SPLICING DEVICE AND METHOD FOR SPLICING SHEETS OF MATERIAL

Abstract

A splicing device is provided, including: a punch plate and a counter plate arranged oppositely to the punch plate, the punch plate and the counter plate being relatively movable versus each other and configured to splice two sheets of material arrangeable in between the punch plate and the counter plate, the punch plate including an array of splicing protrusions and the counter plate including an array of splicing holes, the array of splicing holes including a number of splicing holes and the array of splicing protrusions including a number of splicing protrusions, a number of splicing holes being at least the same as a number of splicing protrusions, and a position of the splicing protrusions in the array of splicing protrusions corresponding to a position of the splicing holes in the array of splicing holes.

Claims

1.-15. (canceled)

16. A splicing device, comprising: a punch plate and a counter plate arranged oppositely to the punch plate, wherein the punch plate and the counter plate are relatively movable versus each other and configured to splice two sheets of material arrangeable in between the punch plate and the counter plate, wherein the punch plate comprises an array of splicing protrusions and the counter plate comprises an array of splicing holes, wherein the array of splicing holes comprises a number of splicing holes and the array of splicing protrusions comprises a number of splicing protrusions, wherein a number of splicing holes is at least the same as a number of splicing protrusions, and wherein a position of the splicing protrusions in the array of splicing protrusions corresponds to a position of the splicing holes in the array of splicing holes.

17. The splicing device according to claim 16, wherein both the punch plate and the counter plate comprise an array of splicing protrusions and an array of splicing holes.

18. The splicing device according to claim 17, wherein splicing protrusions and splicing holes are arranged in an alternating manner on each of the punch plate and the counter plate.

19. The splicing device according to claim 16, wherein the punch plate and the counter plate are arranged parallel to each other.

20. The splicing device according to claim 16, wherein the splicing protrusions are splicing pins.

21. The splicing device according to claim 16, wherein the splicing protrusions have a round, circular, triangular, polygonal, square, or star-shaped cross-section.

22. The splicing device according to claim 16, further comprising a detacher configured to detach a sheet of material from the punch plate or from the counter plate.

23. The splicing device according to claim 22, wherein the detacher is provided at least at one of the punch plate and the counter plate.

24. The splicing device according to claim 22, wherein the detacher comprises a detacher plate, and wherein the detacher plate is a spring biased detacher plate.

25. The splicing device according to claim 24, wherein a first elastically mounted detacher plate of the detacher is connected to the punch plate and a second elastically mounted detacher plate of the detacher is connected to the counter plate.

26. The splicing device according to claim 24, wherein detacher plates comprise an array of through holes, the array of through holes corresponding to the array of splicing protrusions.

27. A method for splicing sheets of material using a splicing device according to claim 16, the method comprising: providing a first sheet of material from a first bobbin and providing a second sheet of material from a second bobbin; positioning the first sheet of material and the second sheet of material in a splicing location and overlapping the first sheet and the second sheet in the splicing location; and splicing the first sheet of material and the second sheet of material in the splicing location by interpenetration of the first sheet of material and the second sheet of material by an array of splicing protrusions and a corresponding array of splicing holes, thereby moving the array of splicing protrusions and the array of splicing holes versus each other and pressing at least one of the two sheets of material into the array of splicing holes by the array of splicing protrusions, thereby forming a spliced portion of the first and the second sheets of material.

28. The method according to claim 27, further comprising moving splicing protrusions and corresponding splicing holes along a same straight line for splicing the sheets of material.

29. The method according to claim 27, further comprising moving a punch plate and a counter plate in an opposite direction and perpendicular to a splicing direction, thereby enhancing a strength of the spliced portion.

30. The method according to claim 27, further comprising detaching the spliced portion from the array of splicing protrusions by lifting the spliced portion off the splicing protrusions.

