SMOKING ARTICLE ASSEMBLY

Abstract

A modular apparatus is configured to cause received rods of smokable material to undergo a first sequence of operations. The modular apparatus can be reconfigured so as to cause received rods of smokable material to undergo a second sequence of operations, different to the first sequence of operations. The first and second sequences of operations respectively form at least part of first and second processes for assembling smoking articles, each smoking article comprising one of said rods of smokable material, which is smoked in use. The modular apparatus comprises a first inserter configured to insert a first rod article between two tobacco rods, a first rod divider configured to divide the first rod article into at least two parts, a separator configured to separate a first group comprising a rod of smokable material and one of said parts from a second group comprising a rod of smokable material and another of said parts and a second inserter configured to insert a second rod article between the first and second groups.

Claims

1. A modular apparatus for smoking article assembly, configured to cause received rods of smokable material to undergo a first sequence of operations, wherein the modular apparatus can be reconfigured so as to cause received rods of smokable material to undergo a second sequence of operations, different from the first sequence of operations, and wherein the first and second sequences of operations respectively form at least part of first and second processes for assembling smoking articles, each smoking article comprising a said rod of smokable material, the modular apparatus comprising: a first inserter configured to insert a first rod article between two tobacco rods; a first rod divider configured to divide the first rod article into at least two parts, a separator configured to separate a first group comprising a rod of smokable material and one of said parts from a second group comprising a rod of smokable material and another of said parts, and wherein the first inserter, the first rod divider, and the separator each include a respective drum forming a conveyance path through the modules.

2. The modular apparatus as claimed in claim 1, further comprising: a second rod divider configured to divide the second rod article into at least two parts; and a wrapping station configured to wrap a wrapper at least partially around an inserted rod article after the inserted rod article is inserted between the two tobacco rods and before the inserted rod article is divided by a rod divider.

3. The modular apparatus as claimed in claim 1 further comprising a first module comprising said first inserter, and a second module comprising said second inserter.

4. The modular apparatus as claimed in claim 2, comprising: the plurality of inserters, each said inserter being configured to insert a rod article between two tobacco rods; the plurality of rod dividers, each said rod divider being configured to divide a rod article into at least two parts, and a plurality of wrapping stations, each said wrapping station being configured to wrap a wrapper at least partially around an inserted rod article after the rod article is inserted between two tobacco rods and before the inserted rod article is divided by a rod divider.

5. The modular apparatus as claimed in claim 1, further comprising at least two modules, each having a base unit and at least one drum, wherein each of said at least two modules, each having a base unit and at least one drum, wherein each of said at least two modules is configured to receive the same number of drums.

6. The modular apparatus as claimed in claim 5, wherein each of said at least two modules are configured to receive drums in corresponding positions with respect to the respective base unit.

7. The modular apparatus as claimed in claim 1, wherein said first process for assembling smoking articles forms a first configuration of smoking article and wherein said second process for assembling smoking articles forms a second configuration of smoking article different from the first configuration.

8. The modular apparatus as claimed in claim 1, wherein said first and second sequences of operations cause rods of smokable material to be respectively combined with at least one rod article.

9. The modular apparatus as claimed in claim 1, further comprising a plurality of modules configured to receive said rods of smokable material, said plurality of modules comprising a plurality of functional units configured to cause said rods of smokable material to undergo said first sequence of operations.

10. The modular apparatus as claimed in claim 9, wherein said functional units comprise a plurality of conveying elements arranged to define a conveyance path through the modular apparatus, along which rods of smokable material are caused to undergo said first sequence of operations.

11. A modular apparatus as claimed in claim 9, wherein said reconfiguration of the modular apparatus comprises repositioning modules relative to one another and/or removing one or more of the modules and/or adding one or more further modules.

12. The modular apparatus as claimed in claim 9, wherein said plurality of modules comprises a reconfigurable module, wherein reconfiguration of the modular apparatus comprises reconfiguring said reconfigurable module.

13. The modular apparatus as claimed in claim 9, wherein when reconfigured, the functional units cause rods of smokable material to undergo said second sequence of operations.

14. The modular apparatus as claims in claim 9, wherein modules are arranged in a row to cause said rods of smokable material to undergo said first and second sequences of operations.

