U.S. patent application number 15/523479 was filed with the patent office on 2017-10-26 for apparatus and method for manufacturing a smoking article pack.
The applicant listed for this patent is British American Tobacco (Investments) Limited. Invention is credited to Andrew BRAY, Gary FALLON, Kie Seon PARK.
Application Number | 20170305648 15/523479 |
Document ID | / |
Family ID | 52118551 |
Filed Date | 2017-10-26 |
United States Patent
Application |
20170305648 |
Kind Code |
A1 |
PARK; Kie Seon ; et
al. |
October 26, 2017 |
APPARATUS AND METHOD FOR MANUFACTURING A SMOKING ARTICLE PACK
Abstract
Apparatus and Method for Manufacturing a Smoking Article Pack An
apparatus (10) for manufacturing a sealed pack (20, 34, 36, 37) of
smoking articles (2) and modifying an internal atmosphere thereof.
The apparatus (10) comprises a handling mechanism (13) for
conveying a sealed pack (20) of smoking articles (2) within the
apparatus (10). The handling mechanism (13) includes a support
plate (24) against which a pack (20) abuts during conveyance by the
handling mechanism (13). The support plate (24) includes a gas port
(29). The apparatus (10) is configured such that, as a pack (20) is
conveyed by the handling mechanism (13) in abutment with the
support plate (24), the gas port (29) may engage a valve (4) formed
in the pack (20) to enable a gaseous atmosphere within the sealed
(20) pack to be modified. Also, a method of manufacturing a pack
(37) of smoking articles (2) by means of such an apparatus
(10).
Inventors: |
PARK; Kie Seon; (London,
GB) ; BRAY; Andrew; (London, GB) ; FALLON;
Gary; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
British American Tobacco (Investments) Limited |
London |
|
GB |
|
|
Family ID: |
52118551 |
Appl. No.: |
15/523479 |
Filed: |
September 29, 2015 |
PCT Filed: |
September 29, 2015 |
PCT NO: |
PCT/GB2015/052830 |
371 Date: |
May 1, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 85/1045 20130101;
B65D 85/10 20130101; B65D 81/2038 20130101; B65B 57/02 20130101;
B65B 19/225 20130101; B65D 85/1081 20130101; B65D 81/2023 20130101;
B65B 19/223 20130101; B65B 19/20 20130101; B65B 19/16 20130101;
B65D 85/1018 20130101; B65B 31/047 20130101; B65B 61/202 20130101;
B65D 81/2084 20130101 |
International
Class: |
B65D 85/10 20060101
B65D085/10; B65B 61/20 20060101 B65B061/20; B65B 19/22 20060101
B65B019/22; B65B 19/20 20060101 B65B019/20 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 31, 2014 |
GB |
1419466.6 |
Claims
1. An apparatus for manufacturing a sealed pack of smoking articles
and modifying an internal atmosphere thereof, the apparatus
comprising a handling mechanism for conveying a sealed pack of
smoking articles within the apparatus, the handling mechanism
including a support plate against which a pack abuts during
conveyance by the handling mechanism, the support plate including a
gas port, the apparatus configured such that, as a pack is conveyed
by the handling mechanism in abutment with the support plate, the
gas port may engage a valve formed in the pack to enable a gaseous
atmosphere within the sealed pack to be modified.
2. An apparatus according to claim 1 wherein the support plate
comprises one of a pair of spaced support plates configured to
retain a pack between the support plates, wherein at least one of
the support plates includes the gas port.
3. An apparatus according to claim 2 comprising a plurality of gas
ports.
4. An apparatus according to claim 3 wherein at least two gas ports
are provided on the same support plate.
5. An apparatus according to claim 3 wherein each support plate
comprises a gas port.
6. An apparatus according to claim 1 wherein the or at least one
gas port includes a sealing element to facilitate formation of an
airtight seal between the gas port(s) and the pack.
7. An apparatus according to claim 1 wherein the or at least one
gas port comprises an aperture extending through the support
plate.
8. An apparatus according to claim 1 wherein the or each gas port
comprises a suction port connected to a vacuum source to enable air
to be evacuated from a pack through the suction port.
9. An apparatus according to claim 1 wherein the or each gas port
comprises a filling port connected to a pressurised gas source to
enable a pack to be filled with gas from the pressurised gas source
through the filling port.
10. An apparatus according to claim 1 wherein the or each gas port
comprises a suction and filling port selectively connected to a
vacuum source and a pressurised gas source to enable air to be
evacuated from a pack through the gas port and for a pack to be
filled with gas from the pressurised gas source through the gas
port.
11. An apparatus according to claim 3, wherein a first gas port
comprises a suction port connected to a vacuum source to enable air
to be evacuated from a pack through the suction port, and a second
gas port comprises a filling port connected to a pressurised gas
source to enable a pack to be filled with gas from the pressurised
gas source through the filling port.
12. An apparatus according to claim 8 wherein a control valve is
provided between the or each gas port and the source of vacuum
and/or pressurised gas supply, and the or each control valve is
operable to control communication of the source of vacuum and/or
pressurised gas supply with the or each gas port.
13. An apparatus according to claim 12 wherein the or one of the
support plate(s) includes a sensor element configured to detect
when a pack is supported in abutment with the support plate,
wherein the or each control valve is configured to be actuated when
it is detected that a pack is in abutment with the support
plate.
14. (canceled)
15. (canceled)
16. An apparatus according to claim 1 comprising a wrapping station
configured to wrap and seal a bundle of smoking articles with a
barrier material to form a sealed package and to provide a valve on
at least one face of the package, and to provide the sealed package
to the handling mechanism.