Description

[0206] Examples will now be further described with reference to the figures in which:

[0207] FIG. 1 shows a schematic lateral view of a system to splice a first sheet and a second sheet;

[0208] FIG. 2 shows a lateral view of a detail of an embodiment of the system of FIG. 1;

[0209] FIG. 3 shows a perspective view of a punch plate;

[0210] FIG. 4 shows a longitudinal cross section of the punch plate of FIG. 3;

[0211] FIG. 5 shows a top view of the punch plate of FIG. 3;

[0212] FIG. 6 shows a perspective view of a counter plate;

[0213] FIG. 7 shows a longitudinal cross section of the counter plate of FIG. 6;

[0214] FIG. 8 shows a top view of the counter plate of FIG. 6;

[0215] FIG. 9 shows a splicing device with detacher;

[0216] FIG. 10 shows a perspective view of a detacher plate;

[0217] FIG. 11 shows a longitudinal cross section of the detacher plate of FIG. 10;

[0218] FIG. 12 shows top view of the detacher plate of FIG. 10;

[0219] FIG. 13 shows another embodiment of splicing device with detacher; and

[0220] FIG. 14 shows two side views and a front view of splicing protrusions.

[0221] With reference to FIG. 1 and FIG. 2, an exemplary system to splice a first sheet and a second sheet of material is globally indicated with reference sign 1. The system 1 is described specifically adapted for the splicing of sheet material being tobacco material containing sheets, in particular homogenized tobacco material containing sheets such as cast leaf but also adapted for splicing fibrous paper sheets.

[0222] The system 1 comprises a first shaft 41 and a second shaft 31, on which a first bobbin 40 and a second bobbin 30 are inserted. The first shaft 41 and second shaft 31 are rotatable around their respective axis. The first bobbin 40 supplies the first sheet of material 4 and the second bobbin 30 supplies the second sheet 3 of material. Preferably, the first sheet 4 and the second sheet 3 are homogenised tobacco sheets.

[0223] The system 1 further comprises a splicing device 2, schematically indicated with a rectangle in FIG. 1. The first sheet 4, which in FIG. 1 is the sheet in use, is supplied to the splicing device 2. The unwinding of the first sheet 4 from the first bobbin 40 and its supply to the splicing device 2 takes place via guide pulley 22. The first sheet 4 is transported towards the splicing device 2 and in the further processing stages along a transport direction which is indicated by the arrow 50.

[0224] Downstream of the splicing device 2, the system 1 comprise an acceleration unit, for example in the form of two acceleration rollers (not shown in FIG. 1). The first sheet and second sheet being passed through the splicing device 2 may be accelerated or slowed down by the acceleration unit. The first sheet 4 or second sheet 3 may be continuously accelerated upon passing the acceleration unit in order to secure a continuous velocity of the sheet. Preferably, for the splicing process, the sheet is stopped by the acceleration unit. After a splicing process, the spliced sheet may be accelerated again to a process velocity.

[0225] Downstream of such an acceleration unit, the system 1 comprises a buffer system 6. The buffer system 6 comprises a plurality of rollers 7, such as a series of idler pulleys, where the first sheet 4 or the second sheet 3 is guided around and forms loops. Some of the idler pulleys 7 are arranged in a movable manner such as to enlarge or shorten a sheet loop in order to be able to further provide sheet material in a downstream direction, even when a supply from the splicing device 2 or from the first bobbin 40 or second bobbin 30 is interrupted or reduced.

[0226] Downstream of the buffer system 6 a pulling unit may be provided to pull the first sheet 4 or the second sheet 3 out of the buffer system 6 to pass the sheet preferably at a constant velocity to further downstream arranged sheet processing units (not visible).

[0227] Further elements and units may be included in the system 1, such as a crimper and a rod former (not shown in the drawings), both located downstream the buffer system 6.

[0228] Between the first shaft 41 and the splicing device 2, along the path taken by the first sheet 4 along the transport direction 50, at least a first sheet sensor 9 is located in the system 1. Sensor 9 is schematically depicted as a rectangle in FIG. 1. The sensor 9 may be a thickness sensor. The sensor 9 may be a width sensor. The sensor 9 may be a moisture sensor. The sensor 9 may be stickiness sensor. The sensor 9 may be a detector for the presence or absence of holes or tears in the first sheet 4.

