Apparatus and method for making a smoking article
10231478 ยท 2019-03-19
Assignee
Inventors
Cpc classification
International classification
A24C5/00
HUMAN NECESSITIES
Abstract
An apparatus for making a smoking article, the smoking article having a rod of smoke able material (15) and a cylindrically wrapped layer of sheet material, comprises a holder (3) for holding sheet material, an embossing unit (8) configured to emboss sheet material drawn from the holder and an assembling station (14) for assembling the smoking article, configured to receive embossed sheet material from the embossing unit and to wrap the embossed sheet material at least partially around a part of the smoking article.
Claims
1. An apparatus for making a smoking article having a rod of smokeable material and a cylindrically wrapped layer of sheet material, the apparatus comprising: a holder for holding sheet material; an embossing unit configured to emboss sheet material drawn from the holder; the embossing unit comprising first and second rollers arranged to form an embossed pattern on the sheet material as it is passed between the rollers, and the first roller having an embossing section comprising one or more embossed patterns extending around a first portion of the periphery of the first roller configured to emboss the sheet material when said first portion faces the second roller, and a non-embossing section extending around a second portion of the periphery of the first roller configured such that when the second portion faces the second roller, the embossing section does not contact the sheet material and the sheet material passes through the embossing unit independently of the rotation of the embossing rollers; a smoking article assembling station, configured to receive embossed sheet material from the embossing unit and to wrap the embossed sheet material at least partially around a part of the smoking article; a controller which determines an embossing position of the sheet material such that a print pattern on the sheet material and the embossed pattern are in register; and a positioning unit which positions the sheet material in the embossing position when the non-embossing section of the first roller faces the second roller.
2. The apparatus according to claim 1, wherein the sheet material is tipping paper.
3. The apparatus according to claim 1, wherein the sheet material comprises a cellulose based material.
4. The apparatus according to claim 1, wherein the assembling station is configured to assemble the smoking article by joining a filter rod to the rod of smokeable material by wrapping the filter rod at least partially with the embossed sheet material.
5. The apparatus according to claim 4, wherein the assembling station is configured to assemble a pair of smoking articles, each having a rod of smokeable material, by: joining the filter rod to the pair of rods of smokeable material by wrapping the filter rod at least partially with the embossed sheet material; and cutting the wrapped filter rod.
6. The apparatus according to claim 1, wherein the assembling station is configured to wrap the embossed sheet material around the rod of smokeable material.
7. The apparatus according to claim 1, further comprising a detector for detecting a position of the print pattern and wherein the controller is configured to determine the embossing position according to the detected position of the pattern.
8. The apparatus according to claim 7, wherein the controller is further configured to: determine whether the detector has detected a change in the position of the printed pattern; and display an error message if the detector has not detected a change in the position of the print pattern.
9. The apparatus according to claim 1, wherein the sheet material is wrapped around the filter rod such that a first region of the sheet material overlaps with a second region of the sheet material; and wherein the non-embossing section is arranged such that the embossing unit does not form the embossed pattern on the second region.
10. The apparatus according to claim 1, wherein the controller is further configured to: determine whether the print pattern is within tolerance; and reject the smoking article if the print pattern is not within tolerance.
11. The apparatus according to claim 1, wherein the controller is configured to send a signal to the positioning unit and thereby control the positioning unit to position the sheet material in the embossing position.
12. The apparatus according to claim 1, further comprising a tensioning unit for adjustably fixing the sheet material tension at a required level.
13. The apparatus according to claim 1, further comprising a conveyor for conveying the sheet material through the apparatus.
14. The apparatus according to claim 4, wherein the sheet material is wrapped around the filter rod such that a first region of the sheet material overlaps with a second region of the sheet material; and wherein the sheet material is arranged such that the embossing unit does not form an embossed pattern on the second region.
15. The apparatus according to claim 2, further comprising a cutting unit for cutting the tipping paper, the cutting unit having a knife drum and a vacuum drum, wherein the vacuum drum rotates faster than the knife drum.
