METHOD AND APPARATUS FOR INTERMEDIATELY STORING DOUBLE-LENGTH SEMI-FINISHED PRODUCTS

Abstract

The method for intermediately storing double-length substantially cylindrical semi-finished products comprises the step of providing a tipping apparatus and forming double-length substantially cylindrical semi-finished products in the tipping apparatus. The method further comprises the steps of providing a cutting device and cutting the double-length semi-finished product into single products with the cutting device and providing a packer and packing single products in the packer. The method yet further comprises the steps of transporting the double-length semi-finished products from the tipping apparatus to the cutting device and transporting the single products from the cutting device to the packer, and intermediately buffering double-length substantially cylindrical semi-finished products in a buffer arranged between the tipping apparatus and the cutting device.

Claims

1. Method for intermediately storing double-length substantially cylindrical semi-finished products, the method comprising the steps of: providing a tipping apparatus and forming double-length substantially cylindrical semi-finished products in the tipping apparatus; providing a cutting device and cutting the double-length semi-finished product into single products with the cutting device; providing a packer and packing single products in the packer; transporting the double-length semi-finished products from the tipping apparatus to the cutting device and transporting the single products from the cutting device to the packer, and intermediately buffering double-length substantially cylindrical semi-finished products in a buffer arranged between the tipping apparatus and the cutting device.

2. Method according to claim 1, wherein the step of packing single products directly follows the step of cutting the double-length semi-finished products.

3. Method according to claim 1, further comprising the steps of detecting an interruption of the manufacturing process in the cutting device or downstream of the cutting device, and transporting the double-length semi-finished products from the tipping apparatus into an expandable buffer section, thereby at least partially filling the expandable buffer section.

4. Method according to claim 3, further comprising the step of emptying the expandable buffer section towards the cutting device, thereby at least partially emptying the expandable buffer section.

5. Method according to claim 1, wherein a segment in the double-length semi-finished product is at least one of an aerosol-forming substrate, an aerosol-cooling segment, a support element and a mouthpiece.

6. Method according to claim 1, wherein the double-length semi-finished products comprise sequences of aerosol-forming substrate, support element, aerosol-cooling segment and mouthpiece, wherein the support element is arranged between the aerosol-forming substrate and the aerosol-cooling segment.

7. Method according to claim 1, wherein a distance between a center of mass of the single product and a midpoint along a length of the single products is between about 5 percent and 20 percent of a total length of the single product.

8. Method according to claim 1, wherein a distal portion of the single product and a proximal portion of the single product have different diameters due to a tipping paper being wrapped around the proximal portion of the single product, and wherein the different diameters describe a stacking angle by which a distal end may be tilted with respect to a horizontal plane the single product is laid onto, and wherein the stacking angle is in a range between 0.08 degree and 0.35 degree.

9. Apparatus for intermediately storing double-length substantially cylindrical semi-finished products, the apparatus comprising: a tipping apparatus for forming double-length substantially cylindrical semi-finished products, a cutting device for cutting the double-length semi-finished products into single products; a packer for packing the single products; and a transport system for transporting the double-length semi-finished products from the tipping apparatus to the cutting device and the single products from the cutting device to the packer, wherein a buffer is arranged between the tipping apparatus and the cutting device for intermediately storing double-length substantially cylindrical semi-finished products.

10. Apparatus according to claim 9, wherein a transport distance between the cutting device and the packer is less than about 50 percent of the total transport distance between the tipping apparatus and the packer.

11. Apparatus according to claim 9, wherein the buffer is a mass-flow buffer system.

12. Apparatus according to claim 9, wherein the buffer has a capacity corresponding to a production capacity of the apparatus of about 5 minutes to 30 minutes.

13. Apparatus according to claim 9, wherein the buffer has a capacity to buffer at least 10,000 semi-finished products.

14. Apparatus according to claim 9, wherein the buffer comprises a conveyor band for transporting double-length semi-finished products arranged on the conveyor band, and support guides for guiding sections of the conveyor band to different levels arranged above each other.

15. Apparatus according to claim 9, further comprising a control device for online controlling semi-finished products.

16. Method according to claim 1, wherein the step of packing single products directly follows the step of cutting the double-length semi-finished products, and being separated only by a step of orienting the single products in a same orientation.

