SUCTION ROD CONVEYORS FOR CIGARETTE MAKERS

Abstract

Cigarette makers and suction rod conveyors for cigarette makers are provided, as well as methods of using the same. A compacting disk of the suction rod conveyor can be configured to assist in providing drive from a suction tape during operation, minimize filler material buildup, and eject dust during use. Suction and trimmer channels and slide bushes can be configured to minimize bridging of filler material. Scrapers with serrated edges, brushes, and/or pressurized air can be provided to minimize buildup of sticky filler material during use.

Claims

1. A suction rod conveyor for a cigarette maker, comprising: a conveying path for a suction tape; a convey section configured to convey filler material; a transfer section configured to transfer the filler material to a garniture; and a compacting disk, wherein the compacting disk comprises a plurality of standard areas and a plurality of flat areas disposed on an outer circumferential surface thereof, wherein an outermost portion of each flat area is closer to a central axis of the compacting disk than is an outermost portion of each standard area, wherein the compacting disk further comprises a side face having a plurality of holes disposed around the central axis of the compacting disk, wherein the compacting disk is configured to assist in providing drive from the suction tape during use, and wherein the suction rod conveyor does not have a dedicated drive for the compacting disk.

2. The suction rod conveyor according to claim 1, wherein the holes are circumferentially equally spaced on the side face of the compacting disk.

3. The suction rod conveyor according to claim 1, wherein the compacting disk further comprises a plurality of first slots disposed around a first edge of the outer circumferential surface of the compacting disk.

4. The suction rod conveyor according to claim 3, wherein the compacting disk further comprises a plurality of second slots disposed around a second edge of the outer circumferential surface of the compacting disk, the second edge being opposite from the first edge.

5. The suction rod conveyor according to claim 4, wherein the first slots are circumferentially equally spaced around the first edge, wherein the second slots are circumferentially equally spaced around the second edge, and wherein the first slots are disposed to correspond to the second slots, such that each first slot is disposed on a standard area of the plurality of standard areas having a second slot disposed thereon.

6. The suction rod conveyor according to claim 1, wherein the compacting disk further comprises a tapered face disposed between the side face of the compacting disk and the outer circumferential surface of the compacting disk.

7. The suction rod conveyor according to claim 1, wherein the standard areas of the plurality of standard areas are disposed alternatingly with the flat areas of the plurality of flat areas around the outer circumferential surface of the compacting disk.

8. The suction rod conveyor according to claim 1, wherein a width of the outer circumferential surface of the compacting disk is no more than 7 millimeters (mm).

9. The suction rod conveyor according to claim 1, further comprising a first source of pressurized air configured to blow pressurized air on the compacting disk during use.

10. The suction rod conveyor according to claim 1, further comprising: a suction channel; a plurality of first slide bushes configured to support the suction tape along the suction channel during use; a trimmer channel comprising at least one pair of plain trimmer disks; and a plurality of second slide bushes configured to support the suction tape along the trimmer channel during use, wherein each first slide bush has a width of at least 7.2 mm, and wherein each second slide bush has a width of at least 7.2 mm.

11. The suction rod conveyor according to claim 10, wherein each first slide bush comprises a first step protruding from its face and into a first channel in a first curved portion of a first wall of the suction channel, and wherein each second slide bush comprises a second step protruding from its face and into a second channel in a second curved portion of a second wall of the trimmer channel.

12. The suction rod conveyor according to claim 10, wherein a height of the suction channel is no more than 34 mm, and wherein a height of the trimmer channel is no more than 29.5 mm.

13. The suction rod conveyor according to claim 10, further comprising a second source of pressurized air configured to blow pressurized air on the suction tape during use, before the suction tape enters the suction channel.

14. The suction rod conveyor according to claim 1, further comprising: a plurality of rollers; and a plurality of scrapers, each scraper of the plurality of scrapers being disposed proximate to a roller of the plurality of rollers, wherein each scraper of the plurality of scrapers comprises a serrated edge that is configured to come into contact with the roller to which the respective scraper is disposed proximate during use.

15. The suction rod conveyor according to claim 14, further comprising at least one brush configured to clean the suction tape during use.