16. The apparatus according to claim 1, wherein the sheet material is wrapped such that a first region of the sheet material overlaps with a second region of the sheet material.
17. The apparatus according to claim 16, wherein the non-embossing section is arranged such that the embossing unit does not form an embossed pattern on the second region.
18. The apparatus according to claim 1, wherein the non-embossing section does not contact the sheet material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In order that the invention may be more fully understood, embodiments thereof will now be described by way of illustrative example with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION
(12) Referring to
(13) The tipping paper 5 may be pre-printed with printing or a pattern. The pattern on the tipping paper may include a plurality of logos associated with a particular brand of cigarette.
(14) The machine 1 includes a tensioning arm 6 which is arranged to adjustably fix the tipping paper tension at a required level.
(15) The machine 1 includes registration rollers 7 which may draw the tipping paper ribbon 5 from the holder 2 and which may be driven by a motor (not shown) such as a servo motor. The motor may be controlled by a controller that will be described hereinafter with reference to
(16) The machine 1 includes an embossing unit that includes a pair of embossing rollers 8 which are arranged to form an embossed pattern on the tipping paper. One or both embossing rollers may be engraved with one or more patterns so as to form an embossed pattern on tipping paper as it is passed between the rollers. The embossing roller speed may be determined by machine speed, registration roller speed, or drive roller speed. The embossing rollers may be fitted in place of the usual tipping paper pulling rollers of a conventional cigarette making machine.
(17) One of the embossing rollers 8 has a peripheral section which does not emboss. The section which does not emboss is arranged such that it does not contact the tipping paper during rotation of the rollers. Accordingly, when the rotational position of the embossing roller is within a predetermined range, the embossing roller does not make contact with the tipping paper. Thus, the registration rollers can adjust the tipping paper position without the paper contacting the embossing roller, and may thereby adjust the tipping paper position independently of the rotation of the embossing roller. Therefore, the registration rollers can position the print pattern relative to the embossed pattern formed by the embossing roller by advancing or retarding the print pattern when the embossing rollers are not embossing. Although the section which does not emboss has been described above as being disposed on one of the embossing rollers, each of the embossing rollers 8 may have a section which does not emboss.
(18) The machine 1 includes a photocell 9 for detecting the location or position of a printing or pattern on the tipping paper, in this instance, a V logo or V logo pair pre-printed on the ribbon 5.
(19) The controller, or other means, may determine an embossing position of the tipping paper in dependence on the detected location or position of the pattern on the tipping paper. The embossing position is determined such that tipping paper in the embossing position is embossed with a pattern in register with the printing or pattern on the tipping paper.
(20) The machine 1 also includes gummer rollers 10 for applying glue to the tipping paper to prepare it for attachment to the filters and tobacco rods that are assembled into cigarettes.
(21) The machine 1 also includes a cutting unit 11 for cutting the tipping paper ribbon 5 into segments 5a, 5b, 5c etc for use in attaching filters to individual cigarettes. The cutting unit 11 comprises a knife drum 12 and a vacuum drum 13. In operation, the vacuum drum may rotate faster than the knife drum to ensure that cut tipping paper is taken away before the next piece is cut. A gearing mechanism, coupled to the drums, may be employed to achieve the required difference in rotational speed. The cutting speed may be determined from the machine speed, registration roller speed or drive roller speed. Thus, the cutting speed and the embossing roller speed may be interdependent. Encoder information may be sent to the controller in order to adjust servo speeds to ensure correct offset with the cutter. The controller may be configured to control the cutting unit such that each cut piece of tipping paper has a single printed sub-pattern and a single embossed sub-pattern.