17. Method according to claim 2, further comprising the steps of detecting an interruption of the manufacturing process in the cutting device or downstream of the cutting device, and transporting the double-length semi-finished products from the tipping apparatus into an expandable buffer section, thereby at least partially filling the expandable buffer section.

18. Method according to claim 1, wherein a distal portion of the single product and a proximal portion of the single product have different diameters due to a tipping paper being wrapped around the proximal portion of the single product, and wherein the different diameters describe a stacking angle by which a distal end may be tilted with respect to a horizontal plane the single product is laid onto, and wherein the stacking angle is in a range between 0.09 degree and 0.30 degree.

19. Method according to claim 4, wherein a segment in the double-length semi-finished product is at least one of an aerosol-forming substrate, an aerosol-cooling segment, a support element and a mouthpiece.

20. Apparatus according to claim 9, wherein the buffer has a capacity corresponding to a production capacity of the apparatus of about 10 minutes to 20 minutes.

Description

[0071] The invention is further described with regard to embodiments, which are illustrated by means of the following drawings, wherein

[0072] FIG. 1 schematically shows a manufacturing process with buffer system;

[0073] FIG. 2 shows a section of a rod of segments manufactured in a combiner;

[0074] FIG. 3 shows a double product manufactured in an apparatus according to the invention;

[0075] FIG. 4 shows the single product manufactured from the double product as shown in FIG. 4;

[0076] FIG. 5 schematically shows another embodiment of a manufacturing process;

[0077] FIG. 6 schematically shows the stacking angle problem of single products.

[0078] In FIG. 1 a manufacturing process of semi-finished products in the form of double-products in a tipping apparatus, which tipping apparatus 6 comprises a combiner 5 adjacently arranged to and upstream of the tipping apparatus 6 is shown. The double products 655 are transported from the tipping apparatus 6 to the buffer 8 and from there to the cutting device 7 followed by the packer 75.

[0079] First rod 10, second rod 20 and third rod 30 of materials used in the manufacture of aerosol-generating articles are supplied and cut with respective cutting devices 15,25,35. The so cut first, second and third segments are supplied in an end-to-end relationship on a longitudinal motion path in the combiner 5.

[0080] In the embodiment shown in FIGS. 2 to 4, first and third rod 10, 30 are cut to double segments 11,33 having a length twice the length of the final plugs 1,3 before being fed to the longitudinal motion path in the combiner 5. Second rod 20 is cut to single segments 2 directly having the length of the plug 2 in the single product 777 before being fed to the longitudinal motion path.

[0081] The segments 11,2,33 form a stream of segments, the axis of the segments being arranged parallel to the longitudinal motion path. A sheet of wrapping material 51, for example cigarette paper, is provided with an adhesive with glue provider 52. The sheet of wrapping material 51 is supplied to and guided along the longitudinal motion path in the combiner 5. The stream of segment is wrapped with the wrapping material 51, for example in a respective garniture provided along the longitudinal motion path. An addition glue provider 53 adds a seam of glue to the wrapping material 51 before the wrapping material is entirely wrapped around the stream of segments. The so formed rod of segments is now cut at the end of the longitudinal motion path in the combiner 5. Thereto, a rod cutting device is provided (not shown) that cuts the rod of segments by cutting the first segment 11 at cutting line 100 (see FIG. 2). The first segment 11 is cut in half such that the two cut parts of the first segments correspond to plugs 1. By this cutting of the endless rod wrapped segment rods 555 are manufactured, which are further processed in the tipping apparatus 6 before being transported to the buffer 8. Plugs 1 each form end segments of the wrapped segment rods 555. The wrapped segment rods 555 are now transferred from the longitudinal motion path in the combiner 5 to a perpendicular motion path in the tipping apparatus 6.

[0082] This may be done by moving the wrapped segment rods further along the longitudinal motion path 500, for example with a linear movement, into flutes of a fluted receiving drum in the tipping apparatus. Therein, a longitudinal axis of the flute is aligned with the longitudinal first motion path. A transfer from the combiner into flutes of a receiving drum may also be performed by a spider mechanism, for example, as described in U.S. Pat. No. 5,327,803 for cigarettes. A wrapped segment rods is then gripped by a spider arm from the combiner and transferred by the spider arm into a flute of the receiving drum in the tipping apparatus.