15. The modular apparatus as claimed in claim 9, wherein at least one module is left unchanged when the modular apparatus is reconfigured for said second sequence of operations.

16. The modular apparatus as claimed in claim 15, wherein said at least one module which is left unchanged comprises an in-feed module configured to receive rods of smokable material.

17. The modular apparatus as claimed in claim 9, wherein each module comprises a servo motor and wherein said servo motors are synchronized.

18. The modular apparatus as claimed in claim 1, further comprising a first group-forming apparatus configured to associate a rod of smokable material with a rod article to form a first group, and a second group-forming apparatus configured to associate a rod article with the first group to form a second group.

19. The modular apparatus as claimed in claim 18, further comprising a first module comprising said first group-forming apparatus and a second module comprising said second group-forming apparatus.

20. The modular apparatus as claimed in claim 1, further comprising a first wrapping station to apply a first wrapper to the smoking article and a second wrapping station to apply a second wrapper to the smoking article after the first wrapper is applied.

21. The modular apparatus as claimed in claim 20, wherein the second wrapping station is configured to apply the second wrapper so that it overlaps with the first wrapper.

22. The modular apparatus as claimed in claim 20, wherein the second wrapping station is configured to apply to the second wrapper so that there is a longitudinal gap between the first wrapper and the second wrapper.

23. A smoking article assembling apparatus comprising a modular apparatus configured to cause received rods of smokable material to undergo a first sequence of operations, wherein the modular apparatus can be reconfigured so as to cause received rods of smokable material to undergo a second sequence of operations, different from the first sequence of operations, and wherein the first and second sequences of operations respectively form at least part of first and second processes for assembling smoking articles, each smoking article comprising a said rod of smokable material, the modular apparatus comprising: a first inserter configured to insert a first rod article between two tobacco rods; a first rod divider configured to divide the first rod article into at least two parts, a separator configured to separate a first group comprising a rod of smokable material and one of said parts from a second group comprising a rod of smokable material and another of said parts, and wherein the first inserter, the first rod divider, and the separator each include a respective drum forming a conveyance path through the modules.

24. A method of assembling a smoking article, comprising: receiving rods of smokable material; and causing said rods of smokable material to undergo a first sequence of operations in a modular apparatus, wherein the modular apparatus can be reconfigured so as to cause received rods of smokable material to undergo a second sequence of operations, different to the first sequence of operations, wherein the first and second sequences of operations respectively form at least part of first and second processes for assembling smoking articles, each smoking article comprising one of said rods of smokable material, wherein the first inserter, the first rod divider, and the separator each include a respective drum forming a conveyance path through the modules.

25. The method as claimed in claim 24, further comprising: making said rods of smokable material at a tobacco rod maker; and transferring said rods of smokable material directly from the tobacco rod maker to the modular apparatus.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order that the invention may be more fully understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0044] FIG. 1 is a schematic showing elements of a cigarette manufacturing apparatus;

[0045] FIG. 1A shows a module of a first type;

[0046] FIG. 2 shows a module of a second type;

[0047] FIG. 2A shows one or more tobacco and filter rods processed by the module of FIG. 2;

[0048] FIG. 3 shows a module of a third type;

[0049] FIG. 3A shows one or more tobacco and filter rods processed by the module of FIG. 3;

[0050] FIG. 4 shows a module of fourth type;

[0051] FIG. 4A shows one or more tobacco and filter rods processed by the module of FIG. 4;

[0052] FIG. 5 shows an arrangement of modules;

[0053] FIG. 6a shows a Max S unit;

[0054] FIG. 6b illustrates a modification to a Max S unit;

[0055] FIG. 7 shows an arrangement of modules linked to the modified Max S unit for making a first type of cigarette, and FIG. 7a illustrates the corresponding cigarette assembly process;

[0056] FIG. 8 shows an arrangement of modules for making a second type of cigarette, and FIG. 8a illustrates the corresponding cigarette assembly process;

[0057] FIG. 9 is a perspective view of the base unit of the modules of FIGS. 2, 3 and 4 mounted with four drums;

[0058] FIG. 10 is the perspective view of FIG. 9, with one drum removed;

[0059] FIG. 11 is a schematic illustrating the regions where suction is applied to the drums, and the direction of rotation of the drums;

[0060] FIG. 12 is the perspective view of FIG. 10 with a suction control element and suction housing removed;

[0061] FIG. 13 is view of the base unit of FIG. 9 from behind; and

[0062] FIG. 14 illustrates a variation of the module of FIG. 1A.