(22) The cigarette making machine also includes an assembling station 14 configured to assemble cigarettes. Referring to
(23) An assembled cigarette 18 thus comprises a filter 19, a rod of generally cylindrically paper wrapped tobacco 15 and a generally cylindrically wrapped segment of tipping paper 5a1. The segment 5a1 is thus glued to the periphery of the filter 19, which may comprise a tow of cellulose acetate material wrapped with a plugwrap (not shown). As shown, the segment of tipping paper 5a1 overlaps the end of the tobacco rod where it abuts the filter 19 and is glued thereto so as to hold the filter and tobacco rod together. The tipping paper 5a1 is printed with a V symbol and is embossed with a V symbol in register with the printed symbol.
(24) The described cigarette making machine has the advantage that the embossing of the logo on the tipping paper 5 is carried out as the ribbon unwinds from the bobbin 2 with the advantage that the embossing is not crushed by the tension of the ribbon in the bobbin, as would occur if the ribbon was pre-embossed before being wound on to the bobbin.
(25)
(26) Operation of an apparatus for making a smoking article is described in
(27) In step B1, a bobbin of pre-printed tipping material web is loaded onto the holder 1.
(28) In step B2, the tension arm 6 adjusts paper tension in the ribbon 5 to a required level.
(29) In step B3, the photocell 9 detects the location of a printing on the tipping paper.
(30) In step B4, the location information is passed to the servo control motors of the registration rollers 7.
(31) In step B5, the registration rollers 7 speed up or slow down and position each printed logo on the ribbon at a required location relative to the embossing head 8.
(32) In step B6, the paper ribbon 5 is embossed in register with the pre-printed logo.
(33) In step B7, the gummer rollers 10 apply glue to the ribbon.
(34) In step B8, the cutting unit 11 cuts the paper into individual segments.
(35) In step B9, the segment of the cut tipping paper 5 is wrapped around the cigarette or cigarette pair.
(36) The cigarette making machine 1 may be electronically controlled by means of a control loop. The control loop process is graphically described in
(37) The printed logo on the ribbon 5 may be initially registered in relation to the embossing rollers 8 upon start-up of the machine and a continuous feedback process may then be used to ensure that the print remains within tolerance. If a print is found to be outside of the tolerance range then a message may be sent to an appropriate part of the cigarette making machine to reject this cigarette at a later stage. It may be determined whether the print is within tolerance, or whether the print is too advanced, or lagging, by detecting the position of the print using the photocell 9.
(38) The control process also flags up errors that have occurred with the photocell on machine start up. In particular, any errors that have occurred with the photocell on machine start up which deem the machine incapable of registering print may be flagged up. This is performed by means of a machine function test. The machine function test includes a step of moving the paper ribbon 5 along a certain distance and a step of determining whether the photocell 9 has recognised and responded to the resulting change in conditions.
(39) The printed paper may be registered to an emboss and to the lap seam of the tipping paper via an encoder on the cigarette making machine or maker to ensure that the emboss does not occur on the lap seam and that both the emboss and the print are a certain distance away from the edge of the paper.
(40) The control process also functions to re-align the printed pattern on the tipping paper to the embossed pattern formed by the embossing rollers by either pulling back on the paper or accelerating the paper forward incrementally. As described hereinabove, an embossing roller may have a pre-positioned non-embossing region such that the embossing roller does not make contact with the paper when the rotational position of the embossing roller is within a predetermined range. Thus, the print pattern can be adjusted relative to the embossed pattern formed by the embossing roller by pulling back on the paper or accelerating the paper forward incrementally when the embossing rollers are not embossing.
(41) The position of the paper is continuously fed back into the system, and movements are made when the print is out of tolerance and when the print is within tolerance but is still deemed not directly in line with the emboss.
(42) The value of X is shared amongst the processes described in
(43) The value x designates the tolerance in mm that the print must be within for a cigarette to be accepted.
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(46) The photocell function test C5 is shown in more detail in
(47) In step P1 of the photocell function test C5, it is determined whether the photocell has detected a change. If the photocell has not detected a change, a REJECT CIGARETTE signal is sent to the maker, as shown in block P2, and the present cigarette is rejected.