16. The suction rod conveyor according to claim 1, wherein the filler material comprises at least one of tobacco, hemp, marijuana, and a sticky plant-based material.

17. A method of forming a rod during cigarette manufacture, the method comprising: providing the suction rod conveyor according to claim 1; providing cigarette paper and the filler material to the suction rod conveyor; and operating the suction rod conveyor to form the rod, wherein the filler material comprises at least one of tobacco, hemp, marijuana, and a sticky plant-based material.

18. A cigarette maker comprising the suction rod conveyor according to claim 1.

19. A suction rod conveyor for a cigarette maker, comprising: a conveying path for a suction tape; a convey section configured to convey filler material; a transfer section configured to transfer the filler material to a garniture; a compacting disk; a first source of pressurized air configured to blow pressurized air on the compacting disk during use; a suction channel; a plurality of first slide bushes configured to support the suction tape along the suction channel during use; a trimmer channel comprising at least one pair of plain trimmer disks; a plurality of second slide bushes configured to support the suction tape along the trimmer channel during use; a second source of pressurized air configured to blow pressurized air on the suction tape during use, before the suction tape enters the suction channel; a plurality of rollers; a plurality of scrapers, each scraper of the plurality of scrapers being disposed proximate to a roller of the plurality of rollers; and at least one brush configured to clean the suction tape during use, wherein the compacting disk comprises a plurality of standard areas and a plurality of flat areas disposed on an outer circumferential surface thereof, wherein an outermost portion of each flat area is closer to a central axis of the compacting disk than is an outermost portion of each standard area, wherein the compacting disk further comprises a side face having a plurality of holes disposed around the central axis of the compacting disk, wherein the compacting disk is configured to assist in providing drive from the suction tape during use, and wherein the suction rod conveyor does not have a dedicated drive for the compacting disk, wherein the holes are circumferentially equally spaced on the side face of the compacting disk, wherein the compacting disk further comprises a plurality of first slots disposed around a first edge of the outer circumferential surface of the compacting disk, wherein the compacting disk further comprises a plurality of second slots disposed around a second edge of the outer circumferential surface of the compacting disk, the second edge being opposite from the first edge, wherein the first slots are circumferentially equally spaced around the first edge, wherein the second slots are circumferentially equally spaced around the second edge, wherein the first slots are disposed to correspond to the second slots, such that each first slot is disposed on a standard area of the plurality of standard areas having a second slot disposed thereon, wherein the compacting disk further comprises a tapered face disposed between the side face of the compacting disk and the outer circumferential surface of the compacting disk, wherein the standard areas of the plurality of standard areas are disposed alternatingly with the flat areas of the plurality of flat areas around the outer circumferential surface of the compacting disk, wherein a width of the outer circumferential surface of the compacting disk is no more than 7 millimeters (mm), wherein each first slide bush has a width of at least 7.2 mm, wherein each second slide bush has a width of at least 7.2 mm, wherein each first slide bush comprises a first step protruding from its face and into a first channel in a first curved portion of a first wall of the suction channel, wherein each second slide bush comprises a second step protruding from its face and into a second channel in a second curved portion of a second wall of the trimmer channel, wherein a height of the suction channel is no more than 34 mm, wherein a height of the trimmer channel is no more than 29.5 mm, wherein each scraper of the plurality of scrapers comprises a serrated edge that is configured to come into contact with the roller to which the respective scraper is disposed proximate during use, wherein the filler material comprises at least one of tobacco, hemp, marijuana, and a sticky plant-based material.

20. A cigarette maker comprising the suction rod conveyor according to claim 19.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0006] FIG. 1 shows a perspective view of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention.

[0007] FIG. 2 shows a perspective view of a portion of a suction rod conveyor, with a compacting disk housed in a tongue rail assembly of a cigarette maker, according to an embodiment of the subject invention.

[0008] FIG. 3 shows a perspective view of a compacting disk of a cigarette maker, according to an embodiment of the subject invention.

[0009] FIG. 4 shows a perspective view of a suction rod conveyor, with suction tape and slide bushes, of a cigarette maker, according to an embodiment of the subject invention.

[0010] FIG. 5 shows a perspective view of a portion of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention. FIG. 5 shows a close-up of a slide bush of the suction channel.