DETAILED DESCRIPTION

[0063] FIG. 1 is a schematic showing elements of a cigarette manufacturing apparatus 100.

[0064] Apparatus 100 comprises a tobacco rod maker 101 and a cigarette assembly machine 104. As shown, cigarette assembly machine 104 comprises a modular apparatus, which includes a group 102 of modules 102a arranged in row, and a filter attachment unit 103. As shown the modules 102a of FIG. 1 are positioned between tobacco rod maker 101 and filter attachment unit 103, and receive tobacco rods directly from tobacco rod maker 101.

[0065] Modules 102 may be configured in different ways to provide different manufacturing options in which different types of cigarette are produced by apparatus 100. Modules 102 may be reconfigured to produce different cigarette types by adding/removing module(s), repositioning modules relative to one another and/or reconfiguring individual modules. In this way, a flexible cigarette assembly machine is provided which facilitates changes in the type of cigarette produced.

[0066] FIGS. 1A, 2, 3 and 4 illustrate exemplary modules 1, 2, 3, 4, and FIGS. 7 and 8 illustrate exemplary configurations of the modular apparatus 102, 103. The configuration of FIG. 7 forms cigarettes having triple-segment filters, discussed in more detail below. The configuration of FIG. 8 forms cigarettes having an extendible filter, discussed in more detail below.

[0067] FIG. 1A shows a module 1 of a first type. The module 1 comprises a base unit 5, which is fitted with a plurality of drums 6, 7, 8 for conveying rod articles through the module 1. The drums 6, 7, 8 include a takeover drum 6, a cutting drum 7 and a separating drum 8. The takeover drum 6 is configured to receive double-length tobacco rods from a tobacco rod making machine. The tobacco rods are conveyed by the takeover drum and passed to the cutting drum 7. As shown cutting drum 7 has a circular knife 7a configured to cut each double length rod into two tobacco rods, which are fed from the cutting drum to separating drum 8. Separating drum 8 is configured to longitudinally separate the two tobacco rods and then feed them out of the module 1. Separating drum 8 is of a known type having four segments on each side which have cam followers running in a track cam. The segments holding the tobacco rods can move from inner to outer position to create a gap between the tobacco rods.

[0068] FIG. 2 shows a module 2 of a second type. As shown, this module 2 includes a base unit 9, which is fitted with a feed drum 10, a cutting drum 11 and circular knife 11a, an intermediate drum 12 and a separating drum 13. As shown, drums 10, 11, 12, 13 form a conveyance path for rod articles through the module 2.

[0069] The module 2 is configured to cut a central rod in a group of received rod articles into two segments, and to then separate the cut segments to form two spaced rod groups.

[0070] As module 2 is configured to cut a central rod in a group of received rod articles into two segments, and to then separate the cut segments to form two spaced rod groups.

[0071] In some exemplary configurations, rather than receiving two tobacco rods together with a single centrally positioned filter rod, the module 2 may alternatively be configured to receive two tobacco rods together with three filter rods positioned centrally between the tobacco rods. In this case, the cutting drum 11 may be configured to cut the central filter rod at a central point into two segments and the separating drum 12 may be configured to separate the rods into two groups such that each group includes one of the cut segments, one rod which has not been cut by the cutting drum 11, and one tobacco rod.

[0072] It will be appreciated that in other configurations, the module 2 may receive two tobacco rods together with five filter rods, or another odd number of filter rods. In some examples, the centrally positioned filter rod or rods may be attached to the tobacco rods (and/or one another) with one or more wrappers when received by the module 2.

[0073] In some embodiments, some or all of the filter rods may be multi-segment filter rods. Alternatively, the filter rods may be single-segment rods.

[0074] FIG. 3 shows a module 3 of a third type. The module 3 of FIG. 3 is the same as the module 2 of FIG. 2, except that the module 3 further comprises a filter feed mechanism 16. Thus, the same reference numerals are retained for corresponding features. The module 3 acts to receive two tobacco rods which are longitudinally separated by a gap, insert a filter rod into the gap, cut the inserted filter rod into two segments and then separate the cut segments to form two spaced rod groups.