17. An apparatus according to claim 16 wherein the wrapping station
includes a continuous web of barrier material having valves at
regularly spaced intervals along the web, each valve disposed over
an aperture through the barrier material, and wherein the wrapping
station is configured to cut sections of barrier material from the
web and to wrap and seal bundles of smoking articles such that the
or each valve is consistently positioned on each sealed
package.
18. An apparatus according to claim 17 further comprising a packing
station configured to form an outer box around the sealed package,
wherein the handling mechanism is disposed between the wrapping
station and the packing station to convey the sealed package
between the wrapping station and the packing station.
19. An apparatus according to claim 18 further comprising an
adhesive applicator configured to apply an adhesive to the sealed
package or an interior surface of the outer box, to bond the sealed
package to the outer box with the adhesive applied over the or at
least one valve of the sealed package.
20. An apparatus according to claim 17 wherein the or at least one
gas port is configured to sit over the or at least one valve on the
wrapped package when engaged therewith, and the or at least one gas
port is of a larger dimension than the or at least one valve.
21. (canceled)
22. A method of manufacturing a sealed pack of smoking articles
having a modified internal atmosphere using an apparatus comprising
a handling mechanism which includes a support plate having a gas
port, the method comprising conveying a sealed pack of smoking
articles within the apparatus using the handling mechanism with the
pack abutting the support plate, engaging the gas port with a valve
formed in the pack and modifying the gaseous atmosphere within the
sealed pack via the valve through the gas port.
23. A method according to claim 22 comprising conveying the pack
held between the support plate and a second support plate whilst
modifying the internal atmosphere within the pack.
24. A method according to claim 22 wherein the gas port comprises a
suction port connected to a vacuum source and the step of modifying
the gaseous atmosphere within the sealed pack comprises evacuating
air from within the sealed pack through the suction port.
25. A method according to claim 22 wherein the gas port comprises a
filling port connected to a source of pressurised gas and the step
of modifying the gaseous atmosphere within the sealed pack
comprises filling the sealed pack with gas from the pressurised gas
source through the filling port.
26. A method according to claim 22 wherein the gas port comprises a
suction and filling port selectively connected to a vacuum source
and a pressurised gas source, and the step of modifying the gaseous
atmosphere within the sealed pack comprises evacuating air from
within the sealed pack through the gas port and filling the sealed
pack with gas from the pressurised gas source through the gas
port.
27. A method according to claim 22 wherein the apparatus comprises
a first gas port comprising a suction port connected to a vacuum
source and a second gas port comprising a filling port connected to
a pressurised gas source, and wherein the step of modifying the
gaseous atmosphere within the pack comprises evacuating air from
within the sealed pack through the suction port and filling the
sealed pack with gas from the pressurised gas source through the
filling port.
28. A method according to claim 22 wherein the apparatus includes a
control valve between the or at least one gas port and the source
of vacuum and/or pressurised gas source, the method comprising
controlling operation of the at least one control valve to control
communication of the source of vacuum and/or pressurised gas source
with the or at least one gas port.
29. (canceled)
30. A method according to claim 28 wherein the or one of the
support plate(s) includes a sensor element, the method comprising
the sensor element detecting when a pack is supported in abutment
with the support plate(s) and actuating the or at least one control
valve to communicate the source of vacuum and/or pressurised gas
source with the or at least one gas port when it is detected that a
pack is in abutment with the support plate.
31. A method according to claim 30 further comprising forming an
outer box around the sealed package at a packing station and the
handling mechanism conveying the sealed package to the packing
station.
32. A method according to claim 31 further comprising applying an
adhesive to the sealed package or to an interior surface of the
outer box using an adhesive applicator to bond the sealed package
to the outer box with the adhesive applied over the or at least one
valve of the sealed package.
Description
FIELD OF THE INVENTION
[0001] This invention relates to an apparatus and method for
manufacturing a pack for smoking articles.
BACKGROUND
[0002] It is known to provide packs of smoking articles that
comprise a bundle of smoking articles in a generally rectangular
parallelepiped configuration, an inner frame of card across the
front and side faces of the bundle, and an outer wrapper of film or
other barrier material enclosing the bundle to form an airtight
pack. Such packs are known to include an access aperture for a user
to remove smoking articles from the pack, and a re-sealable label
over the access aperture to enable the pack to be sealed
closed.
[0003] Such known packs may be provided within an outer box formed
from a blank of card and comprising a body having an open top and a
hinged lid attached to the body and moveable to open or close the
open top.
[0004] It is also known to provide packaging as an airtight
container and to package goods in such a container with the
interior of the container having a reduced pressure or a vacuum, or
being of an atmosphere less reactive than ambient air, to prevent
the contents of the container from spoiling by reaction with oxygen
in air and to increase the shelf-life of the container
contents.
[0005] It is desirable to produce a smoking article pack comprising
a sealed container with a reduced interior pressure or less
reactive interior atmosphere. However, it is problematic to provide
a cost-effective means of producing such packs without the
requirement of a bespoke, and thereby expensive, manufacturing
machinery. It is also desirable to be able to reliably produce such
packs in a high-speed production process.
[0006] The present invention seeks to provide an alternative
apparatus and method of manufacturing smoking article packs that
alleviates or overcomes the above problems.
SUMMARY
[0007] According to the present invention, there is provided an
apparatus for manufacturing a sealed pack of smoking articles and
modifying an internal atmosphere thereof, the apparatus comprising
a handling mechanism for conveying a sealed pack of smoking
articles within the apparatus, the handling mechanism including a
support plate against which a pack abuts during conveyance by the
handling mechanism, the support plate including a gas port, the
apparatus configured such that, as a pack is conveyed by the
handling mechanism in abutment with the support plate, the gas port
may engage a valve formed in the pack to enable a gaseous
atmosphere within the sealed pack to be modified.
[0008] The support plate may comprise one of a pair of spaced
support plates configured to retain a pack between the support
plates, wherein at least one of the support plates includes the gas
port.