[0011] FIG. 6 shows a perspective view of a portion of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention. FIG. 6 shows a close-up of a slide bush of the trimmer channel.

[0012] FIG. 7 shows a perspective view of a portion of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention. FIG. 7 shows a close-up of a scraper for drive rollers.

[0013] FIG. 8 shows a perspective view of a portion of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention. FIG. 7 shows a close-up of a scraper for a roller (i.e., a non-drive roller).

[0014] FIG. 9 shows a perspective view of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention.

DETAILED DESCRIPTION

[0015] Embodiments of the subject invention provide novel and advantageous cigarette makers and suction rod conveyors for cigarette makers, as well as methods of using the same. A compacting disk of the suction rod conveyor can be configured to assist in providing drive from a suction tape during operation, minimize filler material buildup, and eject dust during use. Suction and trimmer channels and slide bushes can be configured to minimize bridging of filler material. Scrapers with serrated edges, brushes, and/or pressurized air can be provided to minimize buildup of sticky filler material during use.

[0016] Embodiments of the subject invention can be used with a cigarette maker, such as the one disclosed in International Patent Application Publication Number WO2022/094534 (hereinafter referred to as WO '534), which is hereby incorporated by reference herein in its entirety. A cigarette maker can include any or all of the parts disclosed in WO '534, and the suction rod conveyor may be replaced by one having any or all of the features disclosed herein.

[0017] Because of the different texture of certain plant based materials that have particles, compared to tobacco, which contains fibers, the suction rod conveyor must be adapted if a cigarette maker is to be efficiently used for such plant-based materials as well as tobacco. Cigarette makers can produce cigarettes made out of tobacco, hemp, expensive plant-based materials, and possibly other filler materials. The term filler material as used herein can refer to, for example, tobacco, hemp, marijuana, expensive (and/or sticky) plant-based materials, and other materials that can be filled in a cigarette made by a cigarette maker (such as the one disclosed in WO '534).

[0018] In an embodiment, a suction rod conveyor can include a conveying path for a suction tape, a convey section to convey filler material, a transfer section to transfer the filler material to a garniture, and a compacting disk. The compacting disk can have a newly-designed outer circumferential surface configured to assist in providing drive from the suction tape during operation. The center web face (or side face) can have holes with a size, position, and/or quantity configured to minimize filler material buildup and convey dust to be ejected out. The outer circumferential surface can have a reduced width to minimize filler material. Pressurized cleaning air can be provided to the compacting disk during use. At least one suction channel and/or a plurality of slide bushes of the suction rod conveyor can have optimized stability of the suction tape and minimized loss of conveying material. The suction channel rail dimensions and/or the trimmer channel rail can have dimensions that minimize bridging of filler material that would otherwise cause issues in material flow. The suction rod conveyor can include at least one scraper with a serrated edge, at least one brush (e.g., at least one brush on each face of the suction tape), and/or pressurized air configured to be provided to the suction tape during use.

[0019] The vacuum suction effect of the suction rod conveyor carries the filler material via the suction tape and transports to the garniture of the rod maker. A trimmer unit with a pair of trimmer disks and a paddle wheel can remove surplus filler material from the filler material stream, and the trimmer disks can be located before the compacting disk and the garniture assembly. The compacting disk, garniture tongue, and rod making garniture assemblies are very critical and sensitive parts of the cigarette maker.

