging guides, the opposing converging
guides coated with a poly-condensated silicone or a polymeric
silazane finish; a folding surface that forms the rod as the
compressed column and the wrapper are drawn through the folding
surface, the folding surface coated with a poly-condensated
silicone or a polymeric silazane finish.
[0025] In one form, the feeder includes moving a lower endless belt
and a guide plate that guides the lower endless belt, the guide
plate coated with a poly-condensated silicone or a polymeric
silazane finish.
[0026] In another form, the opposing converging guides cooperate
with convergent, opposing endless belts to compress the column.
[0027] In still another form, the apparatus further includes a
transition guide at a transition space between sets of convergent,
opposing endless belts, the transition guide abating accumulation
of shredded material and coated with a poly-condensated silicone or
a polymeric silazane finish.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The forms disclosed herein are illustrated by way of
example, and not by way of limitation, in the figures of the
accompanying drawings and in which like reference numerals refer to
similar elements and in which:
[0029] FIG. 1a schematically presents an apparatus for the
formation of machine-made tobacco rods, in accordance herewith;
[0030] FIG. 1b is a side planar view of squeeze bar 60, as shown in
FIG. 1b;
[0031] FIG. 2 is a cross-sectional view taken through section 2-2
of FIG. 1a;
[0032] FIG. 3 schematically presents a top view of the in-feed
section of an apparatus for the formation of machine-made tobacco
rods for use in the production of cigars, in accordance
herewith;
[0033] FIG. 4 presents an exploded view of Section A of FIG.
1a;
[0034] FIG. 5 is a cross-sectional view taken through Section 5-5
of FIG. 1a;
[0035] FIG. 6 is a cross-sectional view taken through Section 6-6
of FIG. 1a; and
[0036] FIGS. 7-10 present cross-sectional views of a tobacco rod as
it progresses through the folding or rolling operation.
DETAILED DESCRIPTION
[0037] Various aspects will now be described with reference to
specific forms selected for purposes of illustration. It will be
appreciated that the spirit and scope of the apparatus, system and
methods disclosed herein are not limited to the selected forms.
Moreover, it is to be noted that the figures provided herein are
not drawn to any particular proportion or scale, and that many
variations can be made to the illustrated forms. Reference is now
made to FIGS. 1-10, wherein like numerals are used to designate
like elements throughout.
[0038] Each of the following terms written in singular grammatical
form: "a," "an," and "the," as used herein, may also refer to, and
encompass, a plurality of the stated entity or object, unless
otherwise specifically defined or stated herein, or, unless the
context clearly dictates otherwise. For example, the phrases "a
device," "an assembly," "a mechanism," "a component," and "an
element," as used herein, may also refer to, and encompass, a
plurality of devices, a plurality of assemblies, a plurality of
mechanisms, a plurality of components, and a plurality of elements,
respectively.
[0039] Each of the following terms: "includes," "including," "has,"
"having," "comprises," and "comprising," and, their linguistic or
grammatical variants, derivatives, and/or conjugates, as used
herein, means "including, but not limited to."
[0040] Throughout the illustrative description, the examples, and
the appended claims, a numerical value of a parameter, feature,
object, or dimension, may be stated or described in terms of a
numerical range format. It is to be fully understood that the
stated numerical range format is provided for illustrating
implementation of the forms disclosed herein, and is not to be
understood or construed as inflexibly limiting the scope of the
forms disclosed herein.
[0041] Moreover, for stating or describing a numerical range, the
phrase "in a range of between about a first numerical value and
about a second numerical value," is considered equivalent to, and
means the same as, the phrase "in a range of from about a first
numerical value to about a second numerical value," and, thus, the
two equivalently meaning phrases may be used interchangeably.