[0009] The apparatus may comprise a plurality of gas ports. At
least two gas ports may be provided on the same support plate. Each
support plate may comprise a gas port.
[0010] The or at least one gas port may include a sealing element
to facilitate formation of an airtight seal between the gas port(s)
and the pack.
[0011] The or at least one gas port may comprise an aperture
extending through the support plate.
[0012] The or each gas port may comprise a suction port connected
to a vacuum source to enable air to be evacuated from a pack
through the suction port.
[0013] The or each gas port may comprise a filling port connected
to a pressurised gas source to enable a pack to be filled with gas
from the pressurised gas source through the filling port.
[0014] The or each gas port may comprise a suction and filling port
selectively connected to a vacuum source and a pressurised gas
source to enable air to be evacuated from a pack through the gas
port and for a pack to be filled with gas from the pressurised gas
source through the gas port.
[0015] A first gas port may comprise a suction port connected to a
vacuum source to enable air to be evacuated from a pack through the
suction port, and a second gas port may comprise a filling port
connected to a pressurised gas source to enable a pack to be filled
with gas from the pressurised gas source through the filling
port.
[0016] A control valve may be provided between the or each gas port
and the source of vacuum and/or pressurised gas supply, and the or
each control valve may be operable to control communication of the
source of vacuum and/or pressurised gas supply with the or each gas
port.
[0017] The or one of the support plate(s) may include a sensor
element configured to detect when a pack is supported in abutment
with the support plate, and the or each control valve may be
configured to be actuated when it is detected that a pack is in
abutment with the support plate.
[0018] The apparatus may further comprise a controller connected to
the or each control valve to control operation thereof. The sensor
element may be connected to the controller.
[0019] The apparatus may comprise a wrapping station configured to
wrap and seal a bundle of smoking articles with a barrier material
to form a sealed package and to provide a valve on at least one
face of the package, and to provide the sealed package to the
handling mechanism.
[0020] The wrapping station may include a continuous web of barrier
material having valves at regularly spaced intervals along the web,
each valve disposed over an aperture through the barrier material,
and wherein the wrapping station may be configured to cut sections
of barrier material from the web and to wrap and seal bundles of
smoking articles such that the or each valve is consistently
positioned on each sealed package.
[0021] The apparatus may further comprise a packing station
configured to form an outer box around the sealed package, and the
handling mechanism may be disposed between the wrapping station and
the packing station to convey the sealed package between the
wrapping station and the packing station.
[0022] The apparatus may further comprise an adhesive applicator
configured to apply an adhesive to the sealed package or an
interior surface of the outer box, to bond the sealed package to
the outer box with the adhesive applied over the or at least one
valve of the sealed package.
[0023] The or at least one gas port may be configured to sit over
the or at least one valve on the wrapped package when engaged
therewith, and the or at least one gas port may be of a larger
dimension than the or at least one valve.
[0024] The or at least one gas port and the or at least one valve
may be substantially circular and the or at last one gas port may
be of a greater diameter than the diameter of the or at least one
valve.
[0025] The present invention also provides a method of
manufacturing a sealed pack of smoking articles having a modified
internal atmosphere using an apparatus comprising a handling
mechanism which includes a support plate having a gas port, the
method comprising conveying a sealed pack of smoking articles
within the apparatus using the handling mechanism with the pack
abutting the support plate, engaging the gas port with a valve
formed in the pack and modifying the gaseous atmosphere within the
sealed pack via the valve through the gas port.
[0026] The method may comprise conveying the pack held between the
support plate and a second support plate whilst modifying the
internal atmosphere within the pack.
[0027] The gas port may comprise a suction port connected to a
vacuum source and the step of modifying the gaseous atmosphere
within the sealed pack may comprise evacuating air from within the
sealed pack through the suction port.
[0028] The gas port may comprise a filling port connected to a
source of pressurised gas and the step of modifying the gaseous
atmosphere within the sealed pack may comprise filling the sealed
pack with gas from the pressurised gas source through the filling
port.
[0029] The gas port may comprise a suction and filling port
selectively connected to a vacuum source and a pressurised gas
source, and the step of modifying the gaseous atmosphere within the
sealed pack may comprise evacuating air from within the sealed pack
through the gas port and filling the sealed pack with gas from the
pressurised gas source through the gas port.
[0030] The apparatus may comprise a first gas port comprising a
suction port connected to a vacuum source and a second gas port
comprising a filling port connected to a pressurised gas source,
and the step of modifying the gaseous atmosphere within the pack
may comprise evacuating air from within the sealed pack through the
suction port and filling the sealed pack with gas from the
pressurised gas source through the filling port.
[0031] The apparatus may include a control valve between the or at
least one gas port and the source of vacuum and/or pressurised gas
source, and the method may comprise controlling operation of the at
least one control valve to control communication of the source of
vacuum and/or pressurised gas source with the or at least one gas
port.
[0032] The method may comprise controlling operation of the or at
least one control valve by means of a controller connected to the
or at least one control valve.
[0033] The or one of the support plate(s) may include a sensor
element, and the method may comprise the sensor element detecting
when a pack is supported in abutment with the support plate(s) and
actuating the or at least one control valve to communicate the
source of vacuum and/or pressurised gas source with the or at least
one gas port when it is detected that a pack is in abutment with
the support plate.
[0034] The method may further comprise forming an outer box around
the sealed package at a packing station and the handling mechanism
conveying the sealed package to the packing station.