[0020] FIG. 1 shows a perspective view of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention. FIG. 2 shows a perspective view of a portion of a suction rod conveyor of a cigarette maker, according to an embodiment of the subject invention. The compacting disk 130 is highlighted in FIG. 2, and FIG. 3 shows a perspective view of a compacting disk 130, according to an embodiment of the subject invention. The compacting disk 130 can also be referred to as a pressing disk, a compression disk, a compression wheel, a compacting wheel, or a pressing wheel. Referring to FIG. 3, the compacting disk 130 can include flat areas 135 around the outer circumferential surface thereof configured to assist in providing drive from the suction tape during operation. The flat areas 135, which are not present in related art devices, can have a smaller width (and/or thickness) than the standard areas 136 around the outer circumferential surface of the compacting disk 130, and the outermost portion of each flat area 135 can be closer to a central axis of the compacting disk 130 (going through the axle 139) than is the outermost portion of each standard area 136. The compacting disk 130 can further include slots 137 (e.g., eight slots) around an edge of the outer circumferential surface. The slots 137 can be disposed on both edges of the outer circumferential surface and can be equally spaced around a circumference of the compacting disk 130. The compacting disk 130 can further include holes 138 (e.g., at least four holes, such as six holes) through a center web face (or side face) of the compacting disk 130 and disposed around the axle 139. The holes can be equally spaced around a circumference of the compacting disk 130. The compacting disk 130 can include a tapered face 132 disposed between (and connecting) the side face and the outer circumferential surface (i.e., the flat areas 135 and/or standard areas 136 of the outer circumferential surface).

[0021] The compacting disk 130 is located in a critical area, and adding a separate drive is not economical. Thus, embodiments of the subject invention include a compacting disk 130 with novel flat areas 135 on the outer circumferential surface of the compacting disk 130 to assist in providing drive from the suction tape 140. A perforated suction tape can be driven by existing drive rollers 120, and the suction tape 140 can then drive the compacting disk 130 and overcome a sticky filler material and its dust. Hence, a separate drive for the compacting disk 130 is not required (and can be omitted), and the suction tape 140 can turn/drive the compacting disk 130.

[0022] In addition, the width W.sub.D of the outer circumferential surface of the compacting disk 130 can be reduced compared to related art compacting disks. For example, the width W.sub.D can be no more than 7 millimeters (mm) for a 7 mm channel size. This is a reduction of at least 4% from the width of related art compacting disks. The compacting disk 130 can also have a tapered face 132, as well as a side face (or center web face) with reduced cross-sectional area by including the holes 138 of a large size and/or quantity. The reduced width W.sub.D and side face area can prevent or inhibit sticky filler material buildup on the compacting disk 130. In addition, the holes 138 can be located on the side face of the compacting disk 130 such that the filler material dust is conveyed to the other side of the compacting disk 130 to be ejected out during use. The cigarette maker (e.g., the tongue rail assembly thereof) can also include pressurized cleaning air blowing into the compacting disk 130 during use in order to prevent or inhibit buildup of filler material and/or dust. The pressurized cleaning air can continuously remove filler material and/or filler material dust from this sensitive area (i.e., the compacting disk area).

[0023] FIG. 4 shows a perspective view of a suction rod conveyor 110 of a cigarette maker, according to an embodiment of the subject invention. Each of FIGS. 5 and 6 show a portion of a suction rod conveyor, focusing on a slide bush 150. A plurality of slide bushes 150 can be present in the suction rod conveyor 110 configured to support the suction tape 140 along the suction and trimmer channels during use. Related art standard slide bushes have narrow support, and due to a lack of sufficient support, the suction tape can get twisted, thereby causing the cigarette maker to stop. In order to overcome this problem, in an embodiment, the slide bush 150 can have a wide tape support configured to provide better support for the suction tape 140. The slide bush 150 can have a width of at least 7.2 mm for a 7 mm channel, which is an increase of at least 20% over the width of related art slide bushes. The step of each slide bush 150 can protrude from its respective face and into a channel in a curved portion 160,161 of a wall, which can be shaped differently (160 versus 161) depending on the desired channel size/shape. Different channel sizes (e.g., 8 mm channel and 9 mm channel) can have different slide bushes 150. For example, FIG. 5 shows a slide bush for a suction channel, and FIG. 6 shows a slide bush for a trimmer channel.

[0024] Bridging of certain plant-based materials can occur due to sticky material in the suction and trimmer channels as these channels were designed for tobacco filler materials. In an embodiment, the channel can have a reduced height compared to related art devices, thereby preventing or inhibiting filler material bridging and making the device easier to clean. For example, the height of the channel can be reduced at least 22% compared to related art channels (e.g., a suction channel height of 34 mm compared to a related art suction channel height of 43.7 mm, or a trimmer channel height of 29.5 mm compared to a related art trimmer channel height of 39.5 mm). The height of the suction and trimmer channels can be designed/predetermined based on the trimmer disk set height to make sure sufficient filler material is removed before trimming at the trimmer unit. Surplus filler material can be trimmed by at least one pair of plain trimmer disks (e.g., exactly one pair of plain trimmer disks) and with the support of at least one paddle wheel. Using a reduced height of the suction and trimmer channels provides for removal of the excess filler material sufficient such that the required rod can be made. These channels help resolve bridging, reduce the needed trimming, and make cleaning easier.