[0083] Since the axis of the segments substantially keep their orientation while being processed in the combiner and in the tipping apparatus, the axis of the segments are parallel to the moving direction of the longitudinal motion path of the combiner 5 but perpendicular to the moving direction of the perpendicular motion path of the tipping apparatus 6. Preferably, the tipping apparatus 6 is arranged perpendicular to the combiner 5 such that the respective motion paths are also perpendicular to each other. By this, the axis of the segments are always oriented in a same direction.

[0084] In the tipping apparatus 6 the wrapped segment rods 555 are divided by cutting the second segment 33 at cutting line 200. Thereby, the second segment 33 is cut in half such that the two cut parts of the segments correspond to plugs 3. The so cut wrapped segment rods 555 is separated by a separating device (not shown) along the longitudinal axis of the wrapped segment rods 555. In the space between to so cut and separated pre wrapped segment rods 555 a fourth segment 44 is inserted. The fourth segment is also a double-length segment and is cut in a respective cutting device 45 from a fourth rod 40 supplied to the tipping apparatus 6. A continuous sheet of tipping paper 60 is provided and cut in cutting device 65 to individual tipping wrapper pieces 64. The piece of tipping wrapper 64 is wrapped around the fourth segment 44 as well as around portions of the two parts of the cut pre wrapped segment rods 555. Thus, these elements are combined with each other forming a double product 655 as shown in FIG. 3. This double product is now transported to buffer 8 for intermediate storing of the double product 655. When required, the double product 655 leaves the buffer 8 and is transported to the cutting device 7. There, the double product 655 is cut in half by cutting the fourth segment 44 at cutting line 300. By this, two single and final products 777 as shown in FIG. 4 are manufactured. Each other single product may then be turned such that all products have a same orientation. The so aligned and oriented products are transported to the packer 75 for packing the products, for example directly into smoking article packs. A tray 81 may additionally be provided parallel to the buffer 8. On the tray 81 double-products may be collected either for (long-time) storage and future use or as overflow to extend the capacity of the buffer 8. Accordingly, the transport system or the buffer 8 have means for branching off excess double products.

[0085] In FIG. 5 a manufacturing process for single products is shown in an arrangement of combiner 5 and tipping apparatus 6, where combiner 5 and tipping apparatus 6 are arranged adjacent and perpendicular to each other. The straight longitudinal motion path 500 in the combiner 5 and the perpendicular motion path 600 in the tipping apparatus 6 are also arranged perpendicular to each other. The perpendicular motion path 600 starts where the longitudinal motion path 500 ends. The combiner 5 comprises three hoppers 55,56,57 for feeding three different segments in alternating manner to the longitudinal motion path 500 to form a stream of segments. The stream of segments is then wrapped in the wrapper 58 forming an endless rod of segments. The endless rod of segments is controlled in controller 59 and then cut into wrapped segment rods by rod cutting device 101. Preferably, the rod cutting device 101 is a rotating knife arranged next to the longitudinal motion path 500. The controller 59 may be provided for controlling a position of the segments in the endless rod of segments. For example to determine an exact position where the rod has to be cut, for example to secure that the rod is cut exactly between segments or at a position dividing a segment into smaller segments. The wrapped segment rods are then transferred each into a flute of a fluted receiving drum 65 of the tipping device 6. The longitudinal motion path 500 is a substantially straight path, where the segments or the stream of segments, respectively, are guided along in a substantially straight line. The first motion path 500 extends into the fluted receiving drum 65 of the tipping apparatus. Preferably, the longitudinal motion path is arranged parallel to a flute of the fluted receiving drum 65, such that a wrapped segment rod cut by rod cutting device 101 may be transferred with a continuing straight movement into a flute of the fluted receiving drum longitudinally along the longitudinal motion path.

[0086] The wrapped segment rod is then cut on the fluted receiving drum 65 by product cutting device 201, for example comprising a rotating knife. The two parts of the cut wrapped segment rod are then separated while being arranged in flutes of separating drum 66. Hopper 41 inserts an additional segment, preferably a segment different to the segments of the endless rod of segments, in between the two parts of the cut wrapped segment rod. Preferably, the additional segment is a double-length mouthpiece. The two parts of the cut wrapped segment rods and the inserted additional segment are tipped on tipper 67 with a tipping material, for example a piece of paper. The so combined segments form a double product. At the end of tipping apparatus 6 the double products formed are transported to the buffer 8. From the buffer 8 the double products are transferred to a final cutting device 301, where the double product is cut into two single products. In the subsequently arranged turning device 72, each other single product is turned by 180 degrees or one part of the mass-flow is guided by a 180 degree turn along the transport direction, in order for all single products to have a same orientation. So oriented single products are then transferred to and packed in packer 75.

[0087] In the combiner and in the tipping apparatus including the transfer from the combiner to the tipping device, the wrapped segment rods and double products are processed according to an individual product flow. In an individual product flow, control over an individual product is given at any stage in the manufacturing and processing line. For example, the position and alignment of the product is known at any time. In buffer 8 the products are buffered and transported according to a mass-flow 700. In a mass-flow the products are transported in and along a general moving direction. Thus an exact position of the individual products in the mass-flow is not known. The buffer 8 comprises an expandable buffer section 81 that may accommodate changes in the mass flow, for example when either of the upstream or downstream machines the process speed changes, for example for maintenance. During that time, the expandable buffer section 81 is filled or emptied along the transport path 800. The mass flow 700 through the buffer 8 ends at the final cutting device 301. After the cutting device, in the turning device 75 and after the turning, the aligned single products are again transported according to a mass-flow 900 to a reservoir of the packer 75. There, the single products are preferably collected in the reservoir for being supplied to packer 75. In FIG. 5, the individual product flows are indicated by solid lines and the mass-flows are indicated by dotted lines.

[0088] FIG. 6 shows a side view of part of the stack of aerosol-generating articles such as the single products 777 shown in FIG. 4. Each single product 777 comprises an aerosol-generating substrate 1 secured to a mouthpiece 4 by a tipping wrapper 64. The thickness of the tipping wrapper 64 has been exaggerated to more clearly illustrate the step change in the outer diameter of each single product 777 at the upstream edge 640 of the tipping wrapper 64. As a result of the center of mass 14 of each single product 777 being positioned upstream of the tipping wrapper 64, each single product 777 lies at an angle with respect to the underlying single product 777 on which it sits. Although each individual angle is relatively small, the angles between consecutive pairs of single product 777 provide a cumulative effect such that a significant stacking angle 16 with respect to the horizontal direction 17 is formed at the top of the stack. Over the total height of the entire stack for example in a vertical stacking channel the stacking angle 16 can be large enough to cause the single product 777 at the top of the stack to tip into a vertical orientation, which can cause jams for example in a buffer, particularly at the bottom of a buffer or hopper where the single product 777 reach individual feeding channels.

[0089] Basically, the risk of jamming of products is limited to a transport of products in a mass-flow. However, due to the buffering of double products in a mass-flow buffer 8, the risk of jamming products is avoided or kept at a minimum in the entire manufacturing line. Single products are kept in a mass-flow after the cutting device or possibly in a reservoir of the packer only, before being packed. However, since the amount of single products in a packer reservoir is low, the risk of jamming single products therein is minimal.

[0090] Exemplary data for the process and product as described in FIGS. 1 to 4 are:

[0091] Tobacco rod 10 having a length of 120 mm is cut into double segments 11 of 24 mm length. The double-length segments 11 are then cut into final plugs 1 of 12 mm length.

[0092] Hollow acetate tube rod 20 having a length of 96 mm is cut into plugs 2 of 8 mm length.

[0093] Rod 30 of gathered polylactic acid sheet having a length of 144 mm is cut into double segments 33 of 36 mm length. The double-length segments 33 are then cut into final plugs 3 of 18 mm length.

[0094] Filter rod 40 is cut into double-length segments 44 of 14 mm length. The double-length segments 44 are then cut into final plugs 4 of 7 mm length.

[0095] The length of the semi-finished product 555 is 76 mm. The length of the double product 66 is 90 mm. The final product 77 has a length of 45 mm with a tolerance of less than plus or minus 1 mm, preferable less or equal to plus or minus 0.5 mm. The diameter of the final products is about 7.2 mm.

[0096] The final product is made of a series of tobacco plug 1, hollow acetate tube 2, plug of gathered polylactic acid (PLA) 3 and mouthpiece plug 4. A tipping wrapper 64 has a length of 20 mm and covers the entire length of the mouthpiece plug 4 and part of the PLA plug 3.

[0097] A production speed for the semi-finished product 555 may be about 5000 per minute at a movement speed of the stream of segments along the longitudinal motion path of 380 meters per minute. A production speed of the double product 655 may also be about 5000 per minute such that about 10′000 final products 777 may be produced per minute.