[0075] Suitable filter feed mechanisms 16 for the module 3 are known per se. For example, feed mechanisms from known “Max S” and “Max 90” machines may be used. The filter feed mechanism may be arranged to output a desired type of rod article, for example 2-up, or alternatively 4-up filter rods. As shown in FIG. 3, the feed mechanism 16 has an input 17 for receiving filter rods and an output 18 located for feeding filter rods onto the feed drum 10. The filter feed may also include a cutting mechanism to cut each received rod into filter two rod segments, which are then fed onto the feed drum. For example, the filter feed mechanism may receive 4-up rods, cut each 4-up rod into two 2-up rods and then feed each 2-up rod onto the feed drum. Alternatively, the filter feed mechanism may receive filter rods of a different length, for example 6-up rods, and in some configurations cut the received rods to make segments of a desired length.

[0076] Thus, the module 3 may receive tobacco rods from a preceding module, and also filter rods from the feed mechanism 16. The tobacco rods are received on the feed drum spaced by a suitable gap, the gap being sized to receive a rod article from the feed mechanism 16.

[0077] As illustrated in FIG. 3a, in some configurations, a groove of the feed drum 10 may receive two aligned tobacco rods 14 from a preceding module, the tobacco rods being separated by a gap. The filter feed mechanism may be configured to place a 2-up filter 15 in the gap as the tobacco rods are being conveyed by the feed drum. The cutting drum 11 is configured to cut the inserted filter rod 15 centrally and the separating drum 12 is configured to separate the rods into two groups such that each group includes a filter segment 15a and one tobacco rod 14. The two groups are then fed out of the module 3.

[0078] In other configurations, the module 3 may receive two tobacco rods together with two filter rods from a preceding module so that the four rods are aligned in a groove of the feed drum 10. The rod articles may be received with a central gap sized for receiving a further “2-up” filter rod. In this case, the module 4 may be configured to 1) insert a 2-up filter in the gap, 2) cut the inserted filter rod into two rods and then 3) separate the rods into two groups such that each group includes a cut segment of the inserted rod, one of the filter rods received from the previous module, and one of the tobacco rods.

[0079] FIG. 4 shows a module 4 of a fourth type. As shown, the module 4 includes a base unit 9, which is fitted with a filter feed 16, a feed drum 19, a swash plate drum 20, a rolling drum 21, a roll hand 22, a transfer drum 23, a tipper unit 24 and a glue unit 25. The module 4 is configured to insert a rod article such as a filter rod between two received tobacco rods, and to apply a wrapper in the form of a tipping paper.

[0080] As illustrated in FIG. 4a, the feed drum 19 may receive two tobacco rods from a preceding module. The tobacco rods may be separated by a gap sized to receive a “2-up” filter rod. The filter feed is arranged to fit a 2-up filter rod into the gap. The swash plate drum 20, rolling drum 21, roll hand 22, tipper unit 24 and glue unit 25 then cooperate to wrap the three rods with a tipping paper to join them together, in a manner which is well known to those skilled in the art. In more detail, the swash plate drum acts to longitudinally compress the three rod articles, and a glue lined patch of tipping paper is then applied on the rolling drum to join the three rod articles together. The joined group of two tobacco rods and one double length filter rod are then fed out of the module 4 by the transfer drum 23.

[0081] As mentioned above, the tipper unit 24, glue unit 25 and rollhand 22 are well known components per se, but a brief description of these components will nonetheless now be given.

[0082] Tipper Unit

[0083] The tipper unit 24 has carbide knives cutting against a carbide drum, which cuts the tipping paper to a required length. The tipping patches are then transferred by the carbide drum (tipping drum) onto the cigarettes. The length of the tipping patches is determined by the feed roller which is mounted before the glue unit, and can be varied. The patch length is usually equal to the cigarette circumference plus about 2 mm. The tipper unit can apply patches of different widths depending on the width of the tipping paper used.

[0084] Glue Unit

[0085] The glue unit 25 includes a glue roller which runs in the glue. This roller then transfers the glue to the transfer roller. The paper runs over the transfer roller to transfer the glue from the roller to the paper.

[0086] Rollhand/Rolling Drum

[0087] The rollhand 22 is a static curved block which sits below the rolling drum 21. When the cigarettes, which are on the rolling drum, get to the entry point of the roll hand a scraper pushes the cigarette out of the groove and it is then rolled between the drum and roll hand till the cigarette falls into the next groove.