[0042] It is to be understood that the various forms disclosed
herein are not limited in their application to the details of the
order or sequence, and number, of steps or procedures, and
sub-steps or sub-procedures, of operation or implementation of
forms of the method or to the details of type, composition,
construction, arrangement, order and number of the system, system
sub-units, devices, assemblies, sub-assemblies, mechanisms,
structures, components, elements, and configurations, and,
peripheral equipment, utilities, accessories, and materials of
forms of the system, set forth in the following illustrative
description, accompanying drawings, and examples, unless otherwise
specifically stated herein. The apparatus, systems and methods
disclosed herein can be practiced or implemented according to
various other alternative forms and in various other alternative
ways.
[0043] It is also to be understood that all technical and
scientific words, terms, and/or phrases, used herein throughout the
present disclosure have either the identical or similar meaning as
commonly understood by one of ordinary skill in the art, unless
otherwise specifically defined or stated herein. Phraseology,
terminology, and, notation, employed herein throughout the present
disclosure are for the purpose of description and should not be
regarded as limiting.
[0044] As can be the case in the manufacture of certain
machine-made cigars, the tobacco may have a tacky material combined
therewith prior to rod formation, such as by way of addition of
flavorants and other additives. Examples of suitable types of
tobaccos that may be used in the manufacture of machine-made cigars
include, but are not limited to, flue-cured tobacco, Burley
tobacco, Maryland tobacco, Oriental tobacco, rare tobacco,
specialty tobacco, reconstituted tobacco, blends thereof and the
like. Optionally, the tobacco may be pasteurized. In the
alternative, the tobacco material may be fermented.
[0045] Suitable flavorants and aromas include, but are not limited
to, any natural or synthetic flavor or aroma, such as tobacco,
smoke, menthol, mint (such as peppermint and spearmint), chocolate,
licorice, citrus and other fruit flavors, gamma octalactone,
vanillin, ethyl vanillin, breath freshener flavors, spice flavors
such as cinnamon, methyl salicylate, linalool, bergamot oil,
geranium oil, lemon oil, and ginger oil. Other suitable flavors and
aromas may include flavor compounds selected from the group
consisting of an acid, an alcohol, an ester, an aldehyde, a ketone,
a pyrazine, combinations or blends thereof and the like. Suitable
flavor compounds may be selected, for example, from the group
consisting of phenylacetic acid, solanone, megastigmatrienone,
2-heptanone, benzylalcohol, cis-3-hexenyl acetate, valeric acid,
valeric aldehyde, ester, terpene, sesquiterpene, nootkatone,
maltol, damascenone, pyrazine, lactone, anethole, iso-valeric acid,
combinations thereof and the like.
[0046] Exemplary additional natural and artificial flavorants
include, but are not limited to, peppermint, spearmint,
wintergreen, menthol, cinnamon, chocolate, vanillin, licorice,
clove, anise, sandalwood, geranium, rose oil, vanilla, lemon oil,
cassia, fennel, ginger, ethylacetate, isoamylacetate,
propylisobutyrate, isobutyl butyrate, ethylbutyrate, ethylvalerate,
benzylformate, limonene, cymene, pinene, linalool, geraniol,
citronellol, citral, orange oil, coriander oil, borneol, fruit
extract, and the like. Particularly preferred additional flavor and
aroma agents are essential oils and/or essences of coffee, tea,
cacao, and mint.
[0047] Humectants can also be added to the tobacco material to help
maintain the moisture levels. Examples of humectants that can be
used with the tobacco include glycerol and propylene glycol. It is
noted that the humectants can also be provided for a preservative
effect, as the water activity of the product can be decreased with
inclusion of a humectant, thus reducing opportunity for growth of
micro-organisms. Additionally, humectants can be used to provide a
higher moisture feel to a drier tobacco component.
[0048] In one form, the tobacco used in the manufacture of
machine-made cigars employing the apparatus and methods disclosed
herein is a pipe tobacco blend having a degree of tackiness
imparted thereto.
[0049] Referring to FIG. 1, an apparatus 10 for the formation of
machine-made tobacco rods is schematically presented.
Advantageously, apparatus 10 is particularly useful in the
production of cigars from tobacco having a tacky material combined
therewith. One such application is the production of cigars from a
form of pipe tobacco.