(48) In step P3 it is determined whether the previous change was detected by the photocell. If the previous change was detected, the value of X is set to 1. This step is represented in block P4 as log figure X=1. If the previous change was not detected, the value of X is increased by 1 and the new value is stored. This step is represented in block P5 as log figure X=X+1.
(49) In step P6, it is determined whether X is greater than , where is a predetermined number.
(50) If the value of X exceeds , the machine is stopped, as shown in block P7 and a M/C Error message is displayed, as shown in block P8. Thus, the method stops the machine if the number of errors which have occurred in a row is excessive. If the photocell has detected a change, the value of X is reset to zero, as shown in block P9.
(51) The advanced print process C6 is shown in more detail in
(52) In step AP1, it is determined whether the print is too advanced. If the print is too advanced, it is determined whether the print is within tolerance of x mm, as shown in block AP2. x is a predetermined tolerance value. If the print is not within a tolerance of x mm, a REJECT CIGARETTE signal is sent to the maker, as shown in block AP3, and the instant cigarette is rejected.
(53) In block AP4, it is determined whether the previous cigarette was out of tolerance. If the previous cigarette was not within tolerance, the value of X is set to 1. This step is represented in block AP5 as log figure X=1. In step AP6, it is checked whether movement can be made. As shown in block AP7, it is then determined whether the embossing roller is contacting the paper. If the embossing roller is not contacting the paper, it is determined whether the knives are contacting the paper, as shown in block AP8. If none of the conditions of steps AP7 or AP8 are true, the registration rollers are retarded in order to pull back the paper, as shown in block AP9.
(54) If the previous cigarette was out of tolerance, the value of X is increased by 1 and the new value is stored. This step is represented in block AP10 as log figure X=X+1. In step AP11, it is determined whether X is greater than . If X is greater than , the machine is stopped, as shown in block AP12, and an M/C Error message is displayed, as shown in block AP13.
(55) If the print is within tolerance of x mm, the value of X is reset to zero, as shown in block AP14. It is then checked whether movement can be made, as shown in block AP15. As shown in block AP16, it is then determined whether the embossing roller is contacting the paper. If the embossing roller is not contacting the paper, it is determined whether the knives of the cutting unit are contacting the paper, as shown in block AP17. If none of the conditions of steps AP16 or AP17 are true, the registration rollers are retarded in order to pull back the paper, as shown in block AP18.
(56) The lagging process C7 is shown in more detail in
(57) As shown in
(58) In block LP4, it is determined whether the previous cigarette was out of tolerance. If the previous cigarette was not within tolerance, the value of X is set to 1. This step is represented in block LP5 as log figure X=1. In step LP6, it is checked whether movement can be made. As shown in block LP7, it is then determined whether the embossing roller is contacting the paper. If the embossing roller is not contacting the paper, it is determined whether the knives are contacting the paper, as shown in block LP8. If none of the conditions of steps LP7 or LP8 are true, the registration rollers are accelerated in order to push forward the paper, as shown in block LP9.
(59) If the previous cigarette was out of tolerance, the value of X is increased by 1 and the new value is stored. This step is represented in block LP10 as log figure X=X+1. In step LP11, it is determined whether X is greater than . If X is greater than , the machine is stopped, as shown in block LP12, and an M/C Error message is displayed, as shown in block LP13.
(60) If the print is within tolerance of x mm, the value of X is reset to zero, as shown in block LP14. It is then checked whether movement can be made, as shown in block LP15. As shown in block LP16, it is then determined whether the embossing roller is contacting the paper. If the embossing roller is not contacting the paper, it is determined whether the knives of the cutting unit are contacting the paper, as shown in block LP17. If none of the conditions of steps LP16 or LP17 are true, the registration rollers are accelerated in order to push the paper forward, as shown in block LP18.
(61) It will be appreciated that the invention also includes many variations of the above described apparatuses and methods for making smoking articles.