[0035] The method may further comprise applying an adhesive to the
sealed package or to an interior surface of the outer box using an
adhesive applicator to bond the sealed package to the outer box
with the adhesive applied over the or at least one valve of the
sealed package.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Embodiments of the invention will now be described, by way
of example only, with reference to the accompanying drawings, in
which:
[0037] FIG. 1 shows a front perspective view of a smoking article
pack manufactured using an apparatus and method of a first
embodiment of the present invention;
[0038] FIG. 2 shows a schematic view of a pack manufacturing
apparatus of a first embodiment of the present invention;
[0039] FIG. 3 shows an enlarged view of a portion of the schematic
apparatus of FIG. 2;
[0040] FIG. 4 shows a cross-sectional view of the portion of the
apparatus along the line X-X shown in FIG. 3 in contact with a
smoking article pack being produced;
[0041] FIG. 5 shows a front perspective view of a smoking article
pack manufactured using an apparatus and method of a second
embodiment of the present invention;
[0042] FIG. 6 shows a schematic view of a pack manufacturing
apparatus of a second embodiment of the present invention; and
[0043] FIG. 7 shows a cross-sectional view similar to that of FIG.
4, but of a portion of the apparatus shown in FIG. 6 in contact
with a smoking article pack as shown in FIG. 5 being produced.
DETAILED DESCRIPTION
[0044] FIG. 1 shows a pack of smoking articles 1 manufactured using
an apparatus and method of the present invention. (For the purposes
of brevity of the description, smoking articles 2 will hereafter be
referred to as "cigarettes 2"). The pack 1 comprises a bundle of
cigarettes 2 wrapped in an outer barrier layer 3. The outer barrier
layer 3 is sealed around the bundle of cigarettes 2 to provide an
air-tight package enclosing the cigarettes 2. The elongate side
edges of the pack 1 are formed as fin seals as part of the
air-tight sealing configuration of the barrier layer 3. The outer
barrier layer 3 also includes a one-way valve 4 on the outer
surface of the pack 1 configured to allow air to be drawn out of
the pack 1 to establish a negative pressure within the pack 1, but
to prevent air returning back into the pack 1. The pack 1 includes
a cigarette access aperture (not shown) which is formed by a flap
cut from the barrier layer 3 and which is covered by a re-sealable
label 5. The re-sealable label 5 makes a substantially air-tight
seal with the barrier layer 3.
[0045] In the exemplary embodiment shown, the one-way valve 4
comprises a pad 6 bonded around its perimeter over a small aperture
7 in the barrier layer 3, and including moveable flaps 8 that rest
against the surface of the barrier layer 3 beneath the pad 6. When
a vacuum source is applied to the valve 4, air is drawn from within
the pack 1 through the small aperture 7 in the barrier layer 3, and
the flaps 8 lift away from the barrier layer 3 slightly to allow
the air to exit the pack 1. However, once the vacuum source is
removed, the negative pressure within the pack 1 pulls the flaps 8
tight against the underlying barrier layer 3 to make a seal
therewith which prevents any ambient atmosphere from being able to
pass back into the pack 1. The pack 1 is sufficiently sealed to
allow the reduced pressure to be maintained within the pack 1 until
the pack 1 is opened for the first time by lifting the re-sealable
label 5 to open the access aperture.
[0046] The partial vacuum provided within the pack 1 helps preserve
the flavour and freshness of the cigarettes during transport,
storage and retail display until purchased by a consumer for use.
When the pack 1 is opened, ambient air rushes into the pack to
equalise the negative pressure, which gives an audible indicator to
the consumer of the first opening of the pack 1.
[0047] The material of the barrier layer 3 is substantially
gas-impermeable and may, in particular, be impermeable to oxygen to
prevent ingress of oxygen into the pack 1. Also, the
gas-impermeable material of the barrier layer 3 prevents movement
of moisture through the barrier material, so the moisture content
within the pack 1 remains constant and is not affected by external
conditions.
[0048] FIG. 2 shows a schematic view of a pack manufacturing
apparatus 10 of the present invention, and shows the production
process steps. The apparatus 10 comprises an inner frame station
11, a barrier wrap station 12, a lifting station 13, a transfer
wheel 14, a packing station 15 and an outer wrap station 16.
[0049] The inner frame station 11 receives generally cuboidal
bundles of cigarettes 2 and flat card inner frame blanks 17. At the
inner frame station 11, the inner frame blank 17 is folded around
the bundle of cigarettes 2, to form a combined inner frame and
cigarette bundle 18. The inner frame blank 17 is folded around the
cuboidal bundle of cigarettes so as to extends at least partially
extend over both the front and rear faces of the bundle, that is
the largest faces of the cuboidal bundle. The inner frame blank 17
is also folded to at least partially extend over the long side
faces of the bundle between the front and rear faces. The combined
inner frame and cigarette bundle 18 is then transferred to the
barrier wrap station 12.
[0050] The barrier wrap station 12 receives the combined inner
frame and cigarette bundle 18. The barrier wrap station 12 also
receives a continuous web 19 of barrier layer 3 material which has
been pre-formed, at regularly spaced intervals, with cuts defining
the cigarette access apertures (not shown) covered with re-sealable
labels 5, and small apertures 7 over which the valves 4 are bonded.
The barrier wrap station 12 cuts a section of the continuous web 19
of barrier layer material and wraps the cut web section around the
combined inner frame and cigarette bundle 18, sealing the edge
flaps to form an sealed wrapped cigarette package 20. The wrapped
package 20 includes a valve 4 on a lower portion of the front
face--namely on the larger rectangular face over which the majority
of the re-sealable label 5 is adhered, and proximate an opposite
end of the face to the re-sealable label 5.