[0025] Filler material can be conveyed by the suction tape 140 by vacuum, inside a housing of the suction rod conveyor 110 that is in a vacuum state. The suction tape 140 can transport filler material, pick up filler material at a suction channel area, and convey the filler material to a garniture rod making area. The suction tape 140 can pick up sticky filler material and its dust. Clean suction tape is required for smooth continuous efficient operation of the cigarette maker. Scrapers 125 can be included to scrape sticky materials off the rollers 120.

[0026] FIGS. 7 and 8 each shows a perspective view of a portion of a suction rod conveyor 110 of a cigarette maker, according to an embodiment of the subject invention. FIG. 7 shows a close-up of drive rollers 120, and FIG. 8 shows a close-up of another type of roller 170 (i.e., a roller that is not a drive roller). FIG. 9 shows a perspective view of a suction rod conveyor 110 of a cigarette maker, according to an embodiment of the subject invention. The suction rod conveyor 110 can include at least one scraper 125 with serrations on an edge thereof (i.e., the edge that comes into contact with a respective roller 120,170 during operation) configured to efficiently scrape off sticky material. Related art scrapers have flat chisel edges, and they fail to scrape off sticky filler materials. In contrast, the scrapers 125 of embodiments of the subject invention can include a serrated edge to efficiently scrape off sticky material. Any or all rollers 120,170 present in the suction rod conveyor 110 can include a scraper 125 disposed proximate thereto configured to have its serrated edge come into contact with the respective roller 120,170 during operation. In addition, at least one brush can be installed in the suction rod conveyor 110 configured to clean the suction tape 140 during use. The at least one brush can be disposed on either or both faces of the suction tape 140. Further, pressurized air can be provided (e.g., by one or more cleaning blocks) to the suction tape 140 during use. The pressurized air can be provided to the suction tape 140 before it goes into the suction channel area.

[0027] Embodiments of the subject invention provide for more efficiently run cigarette makers that prevent or inhibit stops and/or rod breaks, thereby reducing machine down time, minimizing production loss, and preventing or inhibiting wastage of expensive filler material. The compacting disk 130 has no separate (or dedicated) drive, and flat areas 135 can be included so that the suction tape 140 can drive the compacting disk 130. That is, the outer circumferential surface of the compacting disk 130 is configured for better grip and reduced slippage with respect to the suction tape 140. Hence, no separate drive is required for the compacting disk 130 (i.e., such a drive can be omitted). Further, the surface area on both side faces can be reduced via the holes 138, and the width W.sub.D of the outer circumferential surface of the compacting disk 130 can be reduced to minimize the friction. The holes 138 can also be relocated/positioned for better flow during use (i.e., dust filler particles can be ejected). Pressurized cleaning air can be provided (e.g., from or in the tongue rail assembly) for the compacting disk 130. The compacting disk 130 has overall improved flow of sticky filler material and/or dust that would otherwise build up and/or cause the compacting disk 130 to stop turning.

[0028] Suction and trimmer channels can prevent or inhibit bridging of filler material (e.g., expensive and/or sticky plant-based materials). Scrapers 125 with serrated edges can be provided for the rollers 120,170. Also, the suction tape 140 can be cleaned by at least one brush and/or air cleaning block. This minimizes machine stops and cleaning because the machine runs continuously for longer periods, increasing efficiency and decreasing production loss and wastage of expensive filler material.

[0029] When ranges are used herein, combinations and subcombinations of ranges (including any value or subrange contained therein) are intended to be explicitly included. When the term about is used herein, in conjunction with a numerical value, it is understood that the value can be in a range of 95% of the value to 105% of the value, i.e. the value can be +/5% of the stated value. For example, about 1 kg means from 0.95 kg to 1.05 kg.

[0030] It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application.

[0031] All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.