[0088] Rather than receiving two spaced tobacco rods, in some configurations the module 4 may receive two tobacco rods together with two filter rods, the rod articles being received from a preceding module. The received filter rods may be separated by a gap sized to receive a further 2-up filter. The feed mechanism 16 may be arranged to insert a 2-up filter into the gap. In this case the swash plate drum acts to compress the five rod articles together and the inserted rod is wrapped with a tipping paper on the rolling drum to join it to the rods received from the previous module.

[0089] In some configurations, the module 4 may apply tipping in two separated bands. The configuration for applying banded tipping is the same as for application of conventional tipping, but a slitting knife is also included to split the single tipping band into 2 bands. Also, paper guides are provided to open the two bands to the required positions before gluing. The tipping band is slit after the splicing unit and scraper (not shown), at a position before the glue applicator.

[0090] In embodiments, the filter rods which are inserted by the modules 2, 4 may comprise multiple segments, ie: they may comprise multi-segment rods formed for example of a central “double length” rod segment with two “single length” rod segments to either side of the central segment. Alternatively however, in some embodiments the filter rods which are inserted may be single-segment rods.

[0091] The modules described above may be linked together in different arrangements to provide different sequences of operations for forming the same or different types of cigarettes.

[0092] The final drum of one module may be aligned with the initial drum of the next module so that rods pass from the out-feed of one module to the in-feed of the next.

[0093] Still further flexibility can be achieved by reconfiguring individual modules. The modules 2, 3 and 4 of FIGS. 2 to 4 share a base unit 9 having four drum-receiving shafts, each adapted for removably receiving a drum. Thus, each of the drums on the modules 2, 3 and 4 may be replaced with another suitable drum so as to vary the functionality of the module. For example, the cutting drum 11 of FIG. 2 can be replaced with a transfer drum or a swash plate drum. The intermediate transfer drum 12 of FIG. 2 can be replaced with a rolling drum, transfer drum, ejection drum, laser drum or other suitable drum. Other components may also be added/removed, for example a filter feed, tipper unit, gluing unit, rolling device and a laser for laser perforation.

[0094] The module 2 of the second type can thus be converted to a module 3 of the third type by a reconfiguration process comprising adding a filter feed 16. Furthermore, the module 3 of the third type can be converted to a module 4 of the fourth type by a reconfiguration process comprising replacing the cutting drum 11 with a swash plate drum 20, replacing the intermediate transfer drum 12 with a rolling drum 21, replacing the separating drum 13 with a transfer drum, and adding the tipper unit 24, the glue unit 25 and the roll hand 22.

[0095] In replacing a drum on the base unit 9, a replacement drum typically has the same number of grooves as the drum which it replaces. In FIGS. 2, 3, 4, the first drum 10, 19 may have 20 grooves, the second drum 11, 20 may have 20 grooves, the third drum 12, 21 may have 22 grooves and the fourth drum 13, 23 may have 20 grooves.

[0096] FIG. 9 is a perspective view showing the base unit 9 fitted with a feed drum 19, swash plate drum 20, roll drum 21 (and roll hand 22), and transfer drum 23. As shown, each drum 19, 20, 21, 23 is mounted on a shaft 19a, 20a, 21a, 23a which rotates the drum. As illustrated in FIG. 10, each drum can be unscrewed and detached from its shaft so that another drum can be alternatively fitted.

[0097] As shown in FIGS. 9 and 10, the base unit 9 include a suction housing 200 which applies suction for holding rod articles on the drums 19, 20, 21, 23 and for transferring rod articles from one drum to the next. Referring to FIG. 10, suction housing 200 is in communication with suction control elements 201, which each have a suction outlet 202 shaped to selectively apply suction to appropriate points during rotation of the corresponding drum.

[0098] FIG. 11 is a schematic which illustrates with shading the regions in which suction is applied by the suction control elements, and the direction of rotation of the drums 19, 20, 21, 23.

[0099] Some drums may be replaced without changing the suction control element. For example, the intermediate drum 12 of the module 2 may be replaced by a cutting drum 11 without changing the suction control element. In some cases however the suction element may be changed before a new drum is fitted.

[0100] FIG. 12 shows the base unit 9 with drum 19 and its suction control element 201 removed, and with the suction housing 200 also removed. As shown, vacuum may be applied to suction housing 200 via a hole 203 in the base unit 9.

[0101] FIG. 13 is a rear view of the base unit 9. As shown, the base unit includes a gearbox 205 configured to turn the four drums synchronously. In use, one of the shafts is driven by a servo motor (not shown) to turn the drums.

[0102] Turning again to FIG. 9, as shown the base unit 9 has a joining member 204 at either end to overlap with complementary joining members on other modules. The joining members 204 ensure that the final drum on one module is automatically aligned with the first drum of the next module when two modules are engaged together.

[0103] FIG. 5 shows one possible configuration of modules 26, in which modules 2, 4, 3, 1 of the second, fourth, third and first type are arranged one after the other in a row. Each module may include a gearbox configured to synchronise rotation of the module drums, and may have a servo motor to drive the drums. The servo motors of each module may be synchronised with one another so that rotation of all of the drums in a particular arrangement are synchronised. Other components, e.g: tipper unit, glue unit, may be driven by further servo motors. These further servo motors may also be appropriately synchronised with the servo modules used to drive the module drums.

[0104] The combination of modules 26 may be linked to a filter attachment unit such as a modified Max S unit to carry out further processing. FIG. 6a illustrates a commercially available Max S machine 27 and FIG. 6b illustrates a modified machine 28 adapted for use with the modules 1, 2, 3, 4. As shown, the modified machine 28 of FIG. 6b differs from the known machine 27 only in that the infeed section 27a is removed in the modified machine 28.

[0105] The modified unit 28 differs from the known unit 27 only by the absence of the infeed unit 27a, it will not be described in any further detail here.

[0106] Although FIGS. 6a and 6b show a modified Max S, any filter attachment unit could alternatively be linked to the modules, for example a commercially available machine such as a GD AF12 or a Max 90 unit modified in a similar manner as described above, i.e.: by removing the infeed section. Where a Max 90 is used for example, the modified unit can carry out all of the functions of a Max 90, which include: addition of a filter rod, tipping application and rolling, laser perforation, cutting, turning cigarettes, inspections and a link-up to a tray filler.

[0107] FIG. 7 shows an arrangement of successive modules 29 linked to a modified Max S unit 28 for making a particular type of cigarette. As shown, the arrangement 29 includes a module 1 of the first type, a module 3 of the third type, a module 4 of the fourth type and a module 2 of the second type, arranged successively in a row and linked to a modified Max S unit 28. The first module 1 receives a “double length” tobacco rod from a tobacco rod maker (not shown), and the received tobacco rod is caused to undergo a sequence of operations in the modules 1, 3, 4, 2 and subsequently in the Max S unit 28 to form a filter cigarette 30. As shown in FIG. 7a, the eventual cigarette 30 includes a triple segment filter and is wrapped with two separate tipping papers separated longitudinally by a gap 31.

[0108] FIG. 7a illustrates the sequence of operations carried out by the machinery of FIG. 7. Each box in FIG. 7a illustrates the operations which occur in one of the modules. As shown, each box is labelled with the reference sign of one of the modules 1, 3, 4, 2 to indicate that the operations illustrated in the box occur in the referenced module.

[0109] Referring to FIG. 7a, in the module 1, a “double length” tobacco rod 32 is received from a tobacco rod maker (not shown) and cut into two equal segments 32a, 32b. The two segments are then separated and the separated segments are fed into the next module 3.

[0110] In the module 3, a 2-up filter rod 33, supplied by the module's filter feed mechanism, is inserted in the gap between the two separated tobacco rods 32a, 32b received from the module 1. The filter 33 is then cut centrally into two segments 33a, 33b. A first group 34a comprising one tobacco rod 32a and one filter rod segment 33a is then separated from a second group 34b comprising one tobacco rod 32b and one filter rod segment 33b, and the two separated groups 34a, 34b are fed onto the first drum of the next module 4.