[0051] The wrapped package 20 is subsequently to be conveyed to the
packing station 15 and the apparatus 10 includes a lifting station
13 and a transfer wheel 14 to convey the wrapped package 20 from
the barrier wrap station 12 to the packing station 15. The transfer
wheel 14 comprises a hub 21 and a plurality of pockets 22 disposed
around the perimeter of the hub 21. The lifting station 13
comprises a handling mechanism which is configured to transfer the
wrapped packages 20 from the barrier wrap station 12 to a pocket 22
of the transfer wheel 14. As the transfer wheel 14 rotates it
conveys the wrapped packages 20 to the packing station 15. The
handling mechanism is shown in more detail in FIG. 3 and comprises
a pair of support plates, a lifting plate 23 and a follower plate
24. Each plate 23, 24 is mounted to a respective rotatable support
arm 25, 26 which are moveable to raise and lower the lifting and
follower plates 23, 24. In use, a wrapped package 20 is held
between contact faces 27, 28 of the lifting and follower plates 23,
24 as the support arms 25, 26 rotate to lift the wrapped package 20
into position into a pocket 22 of the transfer wheel 14.
[0052] A gas port in the form of a suction port is associated with
the follower plate 24. The suction port comprises a gas hole to act
as a suction hole 29 formed in the follower plate 24 which is open
at the contact face 28, extends through the follower plate 24 and
is connected to a gas hose to act as a vacuum hose 30 on the
opposite side of the follower plate 24 to the contact face 28. The
vacuum hose 30 is fluidly connected to a vacuum tank 31 via a
control valve 32, and the vacuum tank 31 is connected to a vacuum
pump 33. The control valve 32 may be a solenoid valve or may be
actuated by a solenoid. When the control valve 32 is actuated into
an open position, the vacuum causes air to be sucked through the
suction hole 29 into the vacuum tank 31. The control valve 32 may
be connected to a controller (not shown) of the apparatus 10 to
control operation of the control valve.
[0053] The apparatus 10 is configured such that when the wrapped
package 20 is held between the lifting and follower plates 23, 24,
the suction hole 29 is aligned with the valve 4. During the lifting
step of the wrapped package 20 from the barrier wrap station 12 to
the transfer wheel 14, the control valve 32 is actuated to open and
thereby evacuate air from within the wrapped package 20 to form an
evacuated wrapped package 34. As the evacuated wrapped package 34
reaches the transfer wheel 14, the control valve 32 is closed and
the valve 4 prevents ambient air from re-entering the evacuated
wrapped package 34, thereby leaving the interior of the evacuated
sealed wrapped package 34 as a partial vacuum. The inner frame 17
extending over both front and rear faces of the cigarette bundle,
as well as the side faces, supports the barrier material 3 and
provides protection to the cigarettes to prevent them being crushed
under the force of the vacuum within the evacuated wrapped package
34.
[0054] The packing station 15 receives evacuated wrapped packages
34 from the transfer wheel 14, and also receives card outer box
blanks 35, and folds and glues the box blanks 35 around the
evacuated wrapped packages 34 to form hinged lid packs 36
containing the evacuated wrapped packages 34.
[0055] The hinged lid packs 36 proceed to the outer wrap station 16
where they are enveloped in an outer film wrap in a conventional
manner to produce a wrapped hinged lid pack 37.
[0056] It can be seen from FIG. 4 that the contact face 28 of the
follower plate 24 includes a circular seal 38 around the suction
hole 29. This is to facilitate an airtight seal between the wrapped
package 20 and the follower plate 23 so that only air from within
the wrapped package 20 is evacuated by the applied vacuum and
ambient air is not drawn into the vacuum hose 30 which could affect
the effectiveness of the evacuation process. However, the circular
seal is not an essential aspect of the invention and may
alternatively be omitted, with the applied vacuum sufficient to
suck the wrapped package 20 against the follower plate 23 during
the evacuation process. It should also be appreciated that the seal
38 and valve 4 are shown in FIG. 4 with exaggerated dimensions for
clarity of illustration. In practice, the height of the seal 38 and
the valve 4 would be less than shown and the wrapped package 20
would not be spaced from the follower plate 24 but instead, would
abut the follower plate 24.
[0057] In the above-described apparatus and method, air is
evacuated from the pack 1 to provide a negative pressure within the
pack 1, namely a pressure below atmospheric pressure such as an at
least partial vacuum. However, the apparatus and method of pack
manufacture of the invention is not intended to be limited to such
embodiments. In an alternative embodiment of the invention, packs
may be produced with a gas other than air within the sealed pack.
For example, the air within the pack during manufacture may be
evacuated and replaced by a less reactive or inert gas, or may be
displaced by introduction of a less reactive or inert gas. For the
purposes of the description hereafter, any such gas will be
referred to as "inert gas". The inert gas may be provided at a
positive pressure, that is, a pressure elevated above atmospheric
pressure.
[0058] FIG. 5 shows a pack of smoking articles 101 manufactured
using an apparatus and method of a second embodiment of the present
invention. The pack 101 is similar to the pack 1 shown in FIG. 1,
and like features retain the same reference numerals. However, a
difference with the pack of FIG. 5 is that a one-way valve 104 is
provided on the inner surface of the barrier layer 3. The valve 104
is configured to allow gas to be introduced into the pack 101 but
to prevent gas from escaping from the pack 101.
[0059] The one-way valve 104 comprises a pad bonded around its
perimeter over a small aperture 7 in the barrier layer 3, and
includes moveable flaps that rest against the inner surface of the
barrier layer 3 beneath the pad. When a source of pressurised gas
is applied to the valve 104, the gas flows into the pack 101
through the small aperture 7 in the barrier layer 3, and the flaps
of the valve 104 lift away from the barrier layer 3 slightly to
allow the gas to enter the pack 101. However, once the gas source
is removed, the pack 101 is provided with an elevated internal gas
pressure relative to atmospheric pressure. This elevated pressure
pushes the flaps against the underlying barrier layer 3 to make a
seal therewith which prevents the inert gas within the pack 101
from being able to escape from the pack 101. The pack 101 is
sufficiently sealed to allow the elevated pressure to be maintained
within the pack 101 until the pack 1 is opened for the first time
by lifting the re-sealable label 5 to open the access aperture.
[0060] The atmosphere of inert gas provided within the pack 101
helps preserve the flavour and freshness of the cigarettes during
transport, storage and retail display until purchased by a consumer
for use. When the pack 101 is opened, the inert gas rushes out of
the pack 101 to equalise the elevated pressure, which gives an
audible indicator to the consumer of the first opening of the pack
101.
[0061] The material of the barrier layer 3 is substantially
gas-impermeable and may, in particular, be impermeable to oxygen to
prevent ingress of oxygen into the pack 1. Also, the
gas-impermeable material of the barrier layer 3 prevents movement
of moisture through the barrier material, so the moisture content
within the pack 1 remains constant and is not affected by external
conditions.
[0062] FIG. 6 shows a schematic view of a pack manufacturing
apparatus 110 of a second embodiment of the present invention. The
apparatus is similar to that of the first embodiment shown in FIG.
2. Like features retain the same reference numerals and description
thereof will not be repeated. A difference in the apparatus 110 of
the second embodiment is that the barrier wrap station 12 wraps the
cut web section from the continuous web 19 of barrier material
around the combined inner frame and cigarette bundle 18 such that
the resulting wrapped package 20 includes a valve 104 on an inside
of a lower portion of the front face. It will be appreciated
therefore that the web 19 is provided with the valves 104 on the
opposite side of the web 19 to the re-sealable labels 5 (as
represented by the valves 104 being shown in dashed lines in FIG.
6).
[0063] In addition to the above, the apparatus no include the gas
port in the form of a filling port associated with the follower
plate 24. The filling port is similar to the suction port of the
apparatus 10 of the first embodiment, and comprises a gas hole to
act as a filling hole 29 (see FIG. 7) formed in the follower plate
24 which is open at the contact face 28, extends through the
follower plate 24 and is connected to a gas hose to act as a
filling hose 30 on the opposite side of the follower plate 24 to
the contact face 28. The filling hose 30 is fluidly connected to a
pressurised gas supply 131 via a control valve 32. The pressurised
gas supply may comprise an inert gas or less reactive gas than air.
For example, the gas may comprise nitrogen or may comprise
SF.sub.6--sulphur hexafluoride. The control valve 32 may be a
solenoid valve or may be actuated by a solenoid. When the control
valve 32 is actuated into an open position, the gas from the
pressurised gas supply 131 flows through the filling hole 29 into
the pack 101. The control valve 32 may be connected to a controller
(not shown) of the apparatus no to control operation of the control
valve.
[0064] The apparatus no is configured such that when the wrapped
package 20 is held between the lifting and follower plates 23, 24,
the filling hole 29 is aligned with the valve 104 and small
aperture 7 in the barrier layer 3. During the lifting step of the
wrapped package 20 from the barrier wrap station 12 to the transfer
wheel 14, the control valve 32 is actuated to open and thereby fill
the wrapped package 20 with inert gas to form a filled package 134.
As the filled package 134 reaches the transfer wheel 14, the
control valve 32 is closed and the valve 104 prevents gas within
the filled package 134 from escaping.
[0065] The packing station 15 receives filled wrapped packages 134
from the transfer wheel 14, and also receives card outer box blanks
35, and folds and glues the box blanks 35 around the filled wrapped
packages 134 to form hinged lid packs 36 containing the filled
wrapped packages 134. The hinged lid packs 36 then proceed to the
outer wrap station 16 to be enveloped in an outer film wrap as
described previously.
[0066] It can be seen from FIG. 7 that the contact face 28 of the
follower plate 24 includes a circular seal 38 around the filling
hole 29. This is to facilitate an airtight seal between the wrapped
package 20 and the follower plate 28 to prevent leakage of gas from
the pressurised gas supply 131 during a filling process. However,
the circular seal is not an essential aspect of the invention and
may alternatively be omitted.
[0067] In use of the apparatus no of the second embodiment, the
wrapped package may comprise a further valve (not shown) to allow
air initially within the wrapped package 20 to exit the wrapped
package by being displaced as the inert gas is introduced. The
further valve may be configured to be permanently sealed closed
during the process of filling the wrapped package 20 with inert
gas. For example, a pressure or heat activated adhesive may be
provided on the further valve which is activate by application of
heat or pressure to the further valve once pressurised inert gas
has been introduced into the wrapped package to displace the air
initially therein. A support plate 23, 24 may include a heating
element to activate the adhesive. Once the further valve is sealed
closed, further escape of the inert gas is prevented and the
one-way valve 104 acts as described above to retained the elevated
pressure within the filled wrapped package 134. Alternatively, the
handling mechanism may include a sealing means to seal closed the
further valve once the air has been displaced from the wrapped
package 20. The further valve may be omitted and the wrapped
package may comprise a second aperture in the barrier material 3
which is sealed closed by the sealing means once the air has been
displaced from the wrapped package 20. The sealing means may apply
an adhesive pad over the further valve or second aperture.
[0068] An apparatus 210 of a third embodiment of the invention may
be configured to both evacuate air from the wrapped package 20 and
then fill the evacuated package with an inert gas. Such an
apparatus is also shown in FIG. 6, and additionally includes the
features shown in dashed lines. The apparatus includes all features
of the apparatus 10 of the first embodiment shown in FIG. 2, in
addition to the pressurised gas supply 131 of the apparatus 110 of
the second embodiment. In the third embodiment, the apparatus 210
include a gas port associated with the follower plate 24 which
serves as both a suction port and a filling port. In the present
disclosure, the term "gas port" may therefore be taken to encompass
both a suction port or a filling port as described above, and also
to encompass a port which serves as both a filling and suction
port.
[0069] The gas port comprises a gas hole 29 as in the apparatuses
10, 110 of the previous embodiments. The gas port is connected to a
gas hose 30 on the opposite side of the follower plate 24 to the
contact face 28. The gas hose 30 is fluidly connected to both a
vacuum tank 31 and a pressurised gas supply 131 via a control valve
32. The vacuum tank 31 and pressurised gas supply 131 are as
described previously. The control valve 32 may be a solenoid valve
or may be actuated by a solenoid. The control valve 32 is operable
to selectively connect the vacuum tank 31 or the pressurised gas
supply 131 to the gas hole 29. The control valve 32 may also close
off both the vacuum tank 31 and pressurised gas supply 131 from the
gas hole 29. The control valve 32 may be connected to a controller
(not shown) of the apparatus 210 to control operation of the
control valve.
[0070] In operation of the apparatus 210 of the third embodiment of
the invention, the wrapped package 20 is held between the lifting
and follower plates 23, 24 with the gas hole 29 aligned with the
valve 104 and small aperture 7 in the barrier layer 3. During the
lifting step of the wrapped package 20 from the barrier wrap
station 12 to the transfer wheel 14, the control valve 32 is
actuated to first connect the vacuum tank 31 with the gas hole 29
to evacuate air from within the wrapped package 20. Then the
control valve 32 would close the connection with the vacuum tank 31
and connect the pressurised gas supply 131 with the gas hole 29 to
fill the wrapped package 20 with inert gas to form a filled wrapped
package 134. As the filled package 134 reaches the 3o transfer
wheel 14, the control valve 32 is closed and the valve 104 prevents
gas within the filled package 134 from escaping. In order to allow
the valve 104 to permit air to be evacuated from the pack, the gas
port may comprise a projection or other feature (not shown) to
extend through the small aperture 7 to hold the valve 104 open.
[0071] In the exemplary embodiments of the apparatus 10, 110, 210
of the invention, the gas hole 29 and gas hose 30 are provided on
the follower plate 24, although the invention is not intended to be
limited to this configuration and the gas hole 29 and gas hose 30
may alternatively be provided on the lifting plate 23. In such an
alternative configuration, the wrapped package 20 may be provided
to the lifting station 13 with the front face facing downwards,
namely so that the valve 4, 104 faces the lifting plate 23. The gas
hole 29 would be provided in the lifting plate 23 and positioned so
that it is disposed over the valve 4, 104 when the wrapped package
20 is held between the lifting and follower plates 23, 24.
Alternatively, the wrapped package 20 could be configured with the
valve 4, 104 disposed on an opposite, rear face of the package to
face downwards, namely to face and be aligned with the gas hole 29
on the lifting plate 23.
[0072] In addition to the above, in an alternative embodiment, a
gas port may be provided on both the follower and lifting support
plates 23, 24 within the scope of the invention. This may enable a
wrapped package 20 to be conveyed between the support plates either
facing upwards or downwards, and one of the two gas ports may still
be operable in alignment with the valve 4, 104 in the wrapped
package 20 to evacuate air from within the package 20 or to fill
the wrapped package 20 with inert gas. Also, the wrapped packages
20 supplied to the handling mechanism may comprise two valves 4,
104, one on each opposite face of the wrapped package 20. The
valves 4, 104 may be positioned on the packages to correspond to
the positions of the gas ports on the support plates 23, 24. Air
may be evacuated from within, or inert gas may be introduced into,
the wrapped packages 20 through both valves 4, 104 as the wrapped
packages 20 are conveyed by between the support plates 23, 24 by
the handling mechanism.
[0073] In a further variant of the above alternative embodiment
having two gas ports, one on each support plate 23, 24, one gas
port may comprise a suction port and one gas port may comprise a
filling port. In operation, inert gas may be introduced into the
wrapped package 20 through one gas port while the air initially
within the wrapped package 20 may be evacuated though the other gas
port. The wrapped package 20 may include two valves 4, 104. Inert
gas may be introduced through a first valve 104 and air may be
evacuated through a second valve 4. The second valve 4 may be
sealed closed by a sealing means as described above during the
evacuation/filling process to enable the wrapped package to be
filled with the inert gas to an elevated pressure above atmospheric
pressure. The sealing means would seal the second valve closed so
that the inert gas is no longer able to escape therethrough.
[0074] The apparatuses 10, 110, 210 of the invention described
above comprise a packing station 15 which receives evacuated/filled
wrapped packages 34, 134 from the transfer wheel 14 and folds and
glues the box blanks 35 around the evacuated/filled wrapped
packages 34, 134. The evacuated/filled wrapped packages 34, 134 may
be bonded to the inside of the hinged lid packs 36 by adhesive to
retain them in place. The apparatuses 10, 110, 210 may include an
adhesive applicator to apply adhesive to the evacuated/filled
wrapped packages 34, 134. The adhesive applicator may apply the
adhesive over the valve 4, 104, further valve, second valve 4, or
second aperture in the barrier material 3 in the evacuated/filled
wrapped packages 34, 134 in the above-described embodiments. The
adhesive may thereby seal the respective valve/aperture closed once
the evacuated/filled wrapped package 34, 134 is bonded within the
hinged lid pack 36. This adhesive may thereby serve as the
above-described sealing means. The adhesive may also further
reinforce and ensure the integrity of the airtight seal of the
valve 4, 104.
[0075] In the above-described first embodiment of the invention,
air is evacuated from the wrapped package 20 to form a partial
vacuum therein. It will be appreciated that varying degrees of air
may be evacuated from the wrapped package 20, but that the pressure
within the wrapped package 20 will be reduced to a negative
pressure, that is, a pressure lower than ambient atmospheric
pressure. It will also be appreciated that not only air may be
evacuated from the wrapped package 20, and any gas that is present
at that time can be evacuated.