[0229] Between the second shaft 31 and the splicing device 2, along the path taken by the second sheet 3, at least a second sheet sensor 10 is located in the system 1, schematically depicted as a rectangle in FIG. 1. The sensor 10 may be a thickness sensor. The sensor 10 may be a width sensor. The sensor 10 may be a moisture sensor. The sensor 10 may be stickiness sensor. The sensor 10 may be a detector for the presence or absence of holes or tears in the second sheet 3. First sheet sensor 9 and second sheet sensor 10 may be the same type of sensor. First sheet sensor 9 and second sheet sensor 10 may measure the same integrity parameter of the first sheet 4 and second sheet 3, respectively.

[0230] System 1 further includes a control unit 100. Control unit 100 is connected to first sheet sensor 9, second sheet sensor 10 and the splicing device 2. Preferably, control unit 100 is also connected to a bobbin holder (not shown), buffer system 6, and acceleration unit to command the same. Some of the connections are visible in the figures as dotted lines. Not all connections are depicted for clarity of the figures.

[0231] In FIG. 2, the splicing device 2 is shown in more detail. Some parts of the system 1, such as the optional buffer system 6, are not shown in FIG. 2. Splicing device 2 includes a cutting knife 20 to cut the first sheet 4 or the second sheet 3 or both. The splicing device 2 further includes a dispensing unit 23 adapted to dispense water onto the first sheet 4 or second sheet 3. The splicing device 2 also includes a splicer head 24 comprising a punch plate 240 and an oppositely arranged counter plate 250 to perform the actual splicing of the first sheet 4 and the second sheet 3. The splicing device 2 preferably also comprises a heater integrated into the splicer head 24 for heating either the punch plate 240 or counter plate 241 or both. A further heating unit 25, for example a hot air source or a heat radiating source, is arranged downstream adjacent the splicer head 24.

[0232] The functioning of the system 1 is as follow.

[0233] In FIG. 1 and FIG. 2 the first tobacco sheet 4, unwound from the first bobbin 40, is in use and is passing in a substantially straight direction through the splicing device 2. No processing takes place in the splicing device. The first sheet 4 is then buffered for a given length in the buffer system 6 and it is further transported to sheet processing units arranged further downstream (not shown). Such processing units may for example be a crimping unit or a rod forming unit.

[0234] While travelling towards the splicing device 2, the sensor 9 evaluates one or more integrity parameters of the first sheet 4, at a given frequency, checking the surface of the first sheet while the first sheet 4 travels along the transport direction 50. Signals representative of the integrity parameters are sent to the control unit 100 where they are elaborated, for example compared to a threshold.

[0235] In this situation, the buffer system 6 is buffering a length of the first sheet 4, when the rollers 7 are distanced at the maximum distance one from the other. This distance can be along a horizontal direction as shown in FIG. 1 but also in a vertical direction.

[0236] For example, the sensor 9 is a thickness sensor. The sensor 9 measures the thickness of the first sheet 4 at a given frequency. The thickness is then compared by the control unit 100 with a threshold. For example, it is found that the results are not within the acceptable range. This is considered to be a non-acceptable defect of the first sheet 4 and the control unit 100 commands the splicing device 2 to start the splicing. Typically, the control unit 100 receives a signal from a diameter sensor (not shown) signalling that the first bobbin is going to be depleted soon in order to start the splicing process.

[0237] Upon start of the splicing, the second sheet 3 from the second bobbin 30 is guided via guide pulley 22 and supplied to the splicing device 2 (in FIG. 2, the second sheet 3 is supplied from below first sheet 4 in use). Both sheets 3,4 are arranged on top of each other and aligned on a support surface 21 of the splicing device 2. They are then cut by cutting knife 20. The first sheet 4 and second sheet 3 travelling along the transport direction 50 are cut along a same or at different cut lines. Cut lines may be congruent when the first sheet and second sheet are overlapping. By the cut lines, a clearly defined end portion of the first sheet 4, a waste portion of the first sheet and a clearly defined waste portion of the second sheet 3 and a head portion of the second sheet 3 are defined.

[0238] Waste portions may be removed after cutting the sheets 3,4. While the cutting does not necessarily have to be performed with aligned sheets, the splicing process does. The sheets 4, 3 that have been cut are positioned such that the end portion of the first sheet 4 and the head portion of the second sheet 3 overlie each other and form an overlapping portion. In the overlapping portions, two surfaces belonging to the first sheet and second sheet, respectively, are in contact with each other. Water is dispensed onto the lower lying sheet 3, preferably in the overlapping portion only by the dispensing unit 23. By a thin water layer applied to one sheet only, such as the second sheet 3, the water may soften the material of the sheets 3,4 at least in the overlapping portion to support a splicing of the sheets 3,4. However, the amount of water is small enough to not disintegrate the sheets. Alternatively, a liquid adhesive, in particular a liquid natural glue may be applied to one or both sheets.

[0239] The so overlying and wetted sheets 3,4 are then guided through the splicing head 24.

[0240] The sheets are spliced upon passing between punch plate 240 and counter plate 241, which securely splice the two sheets 3,4 to each other. For the splicing, the two sheets 4,3, are kept stationary. The pressure direction applied by the splicing head 24 and moving direction of the punch plate 240 and counter plate 241 is indicated by arrows 51. A short but firm connection is formed upon moving punch plate 240 and counter plate 241 toward each other. For the splicing, only one plate or both plates 240,241 may be moved.

[0241] When the splicing has taken place, the punch plate 240 and the counter plate 241 are moved away from each other and the spliced sheet may continue to move into the transport direction 50. A detacher (not shown in FIG. 2) may be provided to support a release of a spliced portion from the punch plate 240 and optionally also of the counter plate 241.

[0242] A heating unit 25 is provided that heats the spliced sheets. By the heat, the connection is quickly dried such that the spliced tobacco sheet may continue to be provided to further downstream arranged processing units.

[0243] While the splicing takes place, due to the fact that the first sheet needs to be stopped in order to perform the splicing, the first sheet 4 buffered in the buffer system 6 is used in the further processing steps. During the splicing therefore, the first sheet 4 in the buffer system 6 is used and the rollers 7 get closer to each other reaching a minimum distance, as depicted in FIG. 1.

[0244] When the splicing is commanded, the second tobacco sheet 3 from the second bobbin 30 is guided into the splicing device 2. After cutting in the splicing device, the then cut off first tobacco sheet 4 may be removed together with the first bobbin 40 from the first shaft 41. It may be replaced by a new bobbin. As soon as the second bobbin 30 comes to an end, the process may be started again.

[0245] By this process, a new bobbin is provided and prepared for the tobacco sheet on the new bobbin to being spliced with the tobacco sheet in use, while the tobacco sheet is continuously provided to the tobacco processing line.

[0246] In FIGS. 3 to 5 a punch plate 240 provided with an array of splicing protrusions in the form of splicing pins 70 is shown.

[0247] The punch plate 240 is a rectangular plate having a length 52, a width 53 and a thickness 54. The length 52 of the plate is several times larger than its width 53. The punch plate 240 in collaboration with a counter plate 241 as described in FIGS. 6 to 8 below, is capable to generate a small splicing area along a length of a sheet of material to be spliced and over an entire width or a major part of a width of a sheet of material to be spliced.

[0248] The splicing pins 70 are circular tubular pins with a pointed tip. The splicing pins 70 are arranged in three equally distant rows arranged along the length 52 of the punch plate 240. Splicing pins 70 are arranged equidistantly in a row at a pin distance 73. Pins 70 in neighbouring rows are displaced with respect to the length of the punch plate.

[0249] All pins 70 in the embodiment shown in FIGS. 3 to 5 have a same shape and a same size, in particular all pins 70 on the punch plate 240 have a same diameter 76 and same height 71.

[0250] The punch plate 240 comprises a through hole 75 at each of its longitudinal ends. The through holes 75 serve as attachments for a detacher plate (see below).

[0251] Exemplary values of a punch plate 240 are: length 52: 255 mm, width 53: 20 mm and thickness 54: 10 mm; diameter of through holes 75: 6 mm;

[0252] Exemplary values for splicing pins 70 are: height 71: 5 mm, diameter (or extension of cross section) 3 mm;

[0253] Exemplary value of a distance 72 between 1.sup.st and 3.sup.rd row of pins 70 (or lateral extension of array of splicing pins 70): 10 mm;

[0254] Exemplary value of a distance 73 between neighbouring pins 70 in a row: 10 mm;

[0255] A counter plate 241 forming a splicing head with the punch plate 240 as shown in FIGS. 3 to 5 is shown in FIGS. 6 to 8. The counter plate 241 is a rectangular plate having a length 62, a width 63 and a thickness 64. The length 62 of the plate is several times larger than its width 63.

[0256] The counter plate 241 is provided with an array of splicing holes 80 in the form of through holes as may be best seen in FIG. 7.

[0257] The splicing holes 80 are circular drillholes. The splicing holes 80 are arranged in three equally distant rows arranged along the length 62 of the counter plate 241. Splicing holes 80 are arranged equidistantly in a row at a hole distance 83. Splicing holes 80 in neighbouring rows are displaced with respect to the length 62 of the counter plate 241.

[0258] All splicing holes 80 in the embodiment shown in FIGS. 6 to 8 have a same shape and a same size, in particular all splicing holes 80 in the counter plate 241 are circular holes and have a same diameter 86.

[0259] Exemplary values of a counter plate 241 are: length 52: 255 mm, width 53: 20 mm and thickness 54: 10 mm; diameter (or extension of cross sectional) of splicing holes 3 mm;

[0260] Exemplary value of a distance 82 between 1.sup.st and 3.sup.rd row of splicing holes 80 (or lateral extension of array of splicing holes 80): 10 mm;

[0261] Exemplary value of a distance 83 between neighbouring splicing holes 80 in a row: 10 mm;

[0262] In the embodiments shown in FIGS. 3 to 8, the punch plate 240 and counter plate 241 have a same length 52,62, width 53,63 and thickness 54,64. These dimensions may also be different, as long as the array of splicing pins 70 in the punch plate 240 have a correspondingly arranged array of splicing holes 80 in the counter plate 241.

[0263] FIG. 9 shows a splicing head with lower punch plate 240 and upper counter plate 241, for example as described in FIGS. 3 to 8.

[0264] Punch plate 240 and counter plate 241 are arranged opposite and distanced from each other in the open position as shown in FIG. 9.

[0265] Splicing holes 80 are only provided in the counter plate 241. Splicing pins 70 are only provided in the punch plate 240.

[0266] A detacher plate 90 is arranged parallel to the punch plate 240. The detacher plate 90 is connected to the punch plate via springs 91. A coil spring 91 each is arranged at opposite ends of the counter plate 90 and punch plate 240. Preferably, the springs 91 are attached to the punch plate 240 via through holes 75 (see FIG. 3 above). When a splicing action is to be performed, counter plate 241 and punch plate 240 are moved towards each other. The detacher plate 90 is pushed towards the punch plate 240 and the springs 91 are compressed. When the splicing has been performed, punch plate 240 and counter plate 241 are moved away from each other to the open position again, for example upon release of a clamp. The springs 91 expand and push the detacher plate 90 away from the punch plate 240. Thereby, a spliced sheet (not shown in FIG. 9) possibly not detached from either part of the splicing head upon opening of the same, is now detached from the punch plate 240, in particular detached from the splicing pins 70 by the detacher plate 90. Preferably, a movement of the detacher plate 90 away from the punch plate 240 equals to a length of the splicing pins 70. This guarantees a complete detaching of a spliced sheet of material from the splicing pins 70.

[0267] FIGS. 10 to 12 show a detacher plate 90 as may be used in the embodiment of a splicing head as for example shown in FIG. 9 with punch plate as shown and described in FIGS. 3 to 5.

[0268] The detacher plate 90 is a rectangular plate having a length 92, a width 93 and a thickness 94. The length 92 of the plate is several times larger than its width 93.

[0269] The detacher plate 90 is provided with an array of detacher holes 95 in the form of through holes, for example drill holes.

[0270] The detacher holes 95 are circular holes. The detacher holes 95 are arranged in a same array as the splicing pins 70 of the corresponding punch plate 240 shown in FIGS. 3 to 5. The detacher holes 95 are arranged in three equally distant rows arranged along the length 92 of the detacher plate 90. Detacher holes 95 are arranged equidistantly in a row at a hole distance 96. Detacher holes 95 in neighbouring rows are displaced with respect to the length of the detacher plate 90.

[0271] All detacher holes 95 in the embodiment shown in FIGS. 10 to 12 have a same shape and a same size, in particular all detacher holes 95 in the detacher plate 90 are circular holes and have a same diameter 97.

[0272] A spring 91, for example a coils spring, is provided at both longitudinal ends of the detacher plate 90.

[0273] Exemplary values of a detacher plate 90 are: length 92: 255 mm, width 93: 20 mm and thickness 94: 2 mm; diameter 97 of detacher holes 95: 3 mm;

[0274] Exemplary value of a distance 98 between 1.sup.st and 3.sup.rd row of detacher holes 95 (or lateral extension of array of detacher holes 95): 10 mm;

[0275] Exemplary value of a distance 96 between neighbouring detacher holes 95 in a row: 10 mm;

[0276] Exemplary value of a diameter of a spring 91: 6 mm; height 99 of a spring 98 in a released position 10 mm.

[0277] In the embodiment shown in FIGS. 10 to 12, the detacher plate 90 has a same length 92 and width 93 as the punch plate 240. These dimensions may also be different, as long as the array of detacher holes 95 corresponds in its position to the correspondingly arranged array of splicing pins 70 in the punch plate 240.

[0278] In FIG. 13, a punch plate 240 and a counter plate 241 are both embodied as male and female part at the same time. Thus, punch plate 240 and counter plate 241 are both provided with splicing pins 70 and splicing holes 80.

[0279] The splicing head is shown in its open position and a first sheet of material 3 and a second sheet of material 4 are arranged in between the punch plate 240 and the counter plate 241.

[0280] Each of the splicing pins 70 of the counter plate 241 has a corresponding splicing hole 80 in the punch plate 240 and vice versa.

[0281] In the example shown in FIG. 13, slicing pins 70 and splicing holes 80 are arranged in alternating manner in rows along the length 52,62 of the punch plate 240 and counter plate 241, respectively.

[0282] A detacher plate 90 is assigned to each of the counter plate 241 and the punch plate 240. The detacher plates 90 are provided each with an array of detacher holes 95 corresponding to the combination of the splicing holes 80 in the counter plate 241 and the splicing holes 80 punch plate 240, or rather detacher holes 80 corresponding to the array of splicing pins 70 in of the punch plate 240 as well as of the counter plate 241.

[0283] A spring 91 each is arranged between the longitudinal ends of the counter plate 241 and corresponding detacher plate 90.

[0284] A spring 91 each is arranged between the longitudinal ends of the punch plate 240 and corresponding detacher plate 90.

[0285] Indicated in FIG. 13 with arrows 55 is a longitudinal movement of counter plate 240 and punch plate 240 in opposite directions in the length directions of counter plate 240 and punch plate 240. Such a slight transverse movement relative to the (vertical) splicing direction may reinforce the splicing.

[0286] In FIG. 14 a variety of shapes of splicing pins 770-775 is shown. Vertical rows 77, 78, 79 show a splicing pin in the respective longitudinal side view 77 (when seen from the length side of a punch plate 240), front view (78 view onto a tip of a pin) and width side view 79 (when seen from a width of a punch plate 240; view onto side of pin 79 is rotated by 90 degree compared to side view 77).

[0287] Examples show pins with pointed tips 770,772-774, rounded tips 771 or flat tips 775.

[0288] Pins are shown with triangular 770, circular 771,772, 775, and square cross sections 773 at a pin's base.

[0289] Some pins are provided with cutting edges 770,772,773,774, for example four cutting edges.

[0290] Depending on the type of sheet material to be spliced and the desired splice to be achieved, for example a weak or strong splice, a splice by material deformation or rather by perforations, a pin shape and pin size may be chosen.

[0291] Different forms of pins may be provided for a splice of two sheet materials. In particular, different forms of splicing pins may be provided on a punch plate 240 and a corresponding counter plate 241. In particular, different forms of splicing pins may be provided to form an array of splicing pins on a punch plate 240 or on a counter plate, respectively.

[0292] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term about. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.