[0111] In the next module 4, a further filter rod 35 is added in the gap between the two separated groups 34a, 34b. The module 4 then applies tipping in two separated bands 36a, 36b. The first band 36a is wrapped around the tobacco rod 32a, the rod segment 33a and the further rod 35 to join these three rods together. The second band 36b is wrapped around the tobacco rod 32b, the rod segment 33b and the further rod 35 to join these rods together. Thus, filter 35 is joined to a filter segment 33a from the first group 34a and to a segment 33b from the second group 34b by wrapping with the bands 36a, 36b. The wrapped rods 34a, 34b, 33a, 33b, 35 are then fed to the next module.

[0112] In the next module 2, the centrally positioned double length filter rod 35 is cut into two segments 35a, 35b. A first group of rods G1 comprising a filter rod segment 33a, a filter rod segment 35a and a tobacco rod 32a is then separated from a second group of rods G2 comprising a filter rod segment 33b, a filter rod segment 35b, and a tobacco rod 32b. The separated groups G1, G2 are then fed to the first drum of the modified Max S machine 28, as shown in FIG. 7.

[0113] As illustrated in FIGS. 7 and 7a, the modified Max S unit has a filter feed 38 which inserts a 2-up filter rod 37 between the group G1 and the group G2. The 2-up filter rod 37 is then joined to the filter rod segment 35a of the group G1 and to the filter rod segment 35b of the group G2 by wrapping with a single wrapper 39. The wrapper 39 is sized so that it does not overlap with the bands 36a, 36b. Instead, the wrapper 39 is sized so that there is a gap 31 between each end of the wrapper 39 and the bands 36a, 36b.

[0114] The wrapped 2-up filter rod 37 is then cut centrally into two segments 37a, 37b to form two cigarettes 30 which are turned so as to adopt a parallel configuration. As shown, the two cigarettes 30 are identical, and each includes three filter segments 37a, 35a, 33a and two wrappers, the wrappers being longitudinally separated by a gap 31.

[0115] FIG. 8 shows an alternative configuration 40 of successive modules for making a different type of cigarette 41. The eventual cigarette 41 is of the extendible (telescopic) type, in which two filters can be separated by a variable amount by sliding an outer sleeve. Telescope cigarettes are known per se, from for example FR 1547656.

[0116] As shown, the configuration 40 comprises six modules 51, 52, 53, 54, 55, 56.

[0117] The first module 51 is the same as the module 1 of FIG. 1A.

[0118] The second module 52 is the same as the module 4 of FIG. 4.

[0119] The third module 53 comprises a modified version of the module 2 of FIG. 2. The third module 54 is different to the module 2 of FIG. 2 in that the first drum (feed drum 10) has been replaced with a cutting drum, the second drum (cutting drum 11) has been replaced with a separating drum, and the fourth drum (separating drum 13) has been replaced with an inspection drum to inspect for the presence of filters.

[0120] The fourth module 54 is the same as the module 4 shown in FIG. 4.

[0121] The fifth module 55 comprises a modification of the module 4 shown in FIG. 4. The module 55 is different to the module 4 in that the filter feed 16 has been removed and in that the fourth drum (transfer drum 23) is replaced with a laser drum to form perforations in the cigarette.

[0122] The sixth module 56 is a module comprising four drums 56a, 56b, 56c, 56d. The first drum 56a is a cutting drum, the second drum 56b is a transfer drum, the third drum 56c is a turning drum and the fourth drum 56d is an inspection drum configured to perform a leakage test on the cigarettes. The turning drum is known per se, and may be configured to turn the front row of cigarettes over to have the same orientation as the rear row, or may alternatively be configured to turn the rear row of cigarettes over to have the same orientation as the front row.

[0123] A further module may also be provided (not shown) including final end scanners and an ejection drum which serves as a link-up to further downstream machines.

[0124] FIG. 8a illustrates the sequence of operations carried out the form the cigarette 41. Each box in FIG. 8a illustrates the operations which occur in one of the modules 51, 52, 53, 54, 55, 56. As shown, each box is labelled with the reference sign of one of the modules 51, 52, 53, 54, 55, 56 to indicate that the operations illustrated in the box occur in the referenced module.

[0125] As shown, the module 51 is an infeed module configured to receive “double length” tobacco rods 60, for example from a tobacco rod maker. In the module 51, each tobacco rod 60 is cut into two segments 60a, 60b, which are separated and fed into the next module 52.

[0126] The next module 52 is configured to insert a 2-up filter rod 61 between the separated tobacco rods received from the module 52, and to wrap the three rods 60a, 60b, 61 with a wrapper 62 to join them together. The wrapped rods are then fed into the next module 53.

[0127] The next module 53 is configured to cut the filter rod 61 into two segments 61a, 61b, and to separate the segments to form two groups, each comprising a tobacco rod 60a, 60b joined to a filter rod segment 61a, 61b. Each group forms an inner cigarette C of an eventual extendible cigarette 41. The inspection drum then carries out an inspection for the presence of filters. The separated inner cigarettes C are then fed to the next module 54.

[0128] The next module 54 is configured to insert a further filter rod 63 between the filter segments 61a, 61b and to wrap a wide tipping paper patch 64 around the tobacco rods 60a, 60b, the filter rod segments 61a, 61b and the filter rod 63. The glue unit is configured to apply glue to the tipping patch 64 so that the tipping patch 64 is only glued to the centre filter rod 63 and on the overlap of the tipping, so as to form a tube which is only attached to the centre rod 63. The wrapped rods are then fed to the next module 55.

[0129] The next module 55 is configured to apply a further tipping patch 65 around the tipping patch 64 so that it overlaps with the tipping patch 64. The laser drum then applies a pulsed beam to make small perforations through the tipping layers 64, 65.

[0130] The next module 56 is configured to cut the filter 63, through the tipping layers 64, 65 so as to divide the filter 63 into two segments 63a, 63b and thus form two extendible cigarettes 41a, 41b. The turning drum then turns the two cigarettes 41a, 41b so that they are parallel to one another.

[0131] As described above, the inner cigarette C of each extendible cigarette 41a is not glued to the tipping layers 64, 65, so that the inner cigarette C can be slid in the tube formed by the tipping layers 64, 65 to vary the separation between the filter rod 61a, 61b and the filter rod 63a, 63b.

[0132] The modules can be reconfigured to vary the cigarette assembly process as desired, for example by replacing one or more of the drums. Also, the modules can be repositioned relative to one another and/or one or more modules may be added/removed so as to provide yet further cigarette assembly options.

[0133] Many further modifications and variations are possible. For example, although the module 1 of FIG. 1A receives “double length” tobacco rods one at a time from a tobacco rod maker, in some example multiple “double length” tobacco rods may be received at a time, for example from a “double track” tobacco rod maker. FIG. 14 shows a variation of the module 1 of the first type for use with a “double track” tobacco rod maker which makes two tobacco rods at a time. As shown, the modified module 1 of FIG. 14 has a modified take over drum 6a for receiving the two tobacco rods, and two additional intermediate transfer drums I1, 12. As shown, the takeover drum 6a has a plurality of pivoted arms, which each swing out sequentially in use to collect two tobacco rods from the maker. As the drum rotates further in an anticlockwise direction, the arms fall back into position against the drum. As illustrated in FIG. 14, the arms then deliver tobacco rods one at a time to the first intermediate transfer drum II.

[0134] Other modules may also be included in certain configurations to carry out other operations. For example, a discharge module may be included in some arrangements to discharge assembled rod articles at different heights. The discharge module may be configured to discharge rods articles at a particular height for linking to a mass flow feed, for example to a conveyor to carry discharged rod articles to further machinery for further processing. Alternatively, the discharge height may be varied when discharge to a packaging machine is required, or when discharge to a tray filler for storage is required.

[0135] Further, although coupling filter rods to tobacco rods is described above, in some configurations a module may insert a component other than a filter rod, e.g: a rod article such as a tobacco rod, or a rod element comprising one or more plastic elements, e.g: twistable elements having first and second parts which can be rotated relative to one another to change the characteristics of a smoking article, as described for example in EP0395291A1.

[0136] According to various embodiments of the present invention, modules may carry out one or more of the following operations: transfer, insert separate, wrap, rotate, inspect, reject, press-together, laser-cut, turn, sample cigarettes for test, roll tipping. In embodiments, each module carries out two or more of these operations. Each individual operation may be carried out by a single functional unit (e.g: by a single drum).

[0137] As will be appreciated from the foregoing, the drums of the modules may be selected so that each module carries out a selected sequence of assembly operations. Also, the number of modules and their relative position may be chosen so that the modules carry out their respective assembly operations sequentially in a selected order.

[0138] 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 methods. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. 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.