[0076] The partial vacuum within the evacuated wrapped package 34
may have a pressure of less than 1 bar. In some examples, the
partial vacuum is less than 500 millibar, for example between 40
and 300 millibar. In other embodiments, the partial vacuum is less
than 150 millibar, preferably about 80 millibar. However, it will
be appreciated that the partial vacuum within the wrapped package
20 may be any value less than 1 bar.
[0077] The apparatuses 110, 210 and methods of the second and third
embodiments of the invention are described above as producing the
filled package 134 with the inert gas at an elevated pressure.
However, the invention is not intended to be limited to such an
embodiment and the apparatus and method may fill the wrapped
packages 20 with inert gas to at or around atmospheric pressure.
The valve in the pack may enable filling and optionally also
evacuation of air within the pack before filling, and the valve
sealed by a sealing means as described above after filling the
wrapped package 20 with inert gas to at or around atmospheric
pressure.
[0078] The invention is not intended to be limited to any
particular location of gas port(s) on the support plate(s), and
either may be located at any position within the scope of the
invention, such that a valve(s) of the wrapped packages aligns with
the gas port(s) of the support plates.
[0079] The invention is not intended to be limited to any
particular location of control valve 32. The or a control valve 32
may be located on the support plate(s), and may be provided within
or proximate the or each gas hole 29.
[0080] Although the apparatuses 10, 110, 210 of the invention are
shown and described as comprising the gas port extending through
one of the support plates, such as the is follower plate 24, the
invention is not intended to be limited to this particular
configuration. In an alternative embodiment, a gas port may be
provided adjacent one of the support plates such that a gas hole
does not extend through one of the support plates. For example, the
gas port may be fixedly connected to a support plate and the
support plate configured such that the support plate abuts part of
a face of a wrapped package and the adjacent gas port engages
another part of the face of the wrapped package adjacent the
support plate, to evacuate air from within the wrapped package. In
such an embodiment, the support plate may be reduced in size so
that it does not cover the entire surface area of the face of the
wrapped package with which it abuts.
[0081] In an optional embodiment of the apparatus of the invention,
at least one of the support plates 23, 24 may include a sensor
element to detect when a wrapped package 20 is being held by, or is
in contact with the support plates 23, 24. This may comprise, for
example, an electrical sensor or, a mechanical button that is
depressed by a wrapped package 20 when in contact with the
respective support plate 23, 24. The sensor element may be
connected to the control valve 32 to operate the control valve 32
when it is detected that a wrapped package 20 is held between the
lifting and follower plates 23, 24. For example, if the control
valve 32 is connected to a solenoid, the solenoid may be actuated
to open the control valve 32 in response to detection of a wrapped
package 20 by the sensor element. The connection may be by means of
an electrical contact actuated by the sensor element.
Alternatively, the sensor element may be connected to the
controller to provide a signal to the controller when a wrapped
package is in abutment with the lifting or follower plate 23, 24 to
allow the controller to actuate the control valve 32. With such a
sensor element, the application of the vacuum to evacuate the
wrapped package 20, and/or the supply of inert gas to fill the
wrapped package 20, can be controlled only to operate in
coordination with when a wrapped package is held in the handling
mechanism.
[0082] In an advantageous embodiment of the apparatuses 10, 110,
210 of the invention, the gas port may be wider than the valve 4,
104. For example, in embodiments in which the valve 4, 104 and gas
port are circular, the gas port may be of a larger diameter than
the valve 4, 104. For example, the seal 38 and/or the gas hole 29
may be of a larger diameter than the diameter of the valve 4, 104.
In other configurations of valve 4, 104 and gas port, such as
square or rectangular, the outer dimensions of the gas port may be
greater than the outer dimensions of the valve 4, 104. Such an
arrangement may advantageously help ensure the gas port always
locates over the valve 4, 104, and may allow a degree of tolerance
in the positioning of the wrapped package 20 between the support
plates 23, 24. Such a degree of tolerance means that the wrapped
package 20 does not need to be in exact registration with the
support plates 23, 24 in each operation of the handling mechanism,
and may allow for faster apparatus processing speeds and reduced
cost of machinery control systems.
[0083] As used herein, the term "smoking article" includes
smokeable products such as cigarettes, cigars and cigarillos
whether based on tobacco, tobacco derivatives, expanded tobacco,
reconstituted tobacco or tobacco substitutes and also heat-not-burn
products and other nicotine delivery product such as aerosol
generation devices including e-cigarettes. The smoking article may
be provided with a filter for the gaseous flow drawn by the
smoker.
[0084] As used herein, the term "partial vacuum" means that
pressure has been reduced by removing at least a part of the gas
from within a space, for example the enclosure within the barrier
material 3 of the wrapped package 20.
[0085] In order to address various issues and advance the art, the
entirety of this disclosure shows by way of illustration various
embodiments in which the claimed invention(s) may be practiced and
provide for superior apparatus and method for manufacturing a
smoking article pack. The advantages and features of the disclosure
are of a representative sample of embodiments only, and are not
exhaustive and/or exclusive.
[0086] They are presented only to assist in understanding and teach
the claimed features. It is to be understood that advantages,
embodiments, examples, functions, features, structures, and/or
other aspects of the disclosure are not to be considered
limitations on the disclosure as defined by the claims or
limitations on equivalents to the claims, and that other
embodiments may be utilised and modifications may be made without
departing from the scope and/or spirit of the disclosure. Various
embodiments may suitably comprise, consist of, or consist
essentially of, various combinations of the disclosed elements,
components, features, parts, steps, means, etc. In addition, the
disclosure includes other inventions not presently claimed, but
which may be claimed in future.
* * * * *