[0050] As shown, apparatus 10 includes a tobacco feed section 12,
an in-feed section 14 and a finishing section 16. Tobacco feed
section 12 may include at least one conveyer (not shown) for
receiving the stream of tobacco from a source of tobacco. Tobacco
feed section 12 may also include at least one electromagnetic
vibrator (not shown) for providing the stream of tobacco in a
substantially uniform format. Suitable electromagnetic vibrators 18
are available from Eriez Corporation of Erie, Pa. and possess the
ability provide for the relatively high speed feeding of light,
bulky materials.
[0051] In one form, in-feed section 12 may be constructed from
existing equipment, such as an in-feed section of an AMF cigarette
making machine. Finishing section 16 may also be constructed from
existing equipment, such as a Molins Mk 8 or Mk 9 machine,
available from Molins PLC of Milton Keynes, UK.
[0052] Referring still to FIG. 1, in one form, a vibratory
waterfall feeder 20 is positioned downstream of the tobacco feed
section 12 for receiving the stream of tobacco. Vibratory waterfall
feeder 20 feeds tobacco to an in-feed section 14, establishing a
column of tobacco along lower conveyor belt 24, which is driven and
guided by a plurality of pulleys 26. The lower conveyor belt 24 is
kept in tension by a biased tension pulley 28. The stream of
tobacco may optionally proceed past a trimmer unit 22, to establish
a uniform height along the column of tobacco established atop the
lower conveyor belt 24 by the vibratory waterfall feeder 20.
[0053] Referring now to FIG. 2, a view of apparatus 10 taken
through Section 2-2 is presented. As shown, lower conveyor belt 24
rides above a conveyor guide 70, the conveyor guide 70 being
positioned within conveyer base plate 72. Tobacco T from vibratory
waterfall feeder 20 is deposited upon lower conveyor belt 24. A
first trough member 74 and a second trough member 76 guide the
tobacco T onto the lower conveyor belt 24. First trough member 74
is affixed to a first angle bracket 78 and second trough member 76
is affixed to a second angle bracket 80. As shown, first angle
bracket 78 and second angle bracket 80 may extend over a portion of
lower conveyor belt 24 so as to maintain the position of lower
conveyor belt 24 within conveyer base plate 72.
[0054] Referring again to FIG. 1, in one form, the in-feed section
14 includes an upper (compression) belt 50 positioned downstream of
vibratory waterfall feeder 20, above and in opposing relation with
at least a portion of lower conveyor belt 24 and is likewise
disposed with at least a portion of transfer or garniture tube belt
42. Upper compression belt 50 and a portion of transfer or
garniture tube belt 42 are configured to receive and compress the
stream of tobacco. Compression belt 50 is driven and guided by a
plurality of pulleys 52 and is kept in tension by a tension pulley
54.
[0055] Referring also to FIG. 3, squeeze bars 60 and 62 are
provided in a mutually opposing, converging relation for
compressing the tobacco in a transverse direction (side to side),
while also compression belt 50 and lower conveyor belt 24 are in a
mutually opposing, converging relation for compressing the tobacco
from top to bottom of the tobacco column. At the furthest end of
lower conveyor belt 24, the tobacco column is transferred from
lower conveyor belt 24 onto a binder web 30, which is supplied from
a source of binder web 32. Binder web 30 is mated with wrapper web
34, which is supplied from a source of wrapper web 36, and is
supported and drawn by a transfer or garniture tube belt 42. In the
embodiments, the binder web 30 and the wrapper web 34 comprise
tobacco.
[0056] Referring now to FIG. 4, an exploded schematic view of
Section A of FIG. 1 is presented. As shown, in one form, a
transition piece 56 is employed to bridge the transition from lower
conveyor belt 24 to transfer or garniture tube belt 42, creating a
smoother path for a tobacco column to traverse. Additionally, the
transition piece 56 serves to reduce the level of turbulence that
might otherwise be imparted to a tobacco column traversing the
transition from lower conveyor belt 24 to transfer or garniture
tube belt 42. The transition piece 56 occupies space at the
transition between belts 24 and 42, which space would otherwise
allow tobacco to accumulate and intermittently release, with impact
on product consistency.
[0057] Referring again to FIG. 1, the formation of the tobacco
column will be described in more detail. As the tobacco stream
enters the arrangement formed by the pair of squeeze bars 60 and
62, lower conveyor belt 24, and upper compression belt 50, the
cross-sectional area of the arrangement is continuously reduced,
forcing the tobacco to be compressed into an ever-smaller
cross-section, until it reaches the desired cross-sectional
dimension. Referring to FIG. 5, a cross-sectional view of Section
5-5 of FIG. 1 is presented. As may be seen a cross-sectional-area
is formed by the arrangement formed by squeeze bars 60 and 62,
lower conveyor belt 24, and upper compression belt 50. Moving along
apparatus 10 to Section 6-6 of FIG. 1, reference is made to FIG. 6,
wherein a reduced cross-sectional-area is depicted. As one of
ordinary skill in the art would recognize small clearances or gaps
exist along the corners 25 of the arrangement.
[0058] The column of tobacco proceeds to finishing section 16 is
guided through a rod-forming arrangement 40, which includes a
tongue 58. Rod-forming arrangement 40 is configured and arranged to
fold the binder and wrapper web 30 and 34, respectively,
longitudinally around the tobacco column and, in one form, employs
a first garniture or short folder 64 and a second or finishing
folder 66 for folding the wrapper web around the compressed tobacco
column so as to form a continuous rod of tobacco for use in the
production of cigars, the wrapper web provided from a source of
wrapper material. An adhesive, which may be an adhesive such as
PVA, is applied by adhesive applicator 59 to one lap edge of the
wrapper web 34, and seals the lap joint by applying heat, by at
least one heater 67 to set the adhesive.
[0059] To further demonstrate the folding or rolling operation,
reference is made to FIG. 1 and to FIGS. 7-10, where cross-sections
of a tobacco rod are presented to show the relative state of
wrapper/binder folding or rolling at various positions along the
length of rod-forming arrangement 40. As shown in FIG. 7, taken at
Section 7-7 of FIG. 1 at the entrance to tongue 63, the folding
process has yet to begin. As shown in FIG. 8, taken at Section 8-8
of FIG. 1 at the entrance to short folder 64, the folding operation
has begun, with an upper lap edge of the wrapper/binder 30/34
extending substantially vertically and having had an application of
glue applied thereto by adhesive applicator 59. Referring now to
FIG. 9, taken at Section 9-9 of FIG. 1 at the entrance to the
second folder 66, it may be seen that one side of the
wrapper/binder 30/34 has been fully rolled over, while the upper
lap edge of the wrapper/binder 30/34 still extends substantially
vertically. Referring now to FIG. 10, taken at Section 10-10 of
FIG. 1 at the exit of second folder 66, it may be seen that the
tobacco rod has been fully formed and ready for heating to set the
glue applied by adhesive applicator 67.
[0060] A continuous rod is thus produced and is carried by the
garniture tube belt 42 through an optional air bearing arrangement
(not shown). The rod then emerges from the garniture tube belt 42
and may pass through a weight scanner (not shown) and then through
a diameter gauge (not shown) before being cut into discrete rod
lengths by a cutter 68.
[0061] When forming tobacco rods, particularly when the tobacco is
of the type frequently marketed as pipe tobacco, the tobacco tends
to accumulate on the machine surfaces. In manufacturing operations,
to mitigate the problems associated with this accumulation,
opposing parts were designed to have greater clearances greater
than a nominal clearance, which permitted the escape of tobacco
during machine operation. The extra clearances allowed great
amounts of tobacco to escape.
[0062] It has been discovered that the use of a hard ceramic
coating that is heat stable, durable, and which also has a degree
of wear resistance, to coat the parts of the rod making apparatus
that come into contact with tobacco, reduces or eliminates tobacco
accumulation on machine parts having surfaces that come into
contact with tobacco, permitting closer clearances to be employed
between many of the parts, including clearances 25, as shown in
FIG. 5. Previously, clearances such clearances 25 were set to a
dimension on the order of about 0.100 inches. Advantageously, the
application of the hard ceramic coating disclosed herein permit the
setting of such clearances to values of about 20 percent of their
previous values, such as in this example to about 0.020 inches.
[0063] As may be appreciated, closer clearances enable improved
tobacco utilization, since the escape of tobacco is reduced or
minimized during the rod making operation. In operation, the
resultant rod making machine is cleaner, faster, more consistent,
more flexible, and more efficient than prior designs. As may be
appreciated, such advantages can lead to the production of higher
quality product.
[0064] One coating that has been developed is a non-stick ceramic
poly-condensated silicone coating using an inorganic network of
metal alkoxides and an organic network of polysilanes. Typically,
the coating is applied using a sol-gel process. This coating is
typically applied in two layers, where the base or first layer is
typically a combination of polydimethylsiloxane in a matrix of
mixed materials including organoalkoxysilane, silica sol and an
alcoholic solvent. The second layer is usually applied to further
enhance the non-stick properties, and change the surfaces color, by
including fluoroalkoxysilanes along with polydimethylsiloxane and
the matrix of mixed materials listed above. Such coatings are
commercially available from Thermolon, Ltd under the trademark
Thermolon.TM. and come in a number of varieties depending on the
combination of polydimethylsiloxane, flouoalkoxysilanes, and the
matrix materials. Thermolon.TM. coatings can generally withstand
temperatures up to 750 degrees Fahrenheit indefinitely without any
serious loss of performance.
[0065] Another coating having utility in the practice of the
present invention is a polyceramic coating containing both
polymeric and ceramic components to enable hard, durable surfaces
with excellent release properties. A common tradename for one such
product is Cerakote.TM., sold by NIC, where the polyceramic
materials is mixed into a solvent and then applied as a sol-gel via
spraying, brushing or wiping. Another such product is sold under
the Ceraset.TM. trade name by KiON International. This type of
coating is commonly used on products such as gun barrels, which
also desire good release properties.
[0066] In one embodiment, the coating generally is comprised of a
poly-condensated silicone or a polymeric silazane finish (commonly
called Thermolon.TM.) or a poly-ceramic finish (commonly branded
under Ceraset.TM. and Cerakote.TM. brands). In alternate
embodiments, the coating can include any suitable heat stable
coating that is uncommonly hard, provides outstanding release
properties and will adhere to the surfaces that come in contact
with tobacco of a rod forming machine, as described herein.
[0067] Thermolon.TM. possesses excellent mechanical and chemical
resistance properties that are retained to high temperatures. For
example, Thermolon.TM. retains a tensile hardness value of 9 H,
even up to 200.degree. C. (or above). Additionally, the abrasion
resistance of Thermolon.TM. (Reciprocal Abrasion Test; BS7069:
1988; 4.5 kg force; 3M 7447 Scotch-Brite abrasive pad) is excellent
and has been found to withstand 32,000-59,000 cycles, depending
upon the particular formulation. It is highly resistant to thermal
degradation as well as attack by both organic and aqueous
environments.
[0068] In one form, components having surfaces that contact the
tobacco are coated with a material comprising a poly-condensated
silicone or a polymeric silazane finish.
[0069] In one form, squeeze bars 60 and 62 are coated with a
material comprising a poly-condensated silicone or a polymeric
silazane finish. In another from, tongue 58 is also coated with a
material comprising a poly-condensated silicone or a polymeric
silazane finish. In still another form, transition piece 56 is also
coated with a material comprising a poly-condensated silicone or a
polymeric silazane finish. In still yet another form, short folder
64 and, optionally, a second folder 66 for folding a wrapper
material around the compressed tobacco so as to form a continuous
rod of tobacco are coated with a material comprising a
poly-condensated silicone or a polymeric silazane finish. With
respect to the foregoing, the poly-condensated silicone or
polymeric silazane finish may be utilized along surfaces that come
into contact with tobacco.
[0070] It is contemplated that additional components of apparatus
10 may be coated with a poly-condensated silicone or a polymeric
silazane finish. For example, the vibratory waterfall feeder 20
and/or the tobacco feed section 12 may be coated with a
poly-condensated silicone or a polymeric silazane finish. In some
embodiments, the conveyor belt guide 70, which lower conveyor belt
24 rides along, may also be coated with a poly-condensated silicone
or a polymeric silazane finish. In addition, it is contemplated
that the transition piece 56 (see FIG. 4) be coated with a
poly-condensated silicone or a polymeric silazane finish. Use of
with a poly-condensated silicone or a polymeric silazane finish
along the conveyor belt guide 70 avoids accumulation of material
between the conveyor belt guide 70 and the belt 24, which can
otherwise lead to jamming of the belt. The belt has the tendency to
pick up minute pieces of tobacco during its course of travel.
[0071] In one form, apparatus 10 employs a programmable logic
controller (PLC unit) to control the formation of machine-made
tobacco rods. Suitable PLC units are available from a number of
sources, including Allen-Bradley, a division of Rockwell Automation
of Milwaukee, Wis. Vibratory waterfall feeder 20 is fed by a
metering belt (not shown) which may be adjusted proportionally to
the rod-making speed by signals received by PLC unit. In one form,
there is a sensor provided to monitor rod-making speed and the PLC
unit is programmed to dynamically adjust the metering belt in
response to changes in rod-making speed.
[0072] Various signals, which may include a signal representing the
rod diameter, an indication of the tobacco temperature obtained
from a temperature sensor that may be located in a tobacco hopper,
or in the chamber near the trimmer are fed to the PLC unit.
Suitable rod diameter gauges may be as described in U.S. Pat. No.
2,952,262, the contents of which are hereby incorporated by
reference in their entirety.
[0073] In operation, a tobacco column is carried on the gravity
conveyor 24 and drawn by the lower and upper belts 24 and 50,
respectively. between squeeze bars 60 and 62 to garniture tube belt
42. A signal indicative of the firmness of the finished rod may be
used to control the trimmer height preferably after correction to
compensate for moisture variations so that the trimmer is
controlled in response to the "dry firmness." A control motor may
drive the trimmer up and down around an average trimmer height
H.sub.avg, in response to control signals from the microprocessor
66. The actual height H of the trimmer, determined by a trimmer
position sensor (not shown), is fed to the PLC unit to provide a
signal corresponding to the actual resistance of the part of the
filler column that remains after trimming.
[0074] From the data received, the PLC unit may calculate
characteristics of the finished product and display such
information on a display unit. PLC unit and display unit may be
housed within a cabinet, which may also include a control panel,
the combination of which forms a control system. The control panel
may provide the ability to control various functions, including the
heaters, glue applicator, machine start-up, system power, etc.
Suitable control systems may be obtained from Jewett Automation of
Richmond, Va. In one form, control system is a Jewett Automation
Model Q75.
[0075] Alternatively, or in addition, information can be fed to a
central management control system either for instant display or for
storage, or for both.
[0076] Additionally details concerning process controls and control
schemes useful in the operation and control of apparatus 10 are
provided in U.S. Pat. No. 4,567,752, the contents of which are
hereby incorporated by reference in their entirety.
[0077] In another aspect, provided is a method for the formation of
machine-made tobacco rods for use in the production of cigars from
tobacco having a tacky material combined therewith. The method
includes providing a stream of tobacco in a substantially uniform
format; receiving and compressing the stream of tobacco between a
pair of transfer and compression belts, the transfer and
compression driven by a plurality of pulleys; compressing the
tobacco in a direction perpendicular to the pair of transfer and
compression belts between a pair of squeeze bars, the pair of
squeeze bars coated with a poly-condensated silicone or a polymeric
silazane finish; conveying the compressed tobacco downstream to a
tongue, the tongue coated with a poly-condensated silicone or a
polymeric silazane finish; providing a wrapper material from a
source of wrapper material; and folding the wrapper material around
the compressed tobacco so as to form a continuous rod of tobacco
for use in the production of cigars.
[0078] In one form, the step of folding the wrapper material around
the compressed tobacco so as to form a continuous rod of tobacco
for use in the production of cigars utilizes a short folder coated
with a poly-condensated silicone or a polymeric silazane finish. In
another form, each of the plurality of pulleys is coated with a
poly-condensated silicone or a polymeric silazane finish.
[0079] In one aspect, provided is a method of decreasing tobacco
waste during the formation of machine-made tobacco rods for use in
the production of cigars from tobacco having a tacky material
combined therewith, The method includes the steps of coating a
plurality of components of a cigar rod-making machine with a
poly-condensated silicone or a polymeric silazane finish; reducing
at least one gap between at least one of the plurality of
components with an adjacent component of the cigar rod-making
machine to reduce the possibility that the tobacco escapes through
the gap.
[0080] In one form, the method further includes the step of
operating the cigar rod-making machine to produce cigar rods from
the tobacco having a tacky material combined therewith, wherein
tobacco wasted in the production of cigar rods is decreased.
[0081] In another form, the tobacco wasted in the production of
cigar rods is decreased by at least 25%. In yet another form, the
tobacco wasted in the production of cigar rods is decreased by at
least 50%. In still yet another form, the tobacco wasted in the
production of cigar rods is decreased by at least 80%. Tobacco
waste is reduced by decreasing tolerance gaps between components
coated with a poly-condensated silicone or a polymeric silazane
finish by at least 20%, or at least 30%, or at least 40% or
more.
[0082] In a further form, the plurality of components are selected
from a pair of squeeze bars for compressing the tobacco, one or
more pulleys for advancing transfer and/or compression belts, a
tongue for guiding the tobacco, a short folder, or any combination
thereof.
Examples
[0083] Testing was conducted to evaluate the productivity over an
extended period of time for an apparatus designed in accordance
herewith. The focus of the evaluation was on machine runtime v.
downtime, material and filler waste and non-conforming product.
Performance was assessed with respect to productivity (e.g.: target
rod weight, speed in rods per minute, production in terms of trays
of product and machine interference downtime).
[0084] Performance was assessed with respect to waste and
non-conforming product (e.g.: loose wrapper and binder, loose
filler, long-ends (i.e., rod-outs) and wrapper and binder
cores).
[0085] The evaluation was conducted with the inventive rod maker
and control rod maker producing product to a target rod weight of
3,300 mg. The inventive rod maker was running at a speed of 1,100
cigars per minute while the control rod maker was operating at a
speed of 800 cigars per minute.
[0086] Notable causes of machine downtime during the evaluation
include: tongue adjustments, a blade break and change, and cleaning
of cutter gears.
[0087] As noted above, waste was collected from the inventive rod
maker and a control rod maker.
[0088] As indicated above, the use of Thermolon.TM. to coat
critical parts has been found to permit the establishment of
tighter part-to-part clearances, minimizing the escape of tobacco
during the rod formation operation. Thus, through material
selection and the setting of proper clearances, together with the
integration of a PLC control system, improved performance was
achieved.
[0089] While the present inventions have been described in
connection with a number of exemplary forms, and implementations,
the present inventions are not so limited, but rather cover various
modifications, and equivalent arrangements, which fall within the
purview of the present claims. For example, it is contemplated that
the subject matter disclosed herein would have utility in the
formation of any wrapped or formed body produced from a tacky
shredded material, such as shredded herbal material, pouches of
tacky shredded material, moist snuff or the like.
* * * * *