(62) For example, as described above, sections of the tipping paper may be embossed with a pattern such as a pattern comprising logos. Alternatively, the whole tipping paper, substantially the whole tipping paper, or the portion of the tipping paper which is ultimately visible on the cigarette may be embossed. Embossing the tipping paper in this fashion can be referred to as an all-over emboss, and the embossed pattern can be referred to as an all-over emboss pattern.
(63) Alternatively, the tipping paper may be embossed with such an all-over emboss pattern and also with a pattern which comprises logos.
(64) Alternatively, the tipping paper may be pre-embossed with a first pattern, and a second pattern may be embossed onto the tipping paper. The first pattern may, for example, be an all-over emboss embossing pattern.
(65)
(66) Furthermore, instead of having a section which does not emboss, the embossing rollers may be lifted or halted such that the print pattern may be positioned relative to the embossed pattern formed by the embossing unit.
(67) As described above, the section which does not emboss may not contact the tipping paper during rotation of the roller. Alternatively the section which does not emboss may make contact with the tipping paper. In this case, the tipping paper may slide through the section which does not emboss independently of the rotation of the embossing roller. Alternatively, or in addition, the section which does not emboss may be arranged such that the tipping paper may slide through the section which does not emboss without causing the embossing rollers to rotate.
(68) Furthermore, when the tipping paper is wrapped around the double length filter, a first region of the tipping paper segment may overlap with a second region of the tipping paper segment. The machine 1 may be configured so that the region of the tipping paper which is not embossed due to the non-embossing section 8a is in register with the second region of the tipping paper. Thus, the non-embossed section of the tipping paper can be hidden from view and an all-over emboss can be achieved.
(69) Still further, instead of manufacturing pairs of cigarettes, the machine may be configured to manufacture cigarettes one by one. That is, the assembling station may, alternatively, be configured to assemble the smoking article by joining a single length filter to the rod of smokeable material by wrapping the filter at least partially with tipping paper which has been embossed in a suitable way.
(70) Still further, the cutter may be configured to cut the tipping paper such that each repeated sub-pattern is cut in the same place. That is, the cut times of the cutter may be registered with the pattern on the tipping paper.
(71) The cutter and the embossing unit may be driven by the same drive, or may be driven by different drives.
(72) The logos on the tipping paper may be longitudinally separated such that the tipping paper of each assembled cigarette has one or more complete logos. For example, the longitudinal separation between the logos may be the circumference of a cigarette so that a single complete logo is formed on the tipping paper of each assembled cigarette.
(73) Still further, instead of using pre-printed sheet material the apparatus may comprise a printing unit for printing a pattern on the sheet material.
(74) Furthermore, a photo-resistor, a photodiode, a charge coupled device, or any other light detecting means may be used to detect the position of the pattern on the tipping paper.
(75) Furthermore, the embossing position may be determined in dependence on a first position of the tipping paper. The first position of the tipping paper may be determined by detecting a position of the print pattern on the tipping paper, or by other means. For example, the first position of the tipping paper may be detected by mechanical means, or by optical means.
(76) Furthermore, punch or stamp type embossing means, or any other means for forming an embossed pattern on the tipping paper may be used in place of embossing rollers.
(77) Still further, the conveying means may comprise feed or drive rollers which include motors such as servo-motors. The conveying means may also comprise guide rollers which may not be driven.
(78) Still further, the embossing position may be determined in dependence on a first cut time of the cutting unit 11, the first cut time being determined in dependence on a position of the print pattern. Therefore, the controller may synchronise a cut time associated with the print pattern with a cut time associated with the embossed pattern, and thereby bring the embossed pattern and the print pattern into register.
(79) Still further, instead of holding tipping paper, the holder may hold a different sheet material. For example, the holder may hold paper wrapper suitable for wrapping around the rod of smokeable material. The embossing unit may be configured to emboss paper wrapper drawn from the holder. The assembling station may be configured to wrap the embossed paper wrapper around the tobacco rod.
(80) The above embodiments or alternatives may be used either singly or in combination to achieve the effects provided by the invention.
(81) Many further modifications and variations will be evident to those skilled in the art, that fall within the scope of